99 - 2003 Isuzu N Series Brakes Manual

NOTICE
Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended
that you carefully read and thoroughly understand the
information contained in Section 0A under the headings
"GENERAL REPAIR INSTRUCTIONS" and "HOW TO USE THIS
MANUAL".
All material contained in this Manual is based on the latest

product information available at the time of publication.
All rights are reserved to make changes at any time without
prior notice.
Applicable Model
N Series
NHR55 NPR55 NQR66
NHR69 NPR69 NQR70
NKR55 NPR65 NQR71
NKR69 NPR66 NPS66
NKR58 NPR70 NPS71
NKR66 NPR71
NKR77
This manual is applicable to 1994 year model and later vehicles.

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SERVICE INFORMATION 00-1
SECTION 00
SERVICE INFORMATION
CONTENTS
PAGE
Troubleshooting ............................................................................................................... 00- 3
Main Data and Specifications.......................................................................................... 00- 15
Service Standard .............................................................................................................. 00-108
Servicing ........................................................................................................................... 00-109
Fixing Torque.................................................................................................................... 00-120
Special Tools .................................................................................................................... 00-131
00-108 SERVICE INFORMATION
SERVICE STANDARD
ITEMS SERVICE STANDARD SERVICE LIMIT
FRONT DISC BRAKE ASSEMBLY
Pad Thickness (φ 265mm) mm (in) 12.0 (0.472) 1.0 (0.039)
Pad Thickness (φ 282mm) mm (in) 14.0 (0.551) 1.0 (0.039)
Pad Thickness (φ 293 & φ 310mm) mm (in) 13.0 (0.510) 1.0 (0.039)
Piston and Cylinder Clearance mm (in) 0.08-0.18 (0.0031-0.0071) 0.23 (0.0091)
Disc Lateral Run out mm (in) 0.13 (0.005) or less -
Disc Maximum Parallelism mm (in) 0.02 (0.0008) -
Disc Thickness (φ 265mm) mm (in) 30.0 (1.181) 28.5 (1.122)
FRONT DRUM BRAKE ASSEMBLY
Brake Drum Inside Diameter mm (in) 279.4 (11.00) 281.0 (11.06)
300.0 (11.81) 301.5 (11.87)
320.0 (12.60) 321.5 (12.66)
Brake Drum Run-out mm (in) 0.13 (0.005) or less -
Brake Lining Thickness or Rivet Depth mm (in) - 1.0 (0.039)
Wheel Cylinder and Piston Clearance mm (in) - 0.15 (0.006)
REAR DRUM BRAKE ASSEMBLY
240.0 (9.48) 241.5 (9.51)
(for Taiwan, Australia and GCC) (for Taiwan, Australia and GCC)
279.4 (11.0) 281.0 (11.06)
290.0 (11.42) 291.5 (11.48)
300.0 (11.81) 301.5 (11.87)
320.0 (12.60) 321.5 (12.66)
Brake Lining Thickness or Rivet Depth mm (in) - 1.0 (0.039)
Wheel Cylinder and Piston Clearance mm (in) - 0.15 (0.006)
BRAKE PEDAL AND CONTROL
Master Cylinder and Piston Clearance 0.11-0.195 (0.004-0.008) 0.22 (0.009)
mm (in) 0.09 (0.0035) 0.14 (0.0055)
Safety Valve; Piston and Cylinder Body
Clearance mm (in) - 0.17 (0.0067)
Hydromaster; Poppet Valve Body and Seat
Clearance mm (in) 1.4-2.6 (0.055-0.102) -
Hydromaster; Hydraulic Piston and Cylinder
Clearance mm (in) - 0.15 (0.0059)
Hydromaster; Relay Valve Piston and Fitting
Clearance mm (in) - 0.1 (0.0039)
PARKING BRAKE
190.0 (7.48) 191.0 (7.52)
203.0 (8.00) 205.0 (8.07)
254.0 (10.00) 256 (10.08)
Brake Lining Thickness mm (in) - 1.0 (0.039)
EXHAUST BRAKE
Butterfly Valve and Body Clearance
(4HF1 Engine) mm (in) 0.4-0.6 (0.016-0.024) -
(Other Engine) mm (in) 0.1-0.2 (0.004-0.008) -
SERVICING
CONTENTS
PAGE
Service Brakes.................................................................................................................. 00-110
Wheel Brake Adjustment............................................................................................. 00-110
Brake Pedal Adjustment.............................................................................................. 00-111
Brake Bleeding............................................................................................................. 00-113
Hydraulic Booster Line Bleeding................................................................................ 00-115
Parking Brake ................................................................................................................... 00-118
Parking Brake Adjustment .......................................................................................... 00-118
SERVCE INFORMATION 00-111
Brake Pedal Adjustment

