boot ISUZU TF SERIES 2004 User Guide

MAINTENANCE AND LUBRICATION 0B-3
SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading

1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
TRANSMISSION OR TRANSMISSION
WITH TRANSFER CASE


* AT Automatic transmission fluid - - - I - - - I - - - I - - - I - - - I * AT Transfer case oil - R - I - - - R - - - I - - - R - - - I * Manual transmission fluid - R - I - - - R - - - I - - - R - - - I * Transfer case oil - - - I - - - | - - - I - - - | - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Gear control mechani sm for
looseness - - - I - - - I - - - I - - - I - - - I
PROPELLER SHAFT Loose connections - I - I - I - I - I - I - I - I - I - I * Universal joints and splines for wear
- I - I - I - I - I - I - I - I - I - I
4WD Universal joints and splines - L - L - L - L - L - L - L - L - L - L FRONT AND REAR AXLE * Differential gear oil (Front and rear) - R - I - - - R - - - I - - - R - - - I Oi l l eakage I I I I I I I I I I I I I I I I I I I I Shift on the fly system gear oil I - - I - - - I - - - I - - - I - - - I Front axle shaft rubber boot for
damage - - - I - - - I - - - I - - - I - - - I
Axle shafts for distortion or damage - - - I - - - I - - - I - - - I - - - I Axle case for distortion or damage - - - I - - - I - - - I - - - I - - - I STEERING Power steering fl ui d I I I I I I R I I I I I I R I I I I I I Oil leakage I I I I I I I I I I I I I I I I I I I I * Steering system for looseness or
damage - I - I - I - I - I - I - I - I - I - I
Power steering hose - I - I - I - I - I - I - R - I - I - I Steering wheel play I I I I I I I I I I I I I I I I I I I I Steeri ng function I I I I I I I I I I I I I I I I I I I I Right and left turning radius - - - I - - - I - - - I - - - I - - - I Wheel alignment - - - I - - - I - - - I - - - I - - - I Joint ball for oil leakage or damage - I - I - I - I - I - I - I - I - I - I Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I

0B-4 MAINTENANCE AND LUBRICATION




I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
SERVICE BRAKES Brake fluid I - - I - - - I - - - I - - - I - - - I Brake sy stem for fluid l eakage I I I I I I I I I I I I I I I I I I I I Brake functi on I I I I I I I I I I I I I I I I I I I I * Rear brake lining and drum wear - I - I - I - I - I - I - I - I - I - I * Front disc brake pads and discs - I - I - I - I - I - I - I - I - I - I Brake pedal travel and free play I I I I I I I I I I I I I I I I I I I I Pipes and hoses loose connections
or damage I I - I - I - I - I - I - I - I - I - I
PARKING BRAKE Parki ng brake functi on I I I I I I I I I I I I I I I I I I I I Parki ng brake l ever travel I I I I I I I I I I I I I I I I I I I I Cables for looseness or damage
and guide for damage I I I I I I I I I I I I I I I I I I I I
Ratchet for wear or damage - I - I - I - I - I - I - I - I - I - I SUSPENSION Leaf / Coil / Torsion bar springs for
damage I I - I - I - I - I - I - I - I - I - I
Mount for l ooseness or damage I I - I - I - I - I - I - I - I - I - I Shock absorbers for oil leakage - I - I - I - I - I - I - I - I - I - I Shock absorbers mount for
looseness - I - I - I - I - I - I - I - I - I - I
Rubber bushes of suspension wear
or damage - I - I - I - I - I - I - I - I - I - I
Spring action for loss of balance
due to weakening - - - I - - - I - - - I - - - I - - - I
Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I WHEELS Wheel nuts T T - T - T - T - T - T - T - T - T - T Wheel disc for damage I I - I - I - I - I - I - I - I - I - I Hub bearing grease - - - - - R - - - - - R - - - - - R - - Front and rear hub bearing for
looseness - I - I - I - I - I - I - I - I - I - I
Tire pressure and damage I I - I - I - I - I - I - I - I - I - I Tire rotation (Rotate as required) OTHERS Bolts and nuts on chassis and body I I - I - I - I - I - I - I - I - I - I Lube front free – wheding hubs - - - - - L - - - - - L - - - - - L - -

0B-6 MAINTENANCE AND LUBRICATION




I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading or
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60months whichever comes
fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
PROPELLER SHAFT Loose connections (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Loose connections (4JA1-TC) - - I - - I - - I - - I - - I - - I - - * Universal joints and splines for wear (4JH1-TC) - I - I - I - I - I - I - I - I - I - I * Universal joints and splines for wear (4JA1-TC) - - I - - I - - I - - I - - I - - I - - 4WD Universal joints and sliding
sleeve (4JH1-TC) - L - L - L - L - L - L - L - L - L - L FRONT AND REAR AXLE * Differential gear oil (Front and rear) (4JH1-TC) - R - I - - - R - - - I - - - R - - - I * Differential gear oil (Front and rear) (4JA1-TC) - - R - - I - - R - - I - - R - - I - - Oil leakage (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Oil leakage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Shift on the fly system Gear oil (4JH1-TC) I - - I - - - I - - - I - - - I - - - I Gear oil (4JA1-TC) - - - - - - - - I - - - - - - - - I - - Front axle shaft rubber boot for
damage (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Front axle shaft rubber boot for
damage (4JA1-TC) - - - - - - - - I - - - - - - - - I - - Axle case for distortion or damage (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Axle case for distortion or damage (4JA1-TC) - - - - - - - - I - - - - - - - - I - - Axle shafts for distortion or damage (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Axle shafts for distortion or damage (4JA1-TC) - - - - - - - - I - - - - - - - - I - - STEERING Power steering fluid (4JH1-TC) I I I I I I R I I I I I I R I I I I I I Power steering fluid (4JA1-TC) - - - - - - - - - - - I - - - - - - - - Oil leakage (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Oil leakage (4JA1-TC) - - I - - R - - I - - R - - I - - R - - * Steering system for looseness or
damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I * Steering system for looseness or
damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Power steering hose (4JH1-TC) - I - I - I - I - I - I - R - I - I - I Power steering hose (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Steering wheel play (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Steering wheel play (4JA1-TC) - - I - - I - - I - - R - - I - - I - - Steering function (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Steering function (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Right and left turning radius (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Right and left turning radius (4JA1-TC) - - - - - - - - I - - - - - - - - I - - Wheel alignment (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Wheel alignment (4JA1-TC) - - - - - - - - I - - - - - - - - I - - Joint ball for oil leakage or damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Joint ball for oil leakage or damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Joint ball rubber boot for damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Joint ball rubber boot for damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - -

MAINTENANCE AND LUBRICATION 0B-7




I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading or
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60months whichever comes
fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
SERVICE BRAKES Brake fluid (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Brake fluid (4JA1-TC) - - - - - I - - - - - I - - - - - I - - Brake system for fluid leakage
(4JH1-TC) I I I I I I I I I I I I I I I I I I I I Brake system for fluid leakage
(4JA1-TC) - - I - - I - - I - - I - - I - - I - - Brake function (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Brake function (4JA1-TC) - - I - - I - - I - - I - - I - - I - - * Front Disc brake pads and discs wear (4JH1-TC) - I - I - I - I - I - I - I - I - I - I * Front Disc brake pads and discs wear (4JA1-TC) - - I - - I - - I - - I - - I - - I - - * Rear brake lining and drum wear (4JH1-TC) - I - I - I - I - I - I - I - I - I - I * Rear brake lining and drum wear (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Brake pedal travel and play (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Brake pedal travel and play (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Pipes and hoses for loose
connections or damage (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Pipes and hoses for loose
connections or damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - PARKING BRAKE Parking brake function (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Parking brake function (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Parking brake lever travel (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Parking brake lever travel (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Cables for looseness or damage and
guide for damage (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Cables for looseness or damage and
guide for damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Ratchet for wear or damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Ratchet for wear or damage (4JA1-TC) SUSPENSION Leaf/Coil/Torsion bar springs for
damage (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Leaf/Coil/Torsion bar springs for
damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Mount for looseness or damage (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Mount for looseness or damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Shock absorbers for oil leakage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Shock absorbers for oil leakage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Shock absorbers mount for
looseness (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Shock absorbers mount for
looseness (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Rubber bushes of suspension wear
or damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Rubber bushes of suspension wear
or damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Spring action for loss of balance due
to weakening (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Spring action for loss of balance due
to weakening (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Joint ball rubber boot for damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Joint ball rubber boot for damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - -

MAINTENANCE AND LUBRICATION 0B-9


Diesel Engine model (Engine oil that meet or exceeds ACEA B3 specification)
I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate


SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading or
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60months whichever comes
fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
DIESEL ENGINE * Engine oil - - - R - - - R - - - R - - - R - - - R* Engine oil filter - - - R - - - R - - - R - - - R - - - ROil leakage and contamination - - - I - - - I - - - I - - - I - - - I Idling speed and acceleration - - - I - - - I - - - I - - - I - - - I Fan belt tension and damage - - - I - - - I - - - I - - - I - - - I Exhaust system - - - I - - - I - - - I - - - I - - - I All hoses and pipes in engine
compartment for clog of damage
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
I
Valve clearance - - - A - - - A - - - A - - - A - - - A * Air cleaner element - - - I - - - I - - - R - - - I - - - I Fuel filter - - - - - - - - - - - R - - - - - - - - Engine coolant concentration - - - I - - - I - - - I - - - I - - - I Cooling system for water leakage - - - I - - - I - - - I - - - I - - - I CLUTCH Clutch fluid - - - I - - - I - - - I - - - I - - - I Clutch pedal travel and play - - - I - - - I - - - I - - - I - - - I TRANSMISSION OR TRANSMISSION
WITH TRANSFER CASE
* Manual transmission with fluid - - - R - - - I - - - R - - - I - - - I * Transfer case oil - - - R - - - I - - - R - - - I - - - I Oil leakage - - - I - - - I - - - I - - - I - - - I Gear control mechanism for
looseness - - - - - - - - - - - I - - - - - - - -
* AT Automatic transmissi on fl ui d - - - - - - - - - - - I - - - - - - - - * AT Transfer case oil - - - R - - - I - - - R - - - I - - - R PROPELLER SHAFT Loose connections - - - I - - - I - - - I - - - I - - - I * Universal joints and splines for wear - - - I - - - I - - - I - - - I - - - I 4WD Universal joints and sliding
sleeve - - - L - - - L - - - L - - - L - - - L
FRONT AND REAR AXLE * Differential gear oil (Front and rear) - - - R - - - I - - - R - - - I - - - ROil leakage - - - I - - - I - - - I - - - I - - - I Shift on the fly system Gear oi l - - - - - - - - - - - I - - - - - - - - Front axle shaft rubber boot for
damage - - - - - - - - - - - I - - - - - - - I
Axle case for distortion or damage - - - - - - - - - - - I - - - - - - - I Axle shafts for distortion or damage - - - - - - - - - - - I - - - - - - - I STEERING Power steering fluid - - - I - - - R - - - I - - - R - - - I Oil leakage - - - I - - - I - - - I - - - I - - - I * Steering system for looseness or
damage - - - I - - - I - - - I - - - I - - - I
Power steering hose - - - I - - - I - - - I - - - R - - - I Steering wheel play - - - I - - - I - - - I - - - I - - - I Steeri ng function - - - I - - - I - - - I - - - I - - - I Right and left turning radius - - - - - - - - - - - I - - - - - - - - Wheel al i gnment - - - - - - - - - - - I - - - - - - - - Joi nt ball for oil l eakage or damage - - - I - - - I - - - I - - - I - - - I Joi nt ball rubber boot for damage - - - I - - - I - - - I - - - I - - - I

0B-10 MAINTENANCE AND LUBRICATION




I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading or
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60months whichever comes
fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
SERVICE BRAKES Brake fluid - - - - - - - I - - - - - - - I - - - - Brake system for fluid leakage - - - I - - - I - - - I - - - I - - - I Brake function - - - I - - - I - - - I - - - I - - - I * Front Disc brake pads and discs wear - - - I - - - I - - - I - - - I - - - I * Rear brake lining and drum wear - - - I - - - I - - - I - - - I - - - I Brake pedal travel and play - - - I - - - I - - - I - - - I - - - I Pipes and hoses for loose
connections or damage - - - I - - - I - - - I - - - I - - - I
PARKING BRAKE Parking brake function - - - I - - - I - - - I - - - I - - - I Parking brake lever travel - - - I - - - I - - - I - - - I - - - I Cables for looseness or damage and
guide for damage
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
-
Ratchet for wear or damage - - - I - - - I - - - I - - - I - - - I SUSPENSION Leaf/Coil/Torsion bar springs for
damage - - - I - - - I - - - I - - - I - - - I
Mount for looseness or damage - - - I - - - I - - - I - - - I - - - I Shock absorbers for oil leakage - - - I - - - I - - - I - - - I - - - I Shock absorbers mount for
looseness - - - I - - - I - - - I - - - I - - - I
Rubber bushes of suspension wear
or damage - - - I - - - I - - - I - - - I - - - I
Spring action for loss of balance due
to weakening - - - - - - - - - - - I - - - - - - - -
Joi nt ball rubber boot for damage - - - I - - - I - - - I - - - I - - - I WHEELS Wheel nuts - - - T - - - T - - - T - - - T - - - T Wheel disc for damage - - - I - - - I - - - I - - - I - - - I Hub bearing grease - - - - - - - R - - - - - - - R - - - - Front and rear hub bearings for
looseness - - - I - - - I - - - I - - - I - - - I
Tire pressure and damage I - - I - - - I - - - I - - - I - - - I Tire rotation (Rotate as required) OTHERS Bolts and nuts on chassis and body - - - I - - - I - - - I - - - I - - - I Lube front free - wheeling hubs - - - - - - - L - - - - - - - L - - - -

