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

Brake Disc (Rotor)

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See Figure 1



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Fig. Fig. 1: Brake rotor secured in place with retainer bolts-4WD front rotor assembly

INSPECTION



See Figures 2 and 3



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Fig. Fig. 2: Measuring disc run-out



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Fig. Fig. 3: Measuring disc parallelism

Check the disc brake rotor for scoring, cracks or other damage. If rotor run-out is checked, this should be measured while the rotor is installed. Use a dial gauge to check rotor run-out.

  1. Raise and support the front of the vehicle safely using jackstands.
  2.  
  3. Remove the front wheels.
  4.  
  5. Visually inspect the rotor for cracks, excessive scoring or other damage. A light scoring of the surface which does not exceed 0.06 in. (1.5mm) in depth is normal and should not be considered detrimental to brake operation.
  6.  

Before attempting to check rotor run-out on all vehicles, the bearings must be in good condition and exhibit no excessive play.

  1. Check the disc for excessive run-out using a dial indicator:
    1. Position and secure a dial indicator so that the button contacts the disc about 1 in. (25mm) from the outer edge. Set the dial indicator to zero.
    2.  
    3. Rotate the disc one complete revolution. The lateral run-out reading should not exceed 0.005 in. (0.13mm) on 1981-92 models On 1993-96 models, the lateral run-out reading should not exceed or 0.003 in. (0.08mm). If the reading is excessive, recondition or replace the disc.
    4.  

  2.  
  3. Check the disc minimum thickness and the disc parallelism (thickness variation):
    1. Use a micrometer to check the disc thickness at 4 locations around the disc. Make sure the measuring point is at the same distance from the edge at all locations.
    2.  
    3. The thickness should be greater than the minimum specification (which is normally cast onto the disc) and should not vary more than 0.0005 in. (0.013mm). If the variations are excessive, recondition or replace the disc. A disc which is smaller than the discard dimension MUST be replaced for safety.
    4.  

  4.  

REMOVAL & INSTALLATION 2WD Models



EXCEPT HOMBRE

See Figure 4



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Fig. Fig. 4: 2WD front rotor and component assembly-Pick-up

  1. Raise and support the front of the vehicle safely on jackstands.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. Remove the brake caliper mounting bolts and carefully remove the caliper (along with the brake pads) from the rotor. Do not disconnect the brake line. Secure the caliper out of the way with the flexible line still connected.
  6.  

Once the hub/rotor is removed from the vehicle the wheel bearings may be cleaned and repacked or the bearings and races may be replaced. For more information, please refer to the wheel bearing procedures in General Information & Maintenance of this manual.

  1. Carefully pry out the grease cap, then remove the cotter pin, spindle nut, and washer. Remove the hub/rotor, being careful not to drop the outer wheel bearings. As the hub/rotor is pulled forward, the outer wheel bearings will often fall forward.
  2.  
  3. Once the hub/rotor is removed, secure the assembly in a soft-jawed vise. Remove the retainer bolts securing the rotor and hub together. Inspect the hub and replace if needed.
  4.  

To install:
  1. With the rotor secured in a vise, attach the wheel hub to the rotor using the retainer bolts. Tighten the bolts to 47-58 ft. lbs. (61-75 Nm).
  2.  
  3. Carefully install the wheel hub/rotor over the spindle.
  4.  
  5. Using your hands, firmly press the outer bearing into the hub.
  6.  
  7. Loosely install the spindle washer and nut, but do not install the cotter pin or dust cap at this time.
  8.  
  9. Install the brake caliper.
  10.  
  11. Install the tire and wheel assembly.
  12.  
  13. Properly adjust the wheel bearings:
    1. Spin the wheel forward by hand and tighten the nut to 22 ft. lbs. (29 Nm) in order to fully seat the bearings and remove any burrs from the threads.
    2.  
    3. Back off the nut until it is just loose, then finger-tighten the nut.
    4.  
    5. Loosen the nut 1 / 4 - 1 / 2 turn until either hole in the spindle lines up with a slot in the nut, then install a new cotter pin. This may appear to be too loose, but it is the correct adjustment.
    6.  

  14.  
  15. Install the dust cap.
  16.  
  17. Install the wheel/hub cover, then remove the supports and carefully lower the vehicle.
  18.  

HOMBRE

See Figure 5



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Fig. Fig. 5: Front rotor and components-Hombre

  1. Raise and support the front of the vehicle safely on jackstands.
  2.  
  3. Remove the wheel and tire assembly.
  4.  
  5. Remove the brake caliper mounting bolts and carefully remove the caliper (along with the brake pads) from the rotor. Do not disconnect the brake line. Secure the caliper out of the way with the flexible line still connected.
  6.  