Brake Pedal Height and Free Play Adjustment
Vacuum Booster (Master Vac) Type:
The height of push rod should be adjusted so that the distance
from its master cylinder mounting surface to end measures
18.2mm (0.717 in).
For push rod length adjustment, the distance from the center of
crevis pin hole to brake pedal bracket mounting surface should
be set at 109 mm (4.291 in); without spacer, 129mm (5.079 in);
with spacer.
When fixed under this condition, there is no need to adjust the
height of brake pedal from floor and free play.
Note:
• As vacuume booster (Master Vac) is undetachable
type, it should be replaced as an assembly it does not
work well.
• Be sure to adjust the stop light switch.
Hydromaster Type:
For push rod length adjustment, the distance from the center of
crevis pin hole to brake pedal bracket mounting surface should
be set at 109 mm (4.29 in).
When fixed under this condition, there is no need to adjust the
height of brake pedal from floor and free play.
Note:
• Be sure to adjust the stop light switch.
Brake pedal free play and allowance

Standard value: mm (in)
➀ Free play: 4 to 7 (0.16 to 0.28)
1 to 3 (0.04 to 0.12)…Hydromaster type
24 to 29 (0.94 to 1.14)…HBB type
➁ Allowance: mm (in)
NHR Front Disc Brake Model 40 (1.57)
Front Drum Brake Model 50 (1.97)
Front Disc Brake Model 40 (1.57)
Front Less than
NKR Drum Brake 60 (2.36)
GVM 6.5 ton
Model GVM 6.5 ton 40 (1.57)
Front Disc Brake Model 40 (1.57)
NPR Front Less than
60 (2.36)
NQR Drum Brake GVM 7.0 ton
Model GVM 7.0 ton
40 (1.57)
or more
NPS Front Drum Brake Model 40 (1.57)
NQR Hydromaster Model 50 (1.97)
(When depressed with force of the 50 kg (110 lbs).)
NQR HBB type Front Disc Brake Model 35 (1.38)

Front Drum Brake Model 45 (1.77)
(When depressed with force of the 30 kg (66 lbs).)
SERVCE INFORMATION 00-119
Adjusting Screw Notches and Clearance

Notches Clearance mm (in)
30 0.75 (0.029)
for Taiwan, Australia and GCC

Brake Type mm (in) Notches Clearance mm (in)
178 (7.008), 190 (7.480) 30 0.75 (0.029)
203 (7.992), 254 (10.00) 8 0.23 (0.009)
1 Screwdriver
2 Adjusting screw
3 Brake drum
4 Brake shoe
5 Clearance
6 Direction of brake shoe expansion (for 178mm,
190mm)
Brake Type (203mm and 254mm) is direction to the
counter rotation.
7. Reinstall the check hole cover.
8. Lower the rear wheels to the floor.
Parking Brake Lever Travel Adjustment

1. Fully set the parking brake lever and release it several
times.
Leave the parking brake lever in the released position.
2. Loosen the parking brake control wire lock nut 1 .
3. Turn the adjuster 2 to adjust the lever travel to the
specified notches.
Parking brake lever travel at 15 kg (33 lbs/147 N) notches
5 to 8
6 to 8 (for Taiwan, Australia and GCC)
4. Retighten the control wire lock nut 1.
5. Check the parking brake lever travel (measured in
notches).
FIXING TORQUE
Front Wheel Brake (NHR⋅⋅NKR⋅⋅NPR⋅⋅NQR) N⋅⋅m (kg⋅⋅m/lb⋅⋅ft)
Front Wheel Brake (NHR⋅⋅NKR⋅⋅NPR⋅⋅NQR) (for Taiwan, Australia and GCC) N⋅⋅m (kg⋅⋅m/lb⋅⋅ft)
Rear Wheel Brake N⋅⋅m (kg⋅⋅m/lb⋅⋅ft)

Front Disk Brake (NHR⋅⋅NKR⋅⋅NPR) N⋅⋅m (kg⋅⋅m/lb⋅⋅ft)

Brake Pedal and Control N⋅⋅m (kg⋅⋅m/lb⋅⋅ft)

Parking Brake Drum N⋅⋅m (kg⋅⋅m/lb⋅⋅ft)

SPECIAL TOOLS
PART NO. SERVICE EXHAUST
ILLUSTRATION ISUZU PART NAME BRAKE BRAKE
Master Cylinder
5-8840-2371-0 ! –
Support plate
Wrench
(Cylinder inside
diameter 31.7φ)
5-8840-2370-0 ! –
30.1φ
(for Taiwan, Australia and
GCC)
Wrench
5-8840-2369-0 (Cylinder inside ! –
diameter 28.5φ)
Wrench
X-XXXX-XXXX-X (Cylinder inside ! –
diameter 34.9φ)
5-8840-0279-0 Vacuum punp – !
Remover:
5-8840-2215-0 ! –
steering wheel
Pressure Gauge:
5-8840-2190-0 ! –
brake fluid
HOME
HYDRAULIC BRAKES 5A-1
SECTION 5A
HYDRAULIC BRAKES
CONTENTS
PAGE
General Description ......................................................................................................... 5A- 4
On-vehicle Service ........................................................................................................... 5A- 22
Front Disc Brake Assembly ........................................................................................ 5A- 22
Leaf Spring Suspension Models (φ 282mm) ......................................................... 5A- 22
Removal............................................................................................................... 5A- 22
Inspection and Repair ........................................................................................ 5A- 24
Installation........................................................................................................... 5A- 26
Front Disc Brake Pad Replacement .................................................................. 5A- 30
Leaf Spring Suspension Models (φ 293 & φ 310mm)............................................ 5A- 31
Removal............................................................................................................... 5A- 31
Installation........................................................................................................... 5A- 35
Front Disc Brake Pad Replacement .................................................................. 5A- 39
Independent Suspension Models (NHR and NKR) ............................................... 5A- 40
Removal............................................................................................................... 5A- 40
Installation........................................................................................................... 5A- 45
Front Drum Brake Assembly....................................................................................... 5A- 47
Two Leading and Dual Two Leading ..................................................................... 5A- 47
Removal............................................................................................................... 5A- 47
Installation........................................................................................................... 5A- 55
Rear Drum Brake Assembly........................................................................................ 5A- 59
Removal ................................................................................................................... 5A- 59
Inspection and Repair............................................................................................. 5A- 65
Installation ............................................................................................................... 5A- 67
5A-2 HYDRAULIC BRAKES
Brake Pedal and Control ............................................................................................. 5A- 71

