Check ball ISUZU TF SERIES 2004 Owner's Manual

FRONT SUSPENSION 3C-41

4. Support lower control arm with a harness.
5. Remove speed sensor harness.
6. Remove nut and cotter pin then remove knuckle
using remover 5-8840-2121-0.
CAUTION: Be careful not to damage the ball joint
boot.

RTW340SH000401
7. Remove upper ball joint.
8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and
number of shims.
11. Remove caster shims and note the positions and
number of shims.
12. Remove upper control arm assembly.
13. Remove nut (9).
14. Remove plate (8).

15. Remove bushing (7) by using remover 5-8840-
0256-0.

RTW340SH000501



RTW340SH000601
16. Remove fulcrum pin (6).
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

Upper control arm

Bushing


Fulcrum pin

3C-46 FRONT SUSPENSION

Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the following parts:


Lower control arm


Bushing
Installation
1. Install rear bushing by using installer 5-8840-2124-
0.



Front
901RW053
2. Install front bushing by using installer 5-8840-
2123-0.



Front
901RW156



3. Install lower ball joint bolt.
4. Install torsion bar arm bolt.
5. Install lower control arm.
6. Install rear bolt.
7. Install cam bolt the hole and projection are
upward.
8. Install lower ball joint and tighten it to the specified
torque (12).
Torque: 127 N




m (12.9kg




m/94 lb ft)
9. Install shock absorber and tighten it to the
specified torque (13).
Torque: 93 N




m (9.5kg




m/69 lb ft)
10. Install stabilizer link and tighten it to the specified
torque (14).
Torque: 50 N




m (5.1kg




m/37 lb ft)
11. Install torsion bar arm bracket and tighten it to the
specified torque.
Torque: 116 N





m (11.8kg





m/85 lb ft)
12. Install Torsion bar, refer to Torsion Bar in this
section.
13. Install rear nut and tighten lower link nut finger-
tight (4).
NOTE: Apply oil to the thread.
NOTE: Tighten the nut or bolt with the parts in the
position shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 235 N




m (24.0kg




m/174 lb ft)



450R100002

3C-54 FRONT SUSPENSION
TROUBLESHOOTING
1. VIBRATION, SHOCK, AND SHIMMY OF STEERING WHEEL

Checkpoint Trouble Cause Countermeasure



Check front axle


Check wheel alignment


Check suspension ball joint


Check shock absorber or
attaching nut and bolt


Replace


Adjust


Replace


Replace or retighten


Check steering unit and
linkage


Faulty


Worn


Malfunction or loose


Check upper and lower link
bushings
Replace


Adjust


Worn


Incorrect

OK OK OK
NG NG NG NG NG NG
OK OK
Check vehicle trim height





Improperly adjusted or worn front
wheel bearing.


Worn or incorrectl
y adjusted wheel
bearing.
Replace; refer to Section 4C "Front
Wheel Drive"


Insufficientl
y tightened steeringgear housing.


Wear of steering linkage.


Excessive backlash due to
improper ad
justment of the steeringgear box.

Worn column bearing weakened
column bearing spring, or loose
clamp.
Replace; refer to Section 3B
"Steering"


Improper tire pressure.

Imbalance and deformation of frond
wheel.


Unevenl
y worn tire or insufficient
tightening of wheel nuts.
Replace; refer to Section 3E "Wheel
and Tires"

3C-58 FRONT SUSPENSION
4. STIFF STEERING WHEEL

Checkpoint Trouble Cause Countermeasure



Steering gear box or steering
linkage


Steering linkage


Steering gear


Wheel alignment


Replace the part


Replace


Replace


Adjust

Insufficient lubricants or
impurities present; or
excessively worn

Deformed


Worn or damaged


Incorrect


Replace

Stiff or damaged or lack of
grease

OK OK OK OK OK
NG NG NG NG NG
OK
Upper and ball joint


Steering column with turn
signal switch

Replace

Interference abrasion
NG

Tire pressure

Adjust

Improper
NG

FRONT SUSPENSION 3C-59
5. NOISES

Checkpoint Trouble Cause Countermeasure



Lubricating oil and grease for
upper and lower ball joint


Shock absorber


Stabilizer fixing nuts and bolts


Upper and lower links
bushings


Replace


Replace


Retighten


Replace


Insufficient


Faulty


Loose


Worn


Shock absorber fixing nut and
bolt

Retighten

Loose

Continued on the next pageOK OK OK OK
NG NG NG NG NG
OK

Upper and lower ball joint

Replace

Damaged
NG

TRANSFER CASE 7D-21

Oil Pump


Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
If the area into which the shaft is inserted is excessively
worn or damaged, replace the oil pump assembly.