Once the rotor is removed from the vehicle the wheel bearings may be cleaned and repacked or the bearings and races may be replaced. For more information, please refer to the wheel bearing procedures in General Information & Maintenance of this manual.

  1. Carefully pry out the grease cap, then remove the cotter pin, spindle nut, and washer. Remove the hub, being careful not to drop the outer wheel bearings. As the hub is pulled forward, the outer wheel bearings will often fall forward.
  2.  
  3. Remove the rotor from the spindle assembly by detaching the retainers. Be careful not to distort the wheel studs during removal.
  4.  

To install:
  1. Install the rotor to the spindle and secure with retainers.
  2.  
  3. Carefully install the wheel hub over the spindle.
  4.  
  5. Using your hands, firmly press the outer bearing into the hub.
  6.  
  7. Loosely install the spindle washer and nut, but do not install the cotter pin or dust cap at this time.
  8.  
  9. Install the brake caliper.
  10.  
  11. Install the tire and wheel assembly.
  12.  
  13. Properly adjust the wheel bearings:
    1. Spin the wheel forward by hand and tighten the nut to 12 ft. lbs. (16 Nm) in order to fully seat the bearings and remove any burrs from the threads.
    2.  
    3. Back off the nut until it is just loose, then finger-tighten the nut.
    4.  
    5. Loosen the nut 1 / 4 - 1 / 2 turn until either hole in the spindle lines up with a slot in the nut, then install a new cotter pin. This may appear to be too loose, but it is the correct adjustment.
    6.  
    7. Proper adjustment creates 0.001-0.005 in. (0.025-0.127mm) end-play.
    8.  

  14.  
  15. Install the dust cap.
  16.  
  17. Install the wheel/hub cover, then remove the supports and carefully lower the vehicle.
  18.  

4WD Models

See Figures 6, 7, 8, 9 and 10



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Fig. Fig. 6: With the rotor installed on the vehicle, loosen the hub-to-rotor retainer bolts



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Fig. Fig. 7: Loosen and remove the hub retainer bolts-automatic hub shown, manual hub removal is similar



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Fig. Fig. 8: With the outer bearing and clutch components removed, lift off the rotor/hub assembly



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Fig. Fig. 9: Remove hub to rotor retainer bolts



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Fig. Fig. 10: With the retainer bolts removed, separate the hub assembly from the rotor

  1. Place the Transfer shift in the 2H position.
  2.  
  3. Raise and support the front of the vehicle safely on jackstands.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. Loosen the hub to rotor retainer bolts.
  8.  
  9. Remove the brake caliper mounting bolts and carefully remove the caliper (along with the brake pads) from the rotor. Do not disconnect the brake line. Secure the caliper out of the way with the flexible line still connected.
  10.  

Once the hub/rotor is removed from the vehicle the wheel bearings may be cleaned and repacked or the bearings and races may be replaced. For more information, please refer to the wheel bearing procedures in General Information & Maintenance of this manual.

  1. Remove the hub nut using hub wrench J-29020-A or equivalent.
  2.  
  3. Remove the hub cap assembly retainer bolts. Remove the spindle nut, washers, and other components. Remove the hub/rotor, being careful not to drop the outer wheel bearings. As the hub/rotor is pulled forward, the outer wheel bearings will often fall forward.
  4.  
  5. Once the hub/rotor is removed, remove the retainer bolts securing the rotor and hub together. Inspect the hub and replace if needed.
  6.  

To install:
  1. With the rotor secured in a vise, attach the wheel hub to the rotor using the retainer bolts. Tighten the bolts to 47-58 ft. lbs. (61-75 Nm). Apply 2.12 oz. (60 gm) of grease to the hub before installing.
  2.  
  3. Carefully install the wheel hub/rotor over the spindle.
  4.  
  5. Install the bearings washers and other components. Position the lock washer so the hub cap assembly bolt holes line up properly.
  6.  
  7. Install the spindle washer and nut and secure using hub wrench J-29020-A or equivalent. Preload the bearing to 3.31 lbs. (1.5 kg).
  8.  
  9. Install the inner cam and any shims. Install the hub cap assembly and secure in place with retainer bolts. Tighten grade M8 bolts to 17-22 ft. lbs. (22-29 Nm), tighten grade M10 bolts to 40-47 ft. lbs. (52-61 Nm).
  10.  
  11. Install the brake caliper.
  12.  
  13. Install the tire and wheel assembly.
  14.  
  15. Remove the supports and carefully lower the vehicle.
  16.  

 
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