switch ISUZU TF SERIES 2004 Workshop Manual

3B-54 POWER-ASSISTED STEERING SYSTEM

10. Push the born pad area 1-4.
Tighten the born pad fixing screw to the specifed
torque (without SRS air bag)
Torque: 2 - 4 N




m (0.2 – 0.4 kg




m/17 - 35 lb ft)
NOTE: A horn pad is not struck at the time o
f
attachment.



RTW43BSH000401
11. Align the each snap stud of driver air bag to the hole
of steering wheel. (with SRS air bag)
060R300030

060R300020
12. Push the SRS air bag area1 and area2. At that time
confirm the audible noise of each stud. (with SRS ai
r
bag)
060R300036
13. Enable the SRS (Refer to "Enabling the SRS" in this
section). (with SRS air bag)
14. Install driver knee bolster (reinforcement).
15. Install instrument panel lower cover, then install the
engine hood opening lever.
16. Connect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)
17. Connect the battery "-" terminal cable. (with SRS ai
r
bag)

System Inspection (with SRS air bag)
Turn the ignition switch to "ON" while watching warning
light.
The light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.

POWER-ASSISTED STEERING SYSTEM 3B-55

Steering Column
Steering Column and Associated Parts



This illustration is based on the RHD model.
RTW43BLF000201
Legend
(1) Inflator Module or Horn Pad
(2) Steering Wheel
(3) Steering Column Cover
(4) Combination Switch and SRS Coil Assembly
(5) Steering Column Assembly
(6) Second Steering Shaft
(7) Lower Second Steering Shaft
(8) Instrument Panel Lower Cover
(9) Driver Knee Bolster (reinforcement)



Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to "LOCK".

3. Disconnect the battery "-" terminal cable, and wait at
least 5 minutes. (with SRS air bag)
4. Disconnect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)

3B-58 POWER-ASSISTED STEERING SYSTEM

16. Remove steering column cover.
17. Disconnect the wiring harness connectors located
under the steering column.
18. Remove the combination switch assembly with SRS
coil.
NOTE: The SRS coil is a part of the combination switch
assembly, which can not be replaced separately.
Therefore, be sure not to remove the SRS coil from the
combination switch assembly.
430R300014
19. Remove snap ring.
20. Remove cushion rubber.
21. Remove shift lock cable (For A/T).
22. Disconnect the starter switch harness connecto
r
located under the steering column, then remove
lock cylinder assembly.

23.
Apply a setting mark (1) across the universal joint
and transfer gear to reassemble the parts in thei
r
original position, then remove steering column
assembly and second shaft.
NOTE: A setting mark can be easily made if the shaft is
withdrawn a little by loosening the steering shaft
universal joint.



RTW33BSH000501

Inspection
If the abnormal conditions are found through inspection,
replace the steering column assembly.

Column Capsule
Check capsules on steering column bracket assembly;
all must be securely seated in bracket slots and
checked for any loose conditions when pushed or pulled
by hand.
431RW030

POWER-ASSISTED STEERING SYSTEM 3B-59

Check clearance between capsule and bracket. If must
be within 1mm (0.039 in).
431RW031

Column Universal Joint (between the
power steering unit and the steering shaft)
If the resistance is felt when checked by rotate the joint,
replace the lower second steering shaft.

Shaft Universal Joint (between the lower
second steering shaft and the second
steering shaft)
If the resistance is felt when checked by rotate the joint,
replace the second steering shaft assembly.

Tilt Mechanism
Tilt mechanism should moves smoothly.
While locked the tilt mechanism, be sure the steering
column latch securely by pushing the steering wheel
upward and downward.

Installation
1. Align the setting marks on the second steering shaft
and the steering column assembly (applied at
disassembly).
2. Connect the steering column assembly to the second
steering shaft. Tighten the bolts to the specified
torque.
Torque: 26 - 36 N




m (2.7 – 3.7 kg




m/20 - 27 lb ft)
3. Thread the steering column assembly through the
hole in the dashpanel. Temporarily tighten the
steering column and the second steering shaft fixing
bolt.
4. Connect the lower second steering shaft and the
second steering shaft. Tighten the universal joint
bolts to the specified torque.
Torque: 26 - 36 N




m (2.7 – 3.7 kg




m/20 - 27 lb ft)
5. Tighten the steering column fixing bolt (pedal brkt
side) to the specified torque (This bolt was
temporarily tighten in Step 3).
Torque: 18 -23 N




m (1.8 – 2.3 kg




m/13 - 17 lb ft)

6. Tighten the second steering shaft fixing bolt to the
specified torque (This bolt was temporarily tightened
in Step 3)
Torque: 18 -23 N




m (1.8 – 2.3 kg




m/13 - 17 lb ft)
7. Tighten the steering column fixing bolt (dashpanel
side) to the specified torque (This bolt was
temporarily tighten in Step 3).
Torque: 18 -23 N




m (1.8 – 2.3 kg




m/13 - 17 lb ft)
8. Install combination switch and SRS coil assembly.
After installation of combination switch assembly,
connect the combination switch wiring harness
connector and the SRS 2-way connector located
under the steering column.

3B-60 POWER-ASSISTED STEERING SYSTEM

9. Turn the SRS coil counter clockwise to full, return
about 3 turns and align the neutral mark. (with SRS
air bag)
CAUTION: When turning the SRS coil counte
r
clockwise to full, stop turning if resistance is felt.
Forced further turning may damage to the cable in
the SRS coil.
826RW014
10. When installing the steering column cover, be sure to
route each wire harness as illustrated so that the
harnesses do not catch any moving parts.
825RW017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness

11. Install steering wheel and align the setting marks
made when removing.
Refer to the adjustment method in case a mark is
not attached in this section.
NