Brake JMC Camioneta
Brake JMC Camioneta
Brake JMC Camioneta
SECTION 05
BRAKE
COMTENTS
PAGE
General description…………………………………………………………………………………………5—3
Specifications………………………………………………………………………………………………5—6
Fixing torque………………………………………………………………………………………………5—7
Wheel brake assembly:front………………………………………………………………………………5—15
Disassembly&reassembly PAD kif:Disk Brake…………………………………………………………5—15
Disassembly…………………………………………………………………………………………… 5—18
Inspection and Repair……………………………………………………………………………………5—20
Reassembly………………………………………………………………………………………………5—22
Wheel brake assembly:Rare………………………………………………………………………………5—24
Disassembly……………………………………………………………………………………………5—26
Inspection and Repair……………………………………………………………………………………5—26
Reassembly………………………………………………………………………………………………5—27
Brake pedal and control……………………………………………………………………………………5—29
Removal and installation…………………………………………………………………………………5—32
Mastor cylinder……………………………………………………………………………………………5—33
Disassembly and reassembly……………………………………………………………………………5—33
Disassembly………………………………………………………………………………………………5—34
Inspection and repair……………………………………………………………………………………5—36
Reassembly………………………………………………………………………………………………5—37
BRAKE5-2
Master cylinder……………………………………………………………………………………………5—39
Removal and installation…………………………………………………………………………………5—39
Serve unit…………………………………………………………………………………………………5—42
Disassembly……………………………………………………………………………………………5—42
Inspection and repair……………………………………………………………………………………5—45
Reassembly………………………………………………………………………………………………5—46
Parking BRAKE……………………………………………………………………………………………5—50
Removal and installation…………………………………………………………………………………5—50
Disassembly and reassembly……………………………………………………………………………5—54
Inspection and repair……………………………………………………………………………………5—56
Troubles shooting…………………………………………………………………………………………5—57
GENERAL DESCRIPTION
BRAKE5-3
PIPING DIAGRAM
BRAKE5-5
Rear wheel
brake Kg.m
Adjustment of brake
pedal
174-184(6.85-7.24)
Height
193-203 (7.60-7.99)
Notice:
You should stop engine and step brake pedal five times
or more before measuring brake pedal free height.
If the reading don’t accord with the range,you can
adjust brake pedal through following methods.
(a) Removal parking pilot light swtch .
(b) Losen the nut of push rod .
(c) Adjust the height of brake pedal to assigned
volume,then turn the push rod to right direction.
1.5-2.5
(d)Install parking pilot light.
Notice:
The height of pedal is more than 95cm under about
50kg.f power.
Clearence
Cock spae and brake pedal(A) clearence
mm
0.5—1.0
BRAKE5-15
Important operation—disassembly
1. brake flexible hose
Removal the brake flexible hose from the
caliper,then seal the opening of flexible hose with
rubberized tape to avoid something else coming
in.
BRAKE5-16
2.bolt
Removal bolt from caliper.
3.pad kit
Turn caliper body up.
6.holder
Don’t damage brake flexible hose when removaling the braket.
Important operation—intallation
7.Front hub and drum assembly
Installation stepa refer to”front driver”of 4C.
6.bracket
torque kg .m
14.2-17.4
Make a mark on cushion before installing bracket.
4.Clip,Cushion
Use a mew one if necessary.
2.bolt
torque kg .m
2.8-3.8
Notice:
Change mew gasket often.
Be sure to put the end gimp of flexible
hose in the fixed position hole.
BRAKE5-18
BRAKE5-19
Disassembly steps
1. bolt
Removal the bolt from caliper body.
3.cushion assembly
Removal cushion assembly.
Mark down the cushion position if necessary
reassembly.
4.clip;cushion
Discard the used clip and install a new one.
BRAKE5-20
Installation steps
1. clip;cushion
2. cushion assembly.
3. caliper assembly
Put caliper to riginal position.To avoid damage
don’t fwist and tense flexible hose.
4.bolt
Joint bolt to caliper.
Torque kg .m
2.8-3.8
BRAKE5-21
Disassembly
Caliper assembly
Disassembly steps
1. sleeve 6.al piston
2. boot 7. piston
3. toot set 8. seal ring
4. bleeder cap and screw 9. caliper body
5. seal ring
BRAKE5-22
Important operation—disassembly
5.boot
Don’t put hand in front of piston to catch the boot
while compressed air.
7.seal piston
Insert a wood pad into caliper body and drive out
the piston when blow into compressed air from
flexible hose joint.
BRAKE5-23
BRAKE5-24
Disc drum
Caliper body Visual check
Crock diameter Inspect the following parts for wear
Piston corrosion scuffs,scratches,deterioration or
Support shelf other abnormal conditions.
