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

Brake Caliper

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Pad and caliper assembly-Rodeo



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Fig. Fig. 2: Loosen and remove the brake hose-to-caliper retainer bolt-Trooper



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Fig. Fig. 3: After removing the caliper retainer bolts, remove the caliper from the vehicle


CAUTION
Brake shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

  1. Use a turkey baster or other suitable device to remove the brake fluid from the master cylinder reservoir. Discard of the brake fluid properly. Do not reuse old brake fluid.
  2.  
  3. Raise and safely support the vehicle on jackstands.
  4.  
  5. Remove the wheel and tire assemblies.
  6.  
  7. If the brake pads are being replaced (and the caliper is NOT being overhauled), install a C-clamp on the caliper with the solid frame side of the clamp rests against the back of the caliper and the driving screw end rests against the metal part (center backing plate) of the outboard pad. Tighten the clamp until the caliper moves sufficiently to bottom the piston in the bore, then remove the clamp.
  8.  
  9. Remove the caliper mounting bolts from the back of the caliper. If the caliper is not being completely removed from the vehicle, detach it from the mounting bracket and support it using a coat hanger or length of wire. DO NOT allow the hose to be stretched, twisted, kinked or otherwise damaged.
  10.  
  11. If the caliper is being completely removed from the vehicle, place a drip pan below the caliper and disconnect the flexible brake hose-to-caliper banjo-bolt. Discard the pressure fitting washers, then remove the brake caliper from the vehicle and place it on a clean work surface.
  12.  
  13. To inspect the caliper assembly, perform the following procedures:
    1. Check the inside of the caliper assembly for pitting or scoring. If heavy scoring or pitting is present, caliper replacement is recommended.
    2.  
    3. Check the mounting bolts and sleeves for signs of corrosion; if necessary, replace the bolts.
    4.  

  14.  

If the mounting bolts have signs of corrosion, DO NOT attempt to polish away the corrosion. Instead the bolts must be replaced to assure proper caliper sliding and prevent the possibility of brake drag or locking.

To install:
  1. Lubricate and position the caliper bushings and sleeves. Apply silicone lube to the mounting bolts.
  2.  
  3. With both pads installed, place the caliper over the disc, lining up the hole in the caliper ears with the holes in the mounting bracket.
  4.  
  5. If the caliper was completely removed, install the flexible hose to the caliper and secure using the banjo bolt and new washers. Make sure that the brake hose is not twisted or kinked, then tighten the bolt to 24-27 ft. lbs. (31-35 Nm) for all models except Hombre. For Hombre models, tighten to 32 ft. lbs. (44 Nm).
  6.  
  7. Carefully insert the mounting bolts through the bracket and caliper (bushing and sleeves), then tighten to 22-25 ft. lbs. (28-32 Nm) for all models except Hombre. On Hombre models, tighten the bolts to 37 ft. lbs. (50 Nm).
  8.  
  9. Pump the brake pedal a few times to seat the linings against the rotors.
  10.  
  11. Install the wheels, then remove the jackstands and carefully lower the vehicle.
  12.  
  13. Check and refill the master cylinder reservoirs with brake fluid.
  14.  
  15. Properly bleed the hydraulic brake system.
  16.  

OVERHAUL



See Figures 4, 5, 6, 7, 8, 9 and 10



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Fig. Fig. 4: Caliper and components-Hombre



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Fig. Fig. 5: Caliper and component assembly-Trooper, Rodeo, Amigo and Pick-up



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Fig. Fig. 6: With a piece of wood in the caliper, use low pressure compressed air to push the piston out



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Fig. Fig. 7: Remove the piece of wood and piston from the caliper



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Fig. Fig. 8: If equipped, remove the dust boot retainer ring



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Fig. Fig. 9: Remove the dust boot



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Fig. Fig. 10: Use a suitable pick tool to remove the ring seal from inside the caliper bore

  1. Remove the brake caliper from the vehicle and place on a clean work surface.
  2.  
  3. Remove the inlet fitting from the brake caliper and drain all brake fluid.
  4.  
  5. Place a clean shop towel or a piece of wood in the caliper opening. Use a small amount of compressed air and force the piston from the bore.
  6.  


CAUTION
DO NOT apply too much air pressure to the caliper bore. The piston may jump out, causing damage to the piston and/or the operator. Be ABSOLUTELY SURE to keep your fingers away from the piston while air is being applied.

  1. Remove and discard the piston boot and seal. Be careful not to scratch the bore while removing the pieces. Use of a metal tool is NOT recommended.
  2.  
  3. Inspect the piston and the caliper bore for damage or corrosion. Replace the caliper and/or the piston if necessary.
  4.  
  5. Remove the bleeder screw and rubber cap if equipped.
  6.  
  7. Clean all of the parts with non-mineral based solvent and blow dry with compressed air. All rubber parts should be replaced.
  8.  
  9. Inspect the guide pins for corrosion, replace if necessary. When installing the guide pins, coat them with a silicone lubricant.
  10.  

To assemble:
  1. Lubricate the piston, caliper and seal with clean brake fluid.
  2.  
  3. Install the seal into the caliper bore making sure it is not twisted in the bore groove.
  4.  
  5. Install the boot onto the piston, then position the piston into the caliper bore.
  6.  
  7. Bottom the piston into the bore using your hand and a piece of wood to compress the piston. Secure the boot to the housing using J-26267 or an equivalent piston seal installer tool.
  8.  
  9. Install the bleeder valve and tighten to 6-7 ft. lbs. (8-9 Nm).
  10.  
  11. Install the caliper to the vehicle and properly bleed the hydraulic brake system.
  12.  

 
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