Brake Vacuum Booster and Brake Pedal Assembly ............................................ 5A- 71
Removal............................................................................................................... 5A- 71
Installation........................................................................................................... 5A- 74
Master Cylinder Assembly...................................................................................... 5A- 78
Removal............................................................................................................... 5A- 78
Installation........................................................................................................... 5A- 80
Hydraulic Booster and Brake Pedal Assembly ......................................................... 5A- 82
Removal ................................................................................................................... 5A- 82
Installation ............................................................................................................... 5A- 85
Hydraulic Booster ........................................................................................................ 5A- 87
Removal ................................................................................................................... 5A- 87
Installation ............................................................................................................... 5A- 89
Accumulator and O-ring Replacement .................................................................. 5A- 91
Clevis and Lock Nut Replacement......................................................................... 5A- 93
Guard Replacement ................................................................................................ 5A- 94
Load Sensing Proportioning Valve ............................................................................ 5A- 95
Removal ................................................................................................................... 5A- 95
Installation ............................................................................................................... 5A- 97
Load Sensing Proportioning Valve Adjustment ................................................... 5A- 99
Deceleration Sensing Proportioning Valve ............................................................... 5A-102
Unit Repair ........................................................................................................................ 5A-103
Wheel Cylinder Assembly ........................................................................................... 5A-103
Disassembly ............................................................................................................ 5A-103
Inspection and Repair............................................................................................. 5A-104
Reassembly ............................................................................................................. 5A-105
Wheel Cylinder Assembly (Without Auto-adjuster) .................................................. 5A-109
Disassembly ............................................................................................................ 5A-109
Reassembly ............................................................................................................. 5A-111
Wheel Cylinder Assembly (With Auto-adjuster) ........................................................ 5A-113
Disassembly ............................................................................................................ 5A-113
Reassembly ............................................................................................................. 5A-117
Master Cylinder Assembly (NHR) ............................................................................... 5A-126

Disassembly ............................................................................................................ 5A-126
Reassembly ............................................................................................................. 5A-128
Master Cylinder Assembly (NKR••NPR••NQR••NPS without Hydromaster) .............. 5A-130
Disassembly ............................................................................................................ 5A-130
Reassembly ............................................................................................................. 5A-133
Master Cylinder Assembly (NQR with Hydromaster)................................................ 5A-137
Disassembly ............................................................................................................ 5A-137
Reassembly ............................................................................................................. 5A-139
Hydromaster ..................................................................................................................... 5A-141
Safty Valve ........................................................................................................................ 5A-163
Front Drum Brake (Auto-adjuster Type)

Rear Drum Brake (Auto-adjuster Type)

Rear Drum Brake (Auto-adjuster Type)
The dual two leading shoe type brake eliminates the This combination of two leading shoes provides nearly
problem of weaker braking force on reverse stops equal braking force. This prevents an uneven load
common to two leading shoe type brakes while distribution on the wheel hub bearings.
maintaining the many advantages of this type of brake. This type of brakes is widely used on the rear wheels of
many vehicles.
Auto-Adjuster
Operation of Auto-adjuster
The entire auto-adjust mechanism is incorporated into • When the brake shoe 18 comes into contact with
the wheel assembly, and the adjust operation is carried the brake drum, the frictional force generated
out only when in the forward movement. between the adjust screw 13 and the adjust nut 12
The operation of the auto-adjuster is as follows: gets larger, and the adjust gear 11 cannot be
• When fluid pressure is applied to the oil chamber rotated by the force of the over-travel spring 8 .
A , the piston, which is resistant to the over-travel (The adjust gear and the adjust nut are welded into
spring installed between the bracket 14 and the a monolithic construction.) That is, the automatic
adjust lever 6 , is forced out to the brake shoe 18 adjustment of the shoe clearance is carried out until
side. (The piston and bracket are welded into a the brake shoe comes in touch with brake drum.
monolithic construction.) However, over adjust can be avoided since this
automatic adjustment will not be performed for the
• When force delivered by the over-travel spring 18 is
increased amount of the piston shift caused by the
intensified as the piston 2 moves, the balance
deformation of the drum and shoe after their
maintained with the lever return spring 7 installed
contact.
between the adjust lever 6 and lever pin 10 is
destroyed, and the adjust lever 6 with the lever pin • When the fluid pressure is released from the oil
10 as a pivot, rotates the adjust gear 11 in the chamber A , the force by which the lever return
rotational direction. spring 7 rotates the adjust gear 6 adversely gets
weaker than the frictional force generated between
• When the shoe clearance (clearance between the
the adjust screw 13 and the adjust nut 12 ,therefore,
brake shoe and the brake drum) gets to the
the adjust lever 6 slides on the adjust gear 11 to
specified value, the adjust lever 6 adjusts the shoe
get back to its former state before operation and
clearance by driving one gear tooth or more of the
this operation is completed with the adjust gear 11
adjust gear 11 in the rotational direction through the
left in the state in the rotational direction into which
force of the over-travel spring 8 .
its has been driven.
FRONT DRUM BRAKE ASSEMBLY