Bolt
Diretion pin
Disc drum
Thickness mm
standard Limit
22.0 20.6
Radial pulsate
Limit mm
0.13
Parallet tolerance
Limit mm
0.015
BRAKE5-25
10.5 1.0
BRAKE5-26
Reassembly
Caliper assembly
Reassembly steps
1. caliper body 6.dustproof boot
2. seal ring 7.dustproof boot seat
3. piston 8.sleeve
4. seat piston 9.bleeder cap and screw
5. dust proof seal ring
Important operation—reassembly
1. caliper body
2. piston seal
Apply rubber grease to piston seal and cylinder
surface,then insert piston seal into the cylinder.
BRAKE5-27
3.PISTON
Press the piston in the cylinder my hand only,or
other rapping the tools cause to damage the
cylinder surface or piston seal.
4.SEAL PISTON
Spread special rubber lubrication oil 1g on
piston,then join the seal with piston and caliper
body.
6.DUSTPROOF BOOT;SLEEVE
7.DUSTPROOF BOOT SEAT
Spead special rubber lubricating oil 1g on sleeve
and dustproof boot seat,then push sleeve in
dustproof boot,then fix the dustproof boot on the
caliper body.
MAJOR ASSEMBLY
Disassembly steps
1. Holding spring and cup 6.Brake shoes and adjust levers assembly
2. Returu spring;under 7.Parking brake retainer
3. Returu spring;up 8.Washer
(Between brake shoe and adjust lever) 9.Auto adjuster lever
4. Returu spring;up 10.Assistant brake shoes assembly
(Between two shoes) 11.Adjuster assembly
5. Master brake shoes assembly 12.Wheet cylinder assembly
SUBORDINATE ASSEMBLY
Disassembly steps
Wheel cylinder assembly(12)
13.Wheet cylinder boot 16.Piston return spring
14.Piston assembly 17.Bleeders screw and cap
15.Piston cup
BRAKE5-29
BRAKE5-30
IMPORTANT OPERATION
2.RETURN SPRING;LOW
VISUAL CHECK
Inspect the following parts for wear, corrosion,
scuffs, scratches, deterioration or other abnormal
conditions.
RETURN SPRING
Free length Set length Set load
(mm) (mm) (kg)
Wheel cylin-
37.4 8.0 0.9-1.1
der spring
BRAKE5-31
NOTICE:
DO not use mineral-base cleaning solvents such as gasoline,
Kerosend, acetone, paint thinner, carbon tetrachloride.
PISON CUP
Inspect the piston cup for wear,deform,damage or any other
BRAKE DRUM
standard limit
Inside diameter 254 255.5
Out of round 0.05 0.15
BRAKE5-32
REASSEMBLY
SUBORDINATE ASSEMBLY
WHEEL CYLINGDER ASSEMBLY(7)
1. Wheel cylinder bldy 4.Piston assembly
2. piston return spring 5.Wheel cylinder boot
3. piston cup 6.Bleeder screw and cap
MAJOR ASSEMBLY
REASSEMBLY STEPS
7.Wheel cylinder assembly 14.Return spring;up
8.Adjuster assembly(between & two shoes)
9.Assistant brake shie assembly 15.Return spring ;up
10.Auto adjuster lever (between brake shoe and lever )
11.Washer 16.Return spring ,low
12.Parking brake retainer 17.Holding spring and cup
13.Master brake shoe assembly 18.Brake pipe
BRAKE5-33
IMPORTANT ORPERATION
1. WHEEL CYLINDER BODY
Use clean rubber lubricating oil lubricating the
cylinder inner surface.
4.PISTON ASSEMBLY
Assembly new piston cup for each piston, make
sure the dished side of piston face into cylinder
bore.
Assembly the piston return spring and boot on
piston.
6.BLEEDER SCREW
Torque kg.m
0.7-1.2
18.
Torqe Kg-m
1.3-1.9
MASTER CYLINDER
REMOVAL AND INSTALLATION
Iportant opeation-removal
1. brake pipe
Be careful not spoile the fluid on the paint
surface,othervise surface will be damaged
Iportant operation-installation
2.nut
torque Kg.m
1.0-1.6
1. brake pipe
torque Kg.m
0.9-1.5
BRAKE5-37
DISASSEMBLY
Removal steps
1. dust-pretection unit 7.gasket
2. bolt 7. primary piston assembly
3. brake oil tank 8. secondary piston assembly
4. grommet 9. oil tank cap
5. snap ring 10. diophragm
6. stopper bolt 11. master cylinder body assembly
BRAKE5-38
Important operation
Be careful not to make parts contact mineral oil
or dust,only use clean brake fluid to clean piston
cup instead of gasoline or any other mineral-base
clean solvens.
5.snap ring
6.stopper bolt
Push primary and secondary piston body,
unscrew the bolts from the cylinder, then
detached the primary and secondary piston.
