ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Adjustments

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FRONT DISC BRAKES



Disc brakes are not adjustable. They are, in effect, self-adjusting during normal operation.

REAR DRUM BRAKES



Normal adjustments of the rear drum brakes are automatic and are made during the reverse applications of the brakes. The following procedure should be used only if the linings have been replaced.

  1. Raise and support the rear of the vehicle safely on jackstands.
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  3. Using a punch and a hammer on the rear of the backing plates, knock out the lanced metal areas near the star wheel assemblies on each plate. The metal areas may already have been removed and covered with rubber adjustment plugs, if so remove the plugs by grasping and pulling out with a pair of pliers.
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After knocking out the lanced metal areas from the backing plate, the wheels must be removed and all of the metal pieces discarded, then the wheels should be reinstalled for adjustment.

  1. Insert a suitable brake adjustment tool such as J-4735 or equivalent, into the breaking plate slots and engage the lowest possible tooth on the star wheel. Move the end of the brake tool downward to move the star wheel upward and expand the adjusting screw. Repeat this operation until the wheels can just be turned by hand. This is a position immediately before the brakes lock.
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The brake drag should be equal at both wheels.

  1. Back off the adjusting screws 24 notches (clicks). By the time you have backed off the adjustment 12 clicks, the brakes should have no drag. If a heavy drag is still present, the parking brake cable is likely in need of adjustment.
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  3. Make sure both sides of the brakes are properly adjusted. When backing off the brakes on the other side, the adjusting lever must be backed off the same number of turns to prevent side-to-side brake pull.
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  5. After the brakes are adjusted, install a rubber cover into each of the the backing plate slots. To complete the brake adjustment operation, make several stops while backing the vehicle to fully equalize the adjustment.
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Pump the brake pedal to seat the brake shoes before moving the vehicle.

  1. Road test the vehicle.
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BRAKE PEDAL TRAVEL



Except Hombre

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Brake pedal adjustment-except Hombre

The brake pedal travel is the distance the pedal moves toward the floor from the fully released position.

  1. Start the engine and allow it to reach normal operating temperature. Measure brake pedal height (L 2 ) between the floor of the vehicle and the top of the pedal after the engine is revved several times. Ensure pedal is fully returned by the pedal return spring. Pedal height should be between 6.85-7.24 in. (174-184mm).
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  3. Depress the pedal with approximately 110 lbs. (50 kg) of weight and measure the pedal height (L 3 ) between the floor of the vehicle and the top of the pedal after the engine is revved several times. Pedal height should be between 3.7 in (95mm).
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  5. Turn OFF the engine. Depress the brake pedal several times. Measure the pedal free-play (L). If the measured free-play is not within the specification of 0.23-0.39 in. (6-10mm), adjust brake pedal as follows:
    1. Disconnect the stop light switch connector.
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    3. Loosen the stop light switch locknut and back the switch away from brake pedal.
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    5. Loosen the locknut on the pushrod and adjust the brake pedal to the specified height.
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    7. Tighten the locknut to 15 ft. lbs. (19 Nm).
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    9. Adjust the stop light switch (A) to specification, tighten nut and install connector.
    10.  

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Hombre

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Checking brake pedal travel-Hombre

On the Hombre, the brake pedal is not adjustable, but checking the distance will give an indication of system condition. Inspection should be made using 100 lbs. (445 N) of pressure on the brake pedal, when the brake system is cold. On power brake equipped vehicles, be sure to pump the brakes at least 5 times to remove vacuum from the booster before making the check.

To check the travel, first measure the distance from the top of the released pedal to the bottom of the steering wheel, then depress the pedal (using 100 lbs. of force) and re-measure the distance. The difference between the 2 measurements (pedal travel) should be approximately 4 3 / 4 in. (12cm) for manual brakes or 1 7 / 10 in. (42mm) for power brakes.

If the pedal travel is excessive, check the pedal and the hydraulic brake system for wear or damage and repair, as necessary. If no damage can be found adjustment may be possible. Check the pedal pushrod for an adjuster nut. If equipped with an adjustable pushrod and no damage or wear was found in the brake system, adjust the travel as follows:

  1. From under the dash, remove the pushrod-to-pedal clevis pin and separate the pushrod from the brake pedal.
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  3. Loosen the pushrod adjuster locknut, then adjust the pushrod.
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  5. After the correct travel is established, reverse the removal procedure and check for proper operation.
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