TWO LEADING AND DUAL TWO LEADING
REMOVAL
Two Leading Type
Removal Steps
1. Shoe holding spring, cup and pin 4. Wheel cylinder assembly
2. Brake shoe and return spring 5. Back plate and oil shield cover
3. Brake flexible hose and pipe
BRAKE DRUM REMOVAL

(WITH AUTO-ADJUSTER)
Removal Procedure
If the brake drum has step wear or the brake drum edge is
corroded, it will be difficult to remove the brake drum.
The following procedure will make brake drum removal easier.
Drum Inside Diameter 320.0mm (12.60in)

1. Remove the rubber cover from the brake lining clearance
adjusting hole and auto-adjuster lever release hole.
2. Remove the adjust hole cover and adjuster lever release

hole cover.
3. Using φ 5mm plus driver pull it into the adjuster lever

release hole and then pull up the adjust lever.
4. Pull the minus driver into the adjuster hole while pull up the
adjuster lever.
5. Turn the adjuster gear to the marked arrow "LOOSE" on

the packing plate.
Drum Inside diameter 300.0mm (11.81in),

300.0mm (11.81in) and 320.00mm (12.60in)
1. Push the rod to push up the auto-adjuster lever.

adjusting hole.
3. Hold the auto-adjuster lever stationary.
Use a screwdriver to rotate adjusters at back of the brake
to provide clearance between lining and drum.
NOTE:
Be sure to push up the auto-adjuster lever (Step 1).
Failure to do so will result in damage to the teeth of
the auto-adjuster lever.
Take care not to damage the rubber boot with the bar
or the screwdriver.
4. Remove the brake drum.

Dual Two Leading Type
Removal Steps
1. Shoe holding spring, cup and pin 4. Wheel cylinder assembly
2. Brake shoe and spring 5. Back plate and oil shield cover
3. Brake flexible hose and pipe
INSTALLATION
Two Leading Type
Installation Steps
1. Back plate and oil shield cover 4. Brake shoe and return spring
2. Wheel cylinder assembly 5. Shoe holding spring, cup and pin
3. Brake flexible hose pipe
Installation Steps
1. Back Plate and Oil Shield cover
Tighten the back plate and oil shield cover bolts to the
specified torque.
Back Plate and Oil Shield
Cover Bolt Torque N⋅m (kg⋅m/Ib⋅ft)
NPS model 98 (10.0/72)
NQR model 157 (16.0/116)
69 (7.0/51)
Others 88 (9.0/65)
(for Taiwan, Australia and GCC)
2. Wheel Cylinder Assembly

Tighten the wheel cylinder assembly bolts to the specified
torque.
Wheel Cylinder Assembly
Bolt Torque N⋅m (kg⋅m/Ib⋅ft)
Drum Inside Lining
Dia. mm (in) Width mm (in)
279.4 (11.00) 60 (2.36) 27 (2.8/20)
300.0 (11.81) 34 (3.5/25)
75 (2.95)
320.0 (12.60) 43 (4.4/32)
320.0 (12.60) 100 (3.94) 74 (7.5/54)
320.0 (12.60) 120 (4.72) 94 (9.6/69)
3. Brake Flexible Hose and Pope

Tighten the brake pipe flare nuts to the specified torque.
Brake Pipe Flare Nut Torque N⋅m (kg⋅m/Ib⋅ft)
16 (1.6/1.2)
Note
Take care not to twist the piping and the flexible hose.
4. Brake Shoe and Return Spring (Two Leading Type)

1. Before setting the brake shoes, apply a thin coat of
molybdenum disulfide grease to the back plate portions
1 contacting the brake shoe edge as shown in the
illustrations.
2. Apply a coat of molybdenum disulfide grease to the
wheel cylinder parts contacting the shoe 2 .

NOTE:
or the screwdriver.
Drum Inside diameter 279.4mm (11.0in),

300.0mm (11.81in) and 320.00mm (12.60in)

adjusting hole.
NOTE:
or the screwdriver.