BRAKE5-39
BRAKE5-40
INSPECTION
AND REPAIR
Make necessary correction or parts replacement if wear,damage or ony other abnomal conditions are
found
Visual check
Inspect the following parts for wear, corrosion
scuffs, scratches, deterioration or other abnormal
conditions.
0.04-0.125 0.15
Primary piston
Try press the primary pistonin,check
whether it can slid smoothly or not ofter
reassembly.
BRAKE5-41
REASSEMBLY
Reassembly
1. master cylinder assembly and brake 6.bolt
2. primary piston assembly and spring 7.nose joint
3. secondary piston assembly 8.brake fluid reserve
4. snap ring 9.bolt
5. washer 10.seal
11.brake fluid reserve cover
12.dust-protection sel devic
Important operation
6.bolt
Press the primary piston,assembly new gasket on
the stopper screw.
Torque kg-m
0.7-0.9
7.hose joint
Lubricate nose joint with clean rubber grease.then
insert the nose joint into cylinder making the glaxe
of it up.
Lubricate dust-pretection seal with rubber grease.
(according to the arrow point position).
9.bolt
torque kg.m
0.10-0.20
12.dust-protection sealer
Assembly anti-dust sealer. making the groover
down position.
BRAKE5-44
MASTER CYLINDER
Disassembly and installation
Important operation—disassembly
3.brake pipe
When operation, be careful and don’t make the
brake fluid splash to paint. Otherwise it would
damage the paint.
Torque kg.m
1.5-2.5
3.brake pipe
torque kg.m
0.9-1.5
BRAKE5-47
2.vaccumn pipe
(1) Make sur the mark of the vaccumn
pipe poiate to engine when remove or
replace it.
(2) Make sure the secure valve point to
engine.
BRAKE5-48
VACCUMN BOOSTER
DISASSEMBLY
Disassembly steps
13.diaphragm assembly
1. U clevis yoke
14.retainer
2. lock nut
15.silencer
3. retainer
16.silencer
4. seal assembly
17.valve rod key
5. bushing :boot
18rod assembly;valve plunger
6. rear shell
19.reaction disc
7. front shell
20.valve body
8. spring
21.diaphragn plat
9. duaphragn plate
22.rod assembly;push rod
10. retainer
23.switch;low vaccumn(disel
11. bearing
engine only)
12. seal:valve body
BRAKE5-49
Important operation
3.retainer
Take out the retainer with screw driver.
6.rearshell assembly
Apply petting mark across the shell joint
before disassembly
Note that the diaphragm spring pops out of
position as the rear shell is removed.
Notice:
Retainer must be assemblyed according to dashed
Line as illustrated.
10.retainer
Take out the retainer with screw driver.
13.diaphragm plate
Cut out the diaphragm plate carefully.
Notice:
Be careful not to damage valve body when cutting the
diaphragm.
14.retainer
Take out the retainer with screw driver.
Make corretion or parts replacement if wear,damage or other abnormal conditions are found through
inspection.
Visual inspect
Inspect the following parts for wear, damage,
deformation or other abnormal conditions.
Secure valve
Secure valve is located in the vaccumn pipe.
Air con flow from servo unit to engine.
Air is not allowed flow from engine to servo
unit, if above phenomenon is failed, requires
to be replaced.
BRAKE5-52
REASSEMBLY
Important operation
Apply silicon grease on the parts:
Reaction disc
Valve body inside and outside
Diaphragm plate
Seal and plate
Bearing
seal
Important operation
Apply siticon grease on the surface of parts
before reassembly.
3.
Push valve rod in and assembly the stopper key
on rod.
6.ratainer;master cylinder
Push retainer into rear shell carefully.
Notice:
It’s very important to keep the right pressure on
retainer,leakage would occur if pressure is
low,but valve body edge may be damage if
pressure is too high.
8.diaphragm plate
Install the diaphragm to plate and be careful not
to scruff the diaphragm.
9.fixing disc
Apply silicon grease on the reaction disc
before reassembly.
BRAKE5-55
Make necessary correction or parts replacement if wear,damage or any other abnormal conditions
are found through inspection.
Trouble shooting
Brake does not work effectively
No Ok
No Ok Ok No
Replace brake fluid Check brake drum and lining Check hoses for brake booster
(Both pressure and suction)
No
Ok
No
Ok
Brake drag
No
Ok
No
Ok
Check master cylinder for clogged Check wheel brake lining clearance
return port or check valve and shoe return movement
Ok No
Check wheel cylinder for piston-up Adjust clearance or replace return spring ect
sticking
Brake noise
Clean parts
Replenish and bleed air Check for leakage of Check for sticking Clean or replace brake
from line brake fluid of master cylinder line
No
Ok
Replace parts
No Ok
Brake pull
Ok
No
No Ok
No Ok
Ok
No