ISUZU TF SERIES 2004 Workshop Manual

FRONT SUSPENSION 3C-49

CAUTION: Be careful not to damage the ball joint
boot.


RTW340SH000401
4. Remove bolt and nut.
5. Remove upper ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.


Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.


Inspect screw/taper area of ball for damage.


If any defects are found by the above inspections,
replace the ball joint assembly with new one.





450RS023



After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 1.3–3.2 N




m (0.13-0.33kg




m/0.9-
2.4 lb ft)







450RS024
If the above limits specified are exceeded, replace the
ball joint assembly.
Installation
1. Install upper ball joint.
2. Install bolt and nut (1), then tighten them to the
specified torque.
Torque: 57 N




m (5.8kg




m/42 lb ft)
3. Install nut and cotter pin, then tighten the nut to the
specified torque with just enough additional torque
to align cotter pin holes. Install new cotter pin (3).
Torque: 98 N




m (10.0kg




m/72 lb ft)

3C-50 FRONT SUSPENSION

Lower Ball Joint
Lower Ball Joint and Associated Parts


RTW340LF001601
Legend

(1)
Bolt

(2)
Lower Ball Joint


(3) Nut

(4)
Nut and Cotter Pin


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
in this section.
3. Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle
driving shaft to release the shaft from hub. Refer to
Front Hub and Disc in Driveline/Axle section.
5. Support lower control arm with a jack.
6. Remove lower ball joint nut and cotter pin, then
use remover 5-8840-2005-0 to remove the lowe
r
ball joint from the knuckle.

FRONT SUSPENSION 3C-51

CAUTION: Be careful not to damage the ball joint
boot.




901RW271
7. Remove nut.
8. Remove bolt.
9. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found
through inspection.


Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement .


Inspect screw/taper area of ball for damage.

If any defects are found by the above inspections,
replace the ball joint assembly with new one.




450RS026


After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 2.5-6.4 N




m (0.25-0.65kg




m/1.8-
4.7 lb ft)






450RS024


If the above limits specified are exceeded, replace
the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install bolt.
3. Install nut (3) and tighten it to the specified torque.
Torque: 127 N




m (12.9kg




m/94 lb ft)
4. Install ball joint nut, then tighten it to the specified
torque with just enough additional torque to align
cotter pin holes. Install new cotter pin (4).
Torque: 147 N




m (15.0kg




m/108 lb ft)

3C-52 FRONT SUSPENSION

Bump Rubber
Bump Rubber and Associated Parts
RTW340MF001001
Legend

(1)
Bolt

(2)
Bump Rubber




Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove bolt.
3. Remove bump rubber.
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 :

Bump Rubber

Installation
1. Install bump rubber.
NOTE: Arrow points to be vehicle outer side of afte
r
assembly to vehicle.
2. Install bolt (1), then tighten it to the specified
torque.
Torque: 42 N




m (4.3kg




m/31 lb ft)

FRONT SUSPENSION 3C-53

Special Tools (4





2 High Ride Suspension, 4





2)

ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION
PART NO.
PART NAME

5-8840-2000-0
(J-23907)
Remover; Needle bearing
5-8840-0019-0
Sliding hammer 5-8840-2123-0
(J-36833)
Remover and Installer kit;
Lower arm front bushing
5-8840-2128-0
(J-36838)
Installer; Needle bearing 5-8840-2124-0
(J-36834)
Remover and Installer kit;
Lower arm rear bushing
5-8840-0007-0
(J-8092)
Grip 5-8840-2121-0
(J-36831)
Ball joint remover
5-8840-2127-0
(J-36837)
Installer; Oil seal 5-8840-2005-0
(J-29107)
Tie-rod end remover
5-8840-2307-0
(J-39376)
Installer; Upper arm
bushing

5-8840-0256-0
(J-29775)
Remover and Installer
Upper arm bushing

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"

FRONT SUSPENSION 3C-55
2. VEHICLE PULLS TO RIGHT OR LEFT

Checkpoint Trouble Cause Countermeasure



Steering linkage, and upper
and lower link


Rubber bushing for upper and
lower link


Wheel alignment


Vehicle trim height


Replace


Replace


Adjust


Adjust


Deformed


Worn


Incorrect


Incorrect


Brake adjustment (binding)

Adjust


Replace


Incorrect

Collapsed or break (4

2
Except high ride suspension)
Collapsed or twisted (4

4, 4

2
High ride suspension)
Continued on the next pageOK OK OK OK
NG NG NG NG NG NG
OK OK Coil spring (4
2 Except high
ride suspension)
Torsion bar (4

4, 4

2 High
ride suspension)

Front wheel bearing

Adjust or replace

Incorrect adjustment or
abrasion
NG

3C-56 FRONT SUSPENSION
Checkpoint Trouble Cause Countermeasure



Tire tread (right and left)

Replace (tire)

Difference in wear and tear


Adjust or tighten

Improper or instufficient
tightening

NG NG
OK
Tire pressure or wheel nuts
Continued from the previous page

FRONT SUSPENSION 3C-57
3. INSTABILITY OF VEHICLE

Checkpoint Trouble Cause Countermeasure



Tire pressure


Wheel alignment

Rubber bushings for upper
and lower links. (4
2 Except
high ride suspension)


Adjust


Adjust


Replace


Incorrect



Incorrect


Worn


Steering linkage and upper
and lower links

Replace


Adjust


Worn or deformed


Incorrect

OK OK OK
NG NG NG NG NG
OK OK
Vehicle trim height


Road wheel

Adjust

Deformed or unbalanced
NG

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