BRAKE DRUM REMOVAL

(WITH AUTO-ADJUSTER)
Removal Procedure
If the brake drum has step wear or the brake drum edge is
corroded, it will be difficult to remove the brake drum.
The following procedure will make brake drum removal easier.
Drum Inside Diameter 320.0mm (12.60in)

adjusting hole and auto-adjuster lever release hole.

hole cover.

release Hole and then pull up the adjust lever.
adjuster lever.

the packing plate.
Drum Inside diameter 240mm (9.45in), 290mm (11.42in).


hole cover.

release Hole and then pull up the adjust lever.
adjuster lever.

the packing plate.
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Brake Drum
Brake Drum Inside Diameter

Visually inspect the brake drum for excessive wear and
scoring.
If the brake drum is scored or worn, lathed to the specified
limit.
Use a vernier caliper to measure the brake drum inside
diameter.
Brake Drum Inside Diameter mm (in)
Drum size Standard Limit
228.6 228.6 (9.00) 230.0 (9.06)
240.0 240.0 (9.48) 241.5 (9.51)
279.4 279.4 (11.00) 281.0 (11.06)
290.0 290.0 (11.42) 291.5 (11.48)
300.0 300.0 (11.81) 301.5 (11.87)
320.0 320.0 (12.60) 321.5 (12.66)
0.13 (0.005)
Out of round or less
Brake Lining
Brake Lining Thickness Measurement
Use a vernier caliper to measure the brake lining thickness or
the rivet depth.
If the measured value is less than the specified limit, the brake
shoe assembly and/or the lining must be replaced.
Brake Lining Thickness or Rivet Depth mm (in)
Limit 1.0 (0.039)
Brake Lining Replacement

Brake Lining Removal (Riveted type only)
1. Remove the rivet caulking portions with a hammer and
chisel.
2. Remove the rivets with a hammer and punch.
3. Inspect the brake shoe for cracking.
Installation Steps
1. Brake Plate
Tighten the back plate bolts to the specified torque.
Back Plate Bolt Torque N⋅m (kg⋅m/lb⋅ft)
Drum Inside Lining
228.6 (9.00) 75 (2.95) 108 (11.0/80)
240.0 (9.45) 60 (2.36) 108 (11.0/80)
279.4 (11.00) 60 (2.36) 74 (7.5/54)
290.0 (11.42) 75 (2.95) 108 (11.0/80)
* 44 (4.5/33)
300.0 (11.81) 75 (2.95)
** 108 (11.0/80)
75 (2.95) 43 (4.4/32)
320.0 (12.60) 100 (3.94) 94 (9.6/69)
120 (4.72) 94 (9.6/69)
* Single Tire models ** Dual Tire models
2. Wheel Cylinder Assembly

Tighten the wheel cylinder assembly bolts to the specified
torque.
Bolt Torque N⋅m (kg⋅m/lb⋅ft)
Drum Inside Lining
228.6 (9.00) 75 (2.95) 34 (3.5/25)
240.0 (9.45) 60 (2.36) 25 (2.5/18)
279.4 (11.00) 60 (2.36) 27 (2.8/20)
290.0 (11.42) 75 (2.95) 25 (2.5/18)
300.0 (11.81) 75 (2.95) 34 (3.5/25)
75 (2.95) 43 (4.4/32)
320.0 (12.60) 100 (3.94) 94 (9.6/69)
120 (4.72) 94 (9.6/69)
3. Brake Pipe
Tighten the brake pipe flare nuts to the specified torque.
Brake Pipe Flare Nut Torque N⋅m (kg⋅m/lb⋅ft)
16 (1.6/12)
NOTE:
Take care not to twist the piping.
MASTER CYLINDER ASSEMBLY

REMOVAL
Removal Steps
1. Meter cluster 4. Brake hose
2. Switch connector 5. Master cylinder
3. Brake pipe
INSTALLATION
Installation Steps
1. Meter cluster 4. Switch connector
2. Brake hose 5. Master cylinder
3. Brake pipe
HYDRAULIC BOOSTER AND BRAKE PEDAL ASSEMBLY

REMOVAL
Removal Steps
1. Meter cluster 6. ATF pipe
2. Meter 7. Brake pipe and hose
3. Instrument panel and duct 8. Brake pedal assembly with master
4. Heat protector cylinder and hydraulic booster
5. Steering wheel and column assembly
INSTALLATION
Installation Steps
1. Brake pedal assembly with master 5. Heat protector
cylinder and hydraulic booster 6. Instrument panel and duct
2. ATF pipe 7. Meter
3. Brake pipe and hose 8. Meter cluster
4. Steering wheel and column assembly
LOAD SENSING PROPORTIONING VALVE

