This article describes the disassembly of the front caliper disc brake assembly of an Isuzu truck
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Removal
Notice:
Position jack stands under vehicle.
• Remove the wheel.
• Block vehicle wheels and apply the parking brake.
• Rise the axle to clear the tire from the ground.
Notice:
Seal parts cannot be reused. When reassembling, be sure to replace with a new seal kit.
1. Flexible hose
2. Pin bolt (Lock pin side)
3. Caliper assembly
• Slide the caliper assembly free from the inside
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Legend
1. Caliper Assembly
2. Support Assembly
3. Pin Bolt
4. Outer pad
5. Inner pad
6. Pad clips
7. Support assembly
• Remove the hub and disc before removing the support assembly.
8. Wind guide
• Remove the hub and disc before removing the wind guide.
9. Adapter
Disassembly
1. Place a piece of wood across the body assembly to prevent piston damage.
2. Apply approximately 196 kPa (2.0 kg/cm2 / 28.4 psi) of compressed air to the body assembly oil port to remove the pistons
Inspection
1. All parts for wear distortion or other conditions and
replace as needed.
2. Inner and outer pads.
• Use a vernier caliper to measure the inner pad and outer pad thickness.
• If the measured value is less than the specified limit, the pads must be replaced with the repair pad kit.
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3. Piston and Cylinder Clearance.
• Use a micrometer to measure the piston diam- eter.
• Use an inside dial indicator to measure the cyl- inder bore.
• Calculate the piston and cylinder bore clear- ance.
• If the clearance exceeds the specified limit, the piston and/or the body assembly must be re- placed along with the repair seal kit.
