Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 183

5C–49

POWER–ASSISTED BRAKE SYSTEM

Installation

1. Install clip (4).

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2. Apply special grease (approximately 0.2 g) to both

contacting surfaces of the inner shims (5). Wipe off
extruded grease after installing. Install pad assembly
with shim.

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Legend

(5) Inner Shim
(6) Wear indicator

3. Install support bracket and tighten the bolt (7) to the

specified torque.

Torque: 103 N·m (76 lb ft)

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4. Install caliper assembly.
5. Install lock bolt and guide bolt (8) and tighten the bolt

to the specified torque.

Torque: 44 N·m (32 lb ft)

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6. Install brake flexible hose, always use new gaskets

and be sure to put the hooked edge of the flexible
hose end into the anti–rotation cavity then tighten the
eye–bolt (9) to the specified torque.

Torque: 35 N·m (26 lb ft)

5C–50 POWER–ASSISTED BRAKE SYSTEM

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7. Install the wheel and tire assembly, refer to 

Wheels

and Tires System in Section 3E.

8. Bleed brakes. Refer to 

Hydraulic Brakes in this

section.

Rear Disc Brake Caliper (4

×

4 Model)

Rear Disc Brake Caliper Disassembled View

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Legend

(1) Guide Bolt
(2) Lock Bolt
(3) Bleeder with Cap
(4) Caliper Body

(5) Piston Seal
(6) Piston
(7) Dust Boot: Piston
(8) Dust Boot Ring
(9) Dust Boot: Guide Bolt and Lock Bolt

5C–51

POWER–ASSISTED BRAKE SYSTEM

Disassembly

1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot; guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver.

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5. Insert a block of wood into the caliper and force out

the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must
be done prior to removal of the dust boot.
Remove piston.

WARNING: DO NOT PLACE YOUR FINGERS IN
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH
OR PROTECT IT WHEN APPLYING COMPRESSED
AIR.  THIS COULD RESULT IN PERSONAL INJURY.

CAUTION: Use just enough air to ease the piston
out of the bore. If the piston is blown out, it may be
damaged.

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6. Remove dust boot: piston.
7. Remove piston seal.
8. Remove bleeder with cap.
9. Remove caliper body.

Inspection and Repair

Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

D

Rotor

D

Cylinder body

D

Cylinder bore

D

Piston

D

Guide bolt, lock bolt

D

Support bracket

NOTE: The piston dust seal and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace with new ones.

Reassembly

1. Install caliper body.
2. Install bleeder with cap and tighten the cap to the

specified torque.

Torque: 8 N·m (69 lb ft)

3. Install piston seal and apply special rubber grease to

the piston seal and cylinder wall, then insert the piston
seal into the cylinder. The special rubber grease is
included in the repair kit.

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4. When inserting the piston into the cylinder, use finger

pressure only and do not use a mallet or other impact
tool, since damage to the cylinder wall or piston seal
can result.
Install piston.

5C–52 POWER–ASSISTED BRAKE SYSTEM

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5. Apply special grease (approximately 1g) to the piston

and attach the dust boot to the piston and caliper.
Insert the dust boot ring into the dust boot.

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6. Install guide bolt and lock bolt dust boot.
7. Install the dust boot on the support bracket after

applying special grease (Approx. 1g) onto the dust
boot inner surface.  Also apply special grease onto
the lock bolt and guide bolt setting hole of the support
bracket.

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8. Install lock bolt and guide bolt and tighten the bolt to

the specified torque.

Torque: 44 N·m (32 lb ft)