REMOVAL
Removal Steps
1. Bolt 4. Load sensing proportioning valve
2. Nut 5. 6. Bracket
3. Washer
INSTALLATION
(for Taiwan, Australia and GCC)
Installation Steps
1. 2. Bracket 5. Nut
3. Load sensing proportioning valve 6. Bolt
4. Washer
Installation Steps
To install, follow the removal steps in the reverse order.
Load Sensing Proportioning Valve Adjustment Standard Table
A B 2 C 2 D 2
Models kg kg/cm kg/cm kg/cm
NKR69EAL -1DXYE 1000 37.6±6 14.7±2 19.7±3.5
NKR69LL -5DXYE 1000 37.6±6 14.7±2 19.7±3.5
NKR69LL -5HXYE 1000 37.6±6 14.7±2 19.7±3.5
NPR69LU -5DXYE 1000 37.6±6 14.7±2 19.7±3.5
NPR69LL -5DXYE 1000 37.6±6 14.7±2 19.7±3.5
NPR69LU -5HXYE 1000 51.3±6 17.3±2 29.8±3.5
NPR69LL -5HXYE 1000 51.3±6 17.3±2 29.8±3.5
NPR65LU -5JXYEJ 1500 51.3±6 17.3±2 29.8±3.5
NPR65PL -5JXYEJ 1500 51.3±6 17.3±2 29.8±3.5
NPR66LU -5JXYHT 1300 51.3±6 17.3±2 29.8±3.5
NKR58EU -3EXYH 700 37.6±6 14.7±2 19.7±3.5
NKR58EU -1EXYH 700 37.6±6 14.7±2 19.7±3.5
NKR58E2U-5EXYH 700 37.6±6 14.7±2 19.7±3.5
NPR58GU -5EXYH 1100 51.3±6 17.3±2 29.8±3.5
NPR58LU -5EXYH 1100 51.3±6 17.3±2 29.8±3.5
NPR58LU -5HWYH 1100 51.3±6 17.3±2 29.8±3.5
NPR66LU -5JXYH 1100 51.3±6 17.3±2 29.8±3.5
NPR58LU -5JXYH 1100 51.3±6 17.3±2 29.8±3.5
NPR99LU -5JXYZ 900 51.3±6 17.3±2 29.8±3.5
NPR99PU -5JXYZ 900 51.3±6 17.3±2 29.8±3.5
NPR99PU -5LXYZ 1300 51.3±6 17.3±2 29.8±3.5
NPR59PU -5LXYHJ 1300 51.3±6 17.3±2 29.8±3.5
NPR66LU -5LXYH 1300 51.3±6 17.3±2 29.8±3.5
NPR66PU -5LXYH 1300 51.3±6 17.3±2 29.8±3.5
NPS66LU -5JXYH 1800 51.3±6 17.3±2 29.8±3.5
NKR66EU -1EXYH 700 37.6±9 17.3±2 29.8±3.5
NKR66E2U-5EXYH 700 37.6±9 14.7±2 19.7±3.5
NKR66LU -5EXYH 700 37.6±9 14.7±2 19.7±3.5
NKR66EU -3EXYH 700 37.6±9 14.7±2 19.7±3.5
NKR66EU -1EXYH 700 37.6±9 17.3±2 29.8±3.5
NKR66E2U-5EXYH 700 37.6±9 14.7±2 19.7±3.5
NKR66LU -5EXYH 700 37.6±9 14.7±2 19.7±3.5
NKR66EU -3EXYH 700 37.6±9 14.7±2 19.7±3.5
NPR70 -5E 1100 51.3±6 17.3±2 29.8±3.5
NPS71 -5J 1800 51.3±6 17.3±2 29.8±3.5
NPR70 -5L 1300 51.3±6 17.3±2 29.8±3.5
NQR70 -5N 1500 51.3±6 17.3±2 29.8±3.5
UNIT REPAIR
WHEEL CYLINDER ASSEMBLY (without Auto-adjuster)
DISASSEMBLY
Disassembly Steps
1. Adjust screw 4. Boot
2. Lock plate 5. Wheel cylinder body
3. Piston assembly 6. Bleeder screw
REASSEMBLY
Reassembly Steps
1. Bleeder screw 4. Piston assembly
2. Wheel cylinder body 5. Lock plate
3. Boot 6. Adjust screw
Disassembly Steps
(With Auto-adjust wheel cylinder
assembly)
Piston pin of adjust side

1. Fit the waste between the lever and spring not to damage
each parts.
2. Disassemble the lever fixing bolt.
2. Remove the piston assy to hold the lever to fit the bracket.
Disassemble lever spring Piston pin of adjust side

each parts.
2. Remove the lever fixing bolt.
3. After running the lever up on the bracket, turn the lever to

the direction at the connecting point of lever and spring.
4. Disassemble the lever from the bracket.
Reassemble
Lever fixing bolt 1. Reassemble the spring hook (short) to the bracket square
Torque:7.85-11.77N⋅m hole and spring hook (long) to the lever.
(0.80-1.20kg⋅m/
5.79-8.68lb⋅ft) 2. Turn the lever to the direction at the connecting point of
lever and spring and reassemble the lever to the bracket.
3. Install the lever fixing bolt to the specified torque.
4. Make sure not to bite the lever between the bolt sleeve and
body surface.
5. Make sure fit the lever to the gear properly after fixing the
bolt.
Plane washer
Make sure to assemble the plane washer of coating side to the
adjust side.
WHEEL CYLINDER ASSEMBLY (WITH AUTO-ADJUSTER)

DISASSEMBLY
(Adjuster Type I)
Disassembly Steps
1. Overtravel spring 6. Adjuster gear
2. Return spring 7. Piston assembly
3. Fitting 8. Boot
4. Adjuster lever 9. Wheel cylinder body
5. Adjusting screw 10. Bleeder screw

DISASSEMBLY
Disassembly Steps
1. Overtravel spring 9. Piston cup
2. Adjuster lever 10. Boot
3. Adjusting screw & gear 11. Boot
4. Adjusting screw 12. Piston
5. Adjuster gear 13. Piston cup
6. Seal 14. Cylinder
7. Seat 15. Breeder
8. Piston

DISASSEMBLY
(Adjuster Type II)

Disassembly Steps
7. Seat 15. Breeder
8. Piston
REASSEMBLY
Wheel Cylinder Assembly (With Auto-adjuster)
(Drum inside diameter 228.6mm, 279.4mm, 300mm, 320mm (Adj Type I))
(Adjuster Type I)
Resassembly Steps
1. Bleeder screw 6. Adjuster screw
2. Wheel cylinder body 7. Adjuster lever
3. Boot 8. Fitting
4. Piston assembly 9. Overtravel spring
5. Adjuster gear 10. Return spring

DISASSEMBLY
Disassembly Steps
7. Seat 15. Breeder
8. Piston

DISASSEMBLY
(Adjuster Type II)

Disassembly Steps
7. Seat 15. Breeder
8. Piston
Disassembly Steps
(With Auto-adjust wheel cylinder
assembly)
Piston pin of adjust side
each parts.
2. Disassemble the lever fixing bolt.
2. Remove the piston assy to hold the lever to fit the bracket.
Disassemble lever spring piston pin of adjust side

each parts.
2. Remove the lever fixing bolt.
3. After running the lever up on the bracket, turn the lever to

the direction at the connecting point of lever and spring.
4. Disassemble the lever from the bracket.
Reassemble
Lever fixing bolt 1. Reassemble the spring hook (short) to the bracket square
Torque:7.85-11.77N⋅m hole and spring hook (long) to the lever.
(0.80-1.20kg⋅m/
5.79-8.68lb⋅ft) 2. Turn the lever to the direction at the connecting point of
lever and spring and reassemble the lever to the bracket.
3. Install the lever fixing bolt to the specified torque.
4. Make sure not to bite the lever between the bolt sleeve and
body surface.
5. Make sure fit the lever to the gear properly after fixing the
bolt.
Plane washer
Make sure to assemble the plane washer of coating side to the
adjust side.
Disassembly Steps
1. Holder Plate
2. Hose Joint
3. O-ring
4. Primary Piston Assembly
Draw out Piston by hand so that it may not be damaged.
5. Plug and O-ring

Install master cylinder on a support plate 1 , fix the support
in a vice, and loosen plug using a wrench 2 .
Support plate : 5-8840-2371-0
Wrench : 5-8840-2370-0
(Master cylinder inside dia. 31.7mm)
(Master cylinder inside dia. 31.7mm, 30.1mm for Taiwan,
Australia and GCC)
Wrench : 5-8840-2369-0
Wrench for Taiwan, Australia and GCC : 5-XXXX-XXXX-0
(Master cylinder inside dia. 34.9mm for Taiwan, Australia
and GCC)
6. Secondary Cup
7. Bushing
8. Primary Cup
9. Supporter
10. Screw
11. Spring Retainer
12. Primary Piston Spring
13. Primary Piston
14. Plug and O-ring
14a.O-ring (RHYTHM make only)
Install master cylinder on a support plate 1 , fix the support
in a vice, and loosen plug using a wrench 2 .

Wrench : 5-8840-2370-0
Australia and GCC)
Wrench : 5-8840-2369-0
and GCC)
Reassembly Steps
1. Secondary Piston
2. Secondary Piston Spring
3. Spring Retainer
4. Screw
5. Secondary Cup
6. Bushing
Combine secondary cup and bushing with secondary
piston as indicated as arrows, and push the assembly in
until bushing comes into contact with cylinder body step.
6a.O-ring (NABCO make only)
Install the O-ring to the bushing.
7. Primary Cup
8. Supporter
9. Plug and O-ring
9a.O-ring (RHYTHM make only)
Combine primary cup and supporter with plug as indicated
by arrows.
Then tighten plug to specified tightening torque.
Plug Torque N⋅m (kg⋅m/lb⋅ft)

Master 28.5 40 (4.1/30)
Cylinder 30.1
Inside 44 (4.5/33)
31.7
dia. (mm) 34.9 49 (5.0/37)

Wrench : 5-8840-2370-0
Australia and GCC)
Wrench : 5-8840-2369-0
and GCC)
Note:
If plug tightened to specified torque is found floating
from cylinder body.
Plug should be disassembled again and check for
abnormal parts fitting. Then reassemble.
10. Primary Piston

11. Primary Piston Spring
12. Spring Retainer
13. Screw
14. Supporter
15. Primary Cup
16. Bushing
1. Combined the parts of primary piston as indicated by
arrows.
Then push the assembly in until bushing comes into
contact with the step in cylinder body.
2. Draw out primary piston alone taking care not to be let
bushing get out of the step.
17. Secondary Cup

