ISUZU TF SERIES 2004 Workshop Manual

REAR SUSPENSION 3D-5
LEAF SPRING AND SHOCK ABSORBER
LEAF SPRING AND ASSOCIATED PARTS

460R300001

Legend
1. Parking Brake Cable Bracket
2. Nut and Washer
3. Nut and Washer
4. Shock Absorber
5. Nut
6. U Bolt and Seat
7. Lower Clamp
8. Nut
9. Shackle Plate


10. Shackle Pin
11. Rubber Bushing
12. Nut and Plain Washer
13. Spring Pin
14. Leaf Spring
15. Bump Rubber

3D-6 REAR SUSPENSION
F03L100003

Removal
 Jack up the rear axle and place chassis stands under the
frame near the front end of the rear spring brackets.
Note:
 Be careful not to stretch the flexible brake hose o
r
parking brake cable.
 Support the vehicle on the specified jack point.
1. Remove the parking brake cable (1) from the leaf spring.
2. Loosen the shock absorber fixing nut and remove the nu
t
and special washer (2) from the lower clamp.



3. Remove the shock absorber fixing nut and washer (3) at
frame side.
4. Lifting the rear axle by a jack, remove the shock absorbe
r
(4) and lower the jack.
5. Remove the U bolt fixing nut (5).
6. Take out the U bolt (6), seat and lower clamp (7).
7. Support the leaf spring by a jack and remove the shackle
pin fixing nuts (8).
8. Drive out the shackle pin (10), using a brass bar and
hammer.
9. Remove the shackle plate (9) and rubber bushings (11).
10. Remove the nut (12) and drive out the shackle with a
hammer using a brass bar.
11. Remove the leaf spring (14).
12. Remove the bump rubber (15).

REAR SUSPENSION 3D-7
INSPECTION AND REPAIR
Make correction or parts replacement if wear, damage or their abnormal conditions are found through inspection.





Visual Check
Inspect the following parts for wear, damage, nuts or other
abnormal conditions.
 Leaf spring assembly
 Clip
 Center bolt
 U-bolt
 Spring pin
 Shackle pin
 Shock absorber
 Rubber bumper
 Rubber bushing
 Bump rubber seat



Shackle Pin
Shackle Pin diameter mm (in)
17.93 - 18.00 (0.706 - 0.709)



Spring Pin
Spring Pin Diameter mm (in)
13.8 - 14.0 (0.543 - 0.551)



Shock Absorber
Inspection operation of shock absorber
If no resistance is felt while expanding the shock absorber, that
indicates the absorber is faulty.

3D-8 REAR SUSPENSION

Installation
1. Install the bump rubber (15) and bolt and tighten it to the
specified torque.
Torque Nm (kgm/lbft)
42 (4.3/31)
2. Install the leaf spring (14).
 The leaf spring assembly should be installed so that the
built-in rubber bush is toward the front.
 Align the holes of the spring eye and frame bracket.
 Insert the spring pin (13) toward vehicle inner side
through the frame bracket holes and the spring bush
hole.
 Tighten the nut (12) a little and after the vehicle is
lowered, tighten it to the specified torque.
Torque N
m (kg
m/lb
ft)
152 (15.5/112)
RTW340LF000101

 Apply rubber grease to inside and outside of the rubber
bushing.
 Install the rubber bushings (11) into the hole of the
frame side bracket and the spring rear eye.
 Install the shackle pin (10) and shackle plate (9).
 Tighten the nuts (8) a little and after vehicle is lowered,
tighten it to the specified torque.
Torque Nm (kgm/lbft)
98 (10/72)
3. Support the lower clamp (7) under the leaf spring.
4. Apply oil to the thread portion of U bolt (6).
Install the U bolt and seat on the rear axle and insert the U
bolt in the lower clamp holes.
5. Tighten the nut (5) to the specified torque.
Torque Nm (kgm/lbft)
78 (8.0/58)
6. Install the shock absorber (4) and inner washer on the
lower clamp pin and frame side pin.
7. Install the washer and nut (3) on the frame side pin and
tighten the nut to the specified torque.
Torque Nm (kgm/lbft)
39 (4.0/29)
8. Install the washer and nut (2) on the lower clamp pin and
tighten the nut to the specified torque.
Torque Nm (kgm/lbft)
39 (4.0/29)
9. Install the parking brake cable (1) on the leaf spring and
tighten the nut at its bracket.
Torque N
m (kg
m/lb
ft)
7 (0.7/5)

REAR SUSPENSION 3D-9

LEAF SPRING ASSEMBLY

F03L100004

Disassembly
1. Remove the bushing using a bench press and a suitable
metal fitting.



RTW430SH000101

2. Apply a setting mark across the springs before
disassembling the leaf spring assembly.

F03L100006

3. Use a bench press and remove the center bolt.
 Discard center bolt and install a new one.

465R300001

4. Disassemble the leaf spring assembly.


Inspection and Repair
Inspect leaf spring, bush, clips, liners and center spacer for
wear, damage, rust or other abnormal conditions and if
necessary, repair or replace it.

3D-10 REAR SUSPENSION
Reassembly
1. Apply grease to both faces of each leaf spring at
reassembly.
2. Set the leaf springs aligning the setting mark before
disassemble.

F03L100006

3. Assemble the leaf springs using a bench press.
4. Apply grease to the outside of the bushing.
Install a new center bolt and tighten it to the specified
torque.
Torque N
m (kg
m/lb
ft)
29 (3.0/22)
5. Install the bushing using a bench press and a suitable
metal fitting.

REAR SUSPENSION 3D-11
TROUBLESHOOTING
1. BODY INCLINATION

Checkpoint Trouble Cause Countermeasure

ReplaceBushings worn or
disintegrated NG
Mounting brackets
Shock absorbers
ReplaceDefective
Spring brackets and U-bolts
Shackle pins and bushings
Replace
Retighten
Replace
Cracked
Bolt loosened
Worn or disintegrated
Regrease
Replace
Poorly lubricated
Weak or broken
OK OK
OK
NG NG NG NG NG NG
OKSpring

3D-12 REAR SUSPENSION
2. REDUCTION GROUND CLEARANCE

Checkpoint Trouble Cause Countermeasure

Bushings
Leaf springs
Regrease
Replace
Retighten
Replace
Poorly lubricated
Deteriorated or disintegrated
Loosened
Broken
Springs clip bandsReplaceWorn or broken
Continued on the next pageOK
NG NG NG NG NG
OK OK
Condition of load
Wipe off excess greaseOver lubricated NG

REAR SUSPENSION 3D-13
Checkpoint Trouble Cause Countermeasure



Replace

Cracked or damaged


Retighten

Loose

OK
NG
NG
Parts for looseness

Continued from the previous page

3D-14 REAR SUSPENSION
3. SPRING BREAKAGE
Checkpoint Trouble Cause Countermeasure


Replace

Oil leakage

NG

Shock absorber


Replace

Bushing worn


U-bolts


Shackle pins and pivot pins


Replace


Retighten


Retighten


Damaged


Bolts and nuts for loosening


Bolts and nuts for loosening


Replace

Worn or damaged

OK
OK
NG
NG
NG
NG
NG
OK

Condition of loading

Continued on the next page