ISUZU TF SERIES 2004 Workshop Manual

FRONT WHEEL DRIVE 4C1-61
REASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure.


RTW440LF000401


Reassembly Steps


1. Spacer
2. Ring
3. Snap ring


4. Inner assembly
5. Snap ring
6. X-ring


7. Knob


8. Snap ring


9. Retaining spring


10. Follower


11. Compression spring


12. Clutch assembly




13. Wheel pin


14. Bolt


15. ABS sensor rotor


16. Inner bearing


17. Oil seal


18. Outer bearing


19. Hub and disc assembly


20. Hub nut


21. Lock washer


22. Body assembly


23. Snap ring and shim


24. Cover assembly


25. Bolt

4C1-62 FRONT WHEEL DRIVE



Important Operations
1. Spacer
Apply grease to both faces of spacer.
4. Inner Assembly
Apply grease wheel bearing to inside face of ring.
g(oz)
Amount of grease 6 (0.21)


7. Knob
(1) Apply grease Wheel bearing to outer circumference of knob
and inner circumference of cover.
(2) Align detent ball to either groove of cover.




8. Snap Ring
Turn the smoother face to knob side.
9. Retaining Spring
Align the end of spring to the end of cut portion of clutch spring
groove.


10. Follower
Install follower to clutch so that follower nail will come closer to
the bent portion of retaining spring by aligning follower stopper
nail to outer teeth of clutch. Then, hook retaining spring onto
upper portion of hanger nails of follower.




11. Compression Spring
Turn the smaller diameter side to follower.
12. Clutch Assembly
Align follower nail to handle groove, and then assemble clutch
with knob by pushing and turning clutch counterclockwise to
knob.

FRONT WHEEL DRIVE 4C1-63

13. Wheel Pin
(1) Place hub on a wood workbench or a block of wood,
approx. 6” by 6” to protect the wheel stud ends and threads.
(2) Install wheel stud using a hammer.
Be sure wheel stud is started squarely and seats
completely.

(3) Align index marks and install hub to disc.


14. Bolt
Torque N
m (kgf
m/lb
ft)
103 
10 (10.5 
1/75.9 
7.2)



15. ABS sensor rotor
(1) Set a new ABS sensor rotor, if replacement is required.
(2) Install the ABS sensor rotor in the hub, using special tools.
Installer : 5-8840-2789-0
Grip : 5-8840-0007-0
Refer to the section Brake.


16. Inner Bearing
Outer race ; outer bearing
Install the outer race by driving it into the hub.
Installer : 5-8840-2119-0
(J-36829)
Grip : 5-8840-0007-0
(J-8092)

4C1-64 FRONT WHEEL DRIVE

17. Oil Seal
Installer : 5-8840-2120-0
(J-36830)
Grip : 5-8840-0007-0
(J-8092)
Apply grease (Besco L-2 or equivalent) to the lip portion.
Discard the used oil seal and install a new one.


RTW44CSH000201

18. Outer bearing
Outer race ; outer bearing
Install the outer race by driving it into the hub.
Installer : 5-8522-0054-0
(J-29015)
Grip : 5-8840-0007-0
(J-8092)


19. Hub and Disc Assembly
(1) Apply grease in the hub.
(2) Apply grease (Besco L-2 or equivalent) to the outer and
inner bearing.
g(oz)
Hub 35 (1.23)
Outer bearing 10 (0.35)
Inner bearing 15 (0.53)


20. Hub Nut
(1) Turn the place where there is a chamfer in the tapped hole
to the outer side, and attach the nut.
Wrench : 5-8840-2117-0
(J-36827)

FRONT WHEEL DRIVE 4C1-65


Preload Adjustment
Tighten the hub nut at 29.4 Nm (3 kgfm / 21.716 lb.ft), then
loosen the nut to the full.
Tighten the hub nut at the value given below, using a spring
scale on the wheel pin.
Bearing Preload N(lb)

New bearing and New oil seal 20 - 25 (4.4 - 5.5)
Used bearing and New oil seal 12 - 18 (2.68 - 4.0)
If the measured bearing preload is outside the specifications,
adjust it by loosening or tightening the bearing nut.



21. Lock Washer
Turn the side with larger diameter of the tapered bore to the
vehicle outer side, and attach the washer.
If the bolt holes in the lock plate are not aligned with the
corresponding holes in the nut, reverse the lock plate.
If the bolt holes are still out of alignment, turn in the nut just
enough to obtain alignment,. Screw is to be fastened tightly so
its head may come lower than the surface of the washer.


22. Body Assembly
Apply adhesive (Loctite 15 or equivalent) to the both joining
faces.


23. Snap Ring and Shims
Adjust the clearance between the free wheeling hub body and
the snap ring.
Clearance mm(in)
0 - 0.2 (0 - 0.08)
Adjust Shims Available mm(in)
0.2, 0.3, 0.5, 1.0
(0.008, 0.011, 0.020, 0.039)


24. Cover Assembly
Align stopper nails to grooves of body.

4C1-66 FRONT WHEEL DRIVE

25. Bolt
Torque Nm (kgfm/lbft)
12.0 
2.0 (1.2 
0.2 / 8.7 
1.4)

FRONT WHEEL DRIVE 4C1-67
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair front axle problems. Each troubleshooting chart has three
headings arranged from left to right.
(1) Checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into ten sub-sections:

4




2 Model
1. Wanders and pulls
2. Front wheel shimmy

4




4 Model
1. Oil leak at front axle
2. Oil leak at pinion shaft
3. Noises in front axle drive shaft joint
4. Noises in front axle
5. Wanders and pulls
6. Front wheel shimmy

Propeller shaft
1. Noise
2. Vibration

4C1-68 FRONT WHEEL DRIVE
4





2 Model
1. WANDERS AND PULLS

Checkpoint Trouble Cause Countermeasure


Adjust the wheel bearing
preload

Too tight
NG

Adjust the front alignment

Front alignment

Incorrect


Steering unit

Tighten or replace

Loose or worn
NG NG

Suspension

Tighten or replace


Replace or adjust the inflation


Front or rear suspension parts
loose or broken


Tire

Worn or improperly inflated

OK
NG NG OK OK
OK

Wheel bearing preload

FRONT WHEEL DRIVE 4C1-69
2. FRONT WHEEL SHIMMY

Checkpoint Trouble Cause Countermeasure



Ball joint or bush

Replace the ball joint or bush

Worn


Front alignment

Adjust the front alignment


Adjust or replace


Incorrect


Worn or improperly adjusted

OK
OK NG NG NG
OK
Wheel bearing

Tighten or replace

Loose or worn
NO

Shock absorber

Replace the shock absorber

Worn


Tire

Replace or adjust the inflation

Worn or improperly inflated

OK
NG NG OK

Steering unit

4C1-70 FRONT WHEEL DRIVE
4





4 MODEL
1. OIL LEAK AT FRONT AXLE

Checkpoint Trouble Cause Countermeasure

Front axle housingRepair or replaceCracked
Replace the oil sealWorn or defective oil seal
NG NG
OKOil seal



2. OIL LEAK AT PINION SHAFT

Oil sealReplace the oil sealWorn or defective
Correct the oil levelToo much gear oil
NG NG
OKGear oil level
Pinion flangeTighten or replaceLoose or damaged NG OK



3. NOISES IN FRONT AXLE DRIVE SHAFT JOINT


Replace the drive shaft joints
and bellows

Broken or worn
NG
Drive shaft joints and bellows
(UJ and DOJ)