18. Plug and O-ring
Combine secondary cup with plug as indicated by arrow,
and tighten to specified tightening torque.
Plug Torque N⋅m (kg⋅m/lb⋅ft)

Master 28.5 40 (4.1/30)
Cylinder 30.1
Inside 44 (4.5/33)
31.7
dia. (mm) 34.9 49 (5.0/37)

Wrench : 5-8840-2370-0
Australia and GCC)
Wrench : 5-8840-2369-0
and GCC)
Note:
If plug tightened to specified torque is found floating
from cylinder body.
Plug should be disassembled again and check for
abnormal parts fitting. Then reassemble.
5A-150 HYDRULIC BRAKES
Power Piston Assembly
Disassembly Steps
1. Nut 5. Gasket
2. Washer 6. Plate
3. Plate 7. Washer
4. Gasket 8. Push rod
Disassembly Steps
1. Nut
Use a wrench to loosen the nut.
2. Washer
3. Plate
4. Gasket
5. Gasket
6. Plate
7. Washer
8. Push rod
REASSEMBLY
Power Piston Assembly
Reassembly Steps
1. Push rod 5. Gasket
2. Washer 6. Plate
3. Plate 7. Washer
4. Gasket 8. Nut
HOME
HOME
LGBRA-WE-9421
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all countries

except the USA and Canada.
All rights reserved. This manual may not be

reproduced in whole or in part, without the permission
in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
First edition Feb, 1998 8010-15K-0.2

No. LGBRA-WE-9421 PRINTED IN JAPAN

99 - 2003 Isuzu N Series Brakes Manual

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NOTICE

Before using this Workshop Manual to assist you in performing

All material contained in this Manual is based on the latest

This manual is applicable to 1994 year model and later vehicles.

SERVICE INFORMATION 00-1

Brake Pedal Adjustment

Brake pedal free play and allowance

NQR HBB type Front Disc Brake Model 35 (1.38)

Adjusting Screw Notches and Clearance

for Taiwan, Australia and GCC

Parking Brake Lever Travel Adjustment

Rear Wheel Brake N⋅⋅m (kg⋅⋅m/lb⋅⋅ft)

Front Disk Brake (NHR⋅⋅NKR⋅⋅NPR) N⋅⋅m (kg⋅⋅m/lb⋅⋅ft)

Brake Pedal and Control N⋅⋅m (kg⋅⋅m/lb⋅⋅ft)

Parking Brake Drum N⋅⋅m (kg⋅⋅m/lb⋅⋅ft)

5-8840-0279-0 Vacuum punp – !

HYDRAULIC BRAKES 5A-1

Brake Pedal and Control ............................................................................................. 5A- 71

Master Cylinder Assembly (NHR) ............................................................................... 5A-126

Front Drum Brake (Auto-adjuster Type)

Rear Drum Brake (Auto-adjuster Type)

Rear Drum Brake (Auto-adjuster Type)

FRONT DRUM BRAKE ASSEMBLY

BRAKE DRUM REMOVAL

Drum Inside Diameter 320.0mm (12.60in)

2. Remove the adjust hole cover and adjuster lever release

3. Using φ 5mm plus driver pull it into the adjuster lever

5. Turn the adjuster gear to the marked arrow "LOOSE" on

Drum Inside diameter 300.0mm (11.81in),

2. Remove the rubber cover from the brake lining clearance

4. Remove the brake drum.

Dual Two Leading Type

2. Wheel Cylinder Assembly

3. Brake Flexible Hose and Pope

4. Brake Shoe and Return Spring (Two Leading Type)

3. Hold the auto-adjuster lever stationary.

4. Remove the brake drum.

Drum Inside diameter 279.4mm (11.0in),

2. Remove the rubber cover from the brake lining clearance

4. Remove the brake drum.

BRAKE DRUM REMOVAL

Drum Inside Diameter 320.0mm (12.60in)

2. Remove the adjust hole cover and adjuster lever release

3. Using φ 5mm plus driver pull it into the adjuster lever

5. Turn the adjuster gear to the marked arrow "LOOSE" on

Drum Inside diameter 240mm (9.45in), 290mm (11.42in).

2. Remove the adjust hole cover and adjuster lever release

3. Using φ 5mm plus driver pull it into the adjuster lever

5. Turn the adjuster gear to the marked arrow "LOOSE" on

INSPECTION AND REPAIR

Brake Drum Inside Diameter

Brake Lining Replacement

2. Wheel Cylinder Assembly

MASTER CYLINDER ASSEMBLY

HYDRAULIC BOOSTER AND BRAKE PEDAL ASSEMBLY

LOAD SENSING PROPORTIONING VALVE

(for Taiwan, Australia and GCC)

Load Sensing Proportioning Valve Adjustment Standard Table

Piston pin of adjust side

Disassemble lever spring Piston pin of adjust side

3. After running the lever up on the bracket, turn the lever to

WHEEL CYLINDER ASSEMBLY (WITH AUTO-ADJUSTER)

WHEEL CYLINDER ASSEMBLY (WITH AUTO-ADJUSTER)