MANUAL TRANSMISSION 7B1-19

Disassembly
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case
and drain the lubricant.
3. Remove the clutch release bearing with spring
(6)(11) from the transmission case.
4. Remove the shift fork (7)(12), and boot. (Diesel
engine, C24NE)
5. Remove the shift fork snap pin. (6VE1)
6. Remove the shift fork pin and shift fork from the
fulcrum bridge. (6VE1)


RTW47BSH000601

Legend
(1) Shift fork pin
(2) Shift fork
(3) Release bearing
7. Remove the fulcrum bridge from the transmission
case. (6VE1)
RTW37ASH0002

Legend
(1) Fulcrum bridge
8. Remove the front cover (9) and gasket from the
transmission case.
9. Remove snap ring (8) fixing counter front bearing.
10. Use a pair of snap ring pliers to remove the snap
ring (10) fixing top gear bearing.

226RS001
11. Remove the speedometer sensor (2).
Remove the plate (2).
Remove the driven gear bushing and driven gear
(2).
NOTE : Apply a reference mark to the driven gear
bushing before removal.
12. Remove gear control box assembly (1).

MANUAL TRANSMISSION 7B1-77

Disassembly
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case
and drain the lubricant.
3. Remove the clutch release bearing with spring (5)
from the transmission case.
4. Remove the shift fork, and boot. (Diesel engine,
C24NE)
5. Remove the shift fork snap pin. (6VE1)
6. Remove the shift fork pin and shift fork from the
fulcrum bridge. (6VE1)



RTW47BSH000601

Legend
(1) Shift fork pin
(2) Shift fork
(3) Release bearing
7. Remove the fulcrum bridge from the transmission
case. (6VE1)
RTW37ASH0002

Legend
(1) Fulcrum bridge
8. Remove the front cover (8) and gasket from the
transmission case.
9. Remove snap ring (7) fixing counter front bearing.
10. Use a pair of snap ring pliers to remove the snap
ring (9) fixing top gear bearing.

226RS001
11. Remove gear control box assembly (1).
12. Remove the rear case assembly (2) from the
transmission case (4) and intermediate plate (3).
13. Remove intermediate plate with gear assembly (3)
from transmission case (4).

POWER-ASSISTED STEERING SYSTEM 3B-13

Power Steering Unit Disassembled View

This illustration is based on the RHD model. 440R300003
Legend
(1) Tie-rod End
(2) Lock Nut
(3) Clip
(4) Bellows
(5) Band
(6) Tie-rod Assembly
(7) Oil Line
(8) Inner Ball Joint Assembly
(9) Tab Washer
(10) Mounting Rubber
(11) Housing Assembly



Disassembly
NOTE: The valve housing is made of aluminum and
care should be exercised when clamping in a vise, etc.
to prevent distortion or damage.
1. Loosen lock nut and remove tie-rod end.
2. Remove clip and band, then remove bellows.
3. Remove tie-rod assembly.
To remove, move the boot toward the tie-rod end,
then remove tab washer.
4. Remove oil line, mounting rubber and dust cover.
Inspection and Repair
Inspect the following parts for wear, damage or any
abnormal conditions.

FRONT SUSPENSION 3C-9

Shock Absorber
Shock Absorber and Associated Parts


RTW440LF001201

Legend

(1)
Shock Absorber ASM with coil

(2)
Nut

(3)
Nut

(4)
Nut


(5)
Lower ball joint Nut and cot ter pin

(6)
Nut

(7)
Bolt

(8)
Cam bolt


Removal
1. Raise the vehicle and support it with suitable
safety stands.

2. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.
3. Remove nut (6).
CAUTION: Be careful not o break the ball joint boot.