Clutch Hub Spline Play


Set a dial indicator to the clutch hub to be measured.


Move the clutch hub as far as possible to both the
right and the left.

Note the dial indicator reading.


If the measured value exceeds the specified limit,
the clutch hub must be replaced.
Clutch hub spline play
Standard : 0 – 0.1 mm (0 – 0.004 in)
Limit : 0.2 mm (0.008 in)

226RS042
Bearings
1.
Inspect the condition of all the needles and ball
bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2.
Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.




Ball Bearing Play
1.
Use a dial indicator to measure the ball bearing play.
2.
If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)


226R3043

Synchronizers
The synchronizer hubs and sliding sleeves are a
selected assembly and should be kept together as
originally assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:


Teeth for wear, scuffs, nicks, burrs or breaks.


Keys and springs for wear, cracks or distortion,
replace if these conditions are present.


If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace
the component.

UNIT REPAIR (AW30–40LE) 7A4–7
Major Components (2)
Major Componets (2) and Associated Parts
RT W37 A LF00 0801
E nd O FCallo ut
Legend
(1) Converter housing
(2) Oil pan
(3) Oil strainer assembly
(4) Valve body
(5) Check valve, spring
(6) Spring
(7) Accumulator piston (B–2)
(8) Accumulator piston (C–2)(9) Accumulator piston (B–0)
(10) Accumulator piston (C–0)
(11) Second brake drum gasket
(12) Solenoid wiring
(13) Snap ring, rotor, key (4
4)
(14) Snap ring, speedometer sensor drive gear, ball
(4
2)
(15) Spacer, rotor, key, snap ring (4
2)

UNIT REPAIR (AW30–40LE) 7A4–47
18. Remove the thrust washer.
Inspection and Repair
1. Check discs.
Using a micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in)
If the thickness is less than the minimum, replace
the disc.
25 2RY 0 002 7
2. Check piston return spring
Using calipers, measure the free length of the return
spring.
Standard length: 15.8 mm (0.622 in)
25 2RY 0 002 8
3. Check OD direct clutch piston.
Check that the check ball is free by shaking the
piston. Check that the valve does not leak by
applying low-pressure compressed air.
25 2RY 0 0029
4. Check OD direct clutch drum bushings.
Using a dial indicator, measure the inside diameter
of the OD direct clutch drum bushings.
Maximum inside diameter: 27.11 mm (1.0673 in)
If the inside diameter is greater than the maximum,
replace the OD direct clutch drum.
25 2L10 0009

7A4–60 UNIT REPAIR (AW30–40LE)
7. Place the direct clutch drum onto the OD support.
Holding the direct clutch piston by hand, apply
compressed air to the OD support to remove the
direct clutch piston.
Remove the direct clutch piston from direct clutch
drum.
24 8RY 0 003 0
8. Remove two O-rings from piston.
Inspection and Repair
1. Check piston return spring.
Using calipers, measure the free length of the return
spring.
Standard length: 21.3 mm (0.839 in)
24 7RY 0 003 4
2. Check discs.
Using micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04 mm (0.0803 in)
If the thickness is less than the minimum, replace
the disc.
25 2RY 0 0027
3. Check direct clutch piston.
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.
24 8RY 0 0031

7A4–66 UNIT REPAIR (AW30–40LE)
5. Place special tool on the spring retainer and
compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : J–25048
24 8RY 0 000 3
6. Remove the piston return spring.
7. Place the forward clutch drum onto the OD support.
Holding the forward clutch piston by hand, apply
compressed air to the OD support to remove the
forward clutch piston.
24 8RY 0 004 2
8. Remove the O-rings from piston.
9. Remove the O-ring from forward clutch drum.
10. Remove the oil seal rings and thrust bearing from
forward clutch drum.
Inspection and Repair
1. Check forward clutch piston
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.
24 8RY 0 0031
2. Check forward clutch drum bushing.
Using a dial indicator, measure the inside diameter
of the forward clutch drum bushing.
Maximum inside diameter: 24.08 mm (0.948 in)
If the inside diameter is greater then the maximum,
replace the forward clutch drum.
24 8RY 0 0043
3. Check disc, plate and flange.
Check to see if the sliding surface of the disc, plate
and flange are worn or burnt. If necessary, replace
them.
If the lining of the disc is peeling off or discolored,
or even if parts of the printed numbers are
defaced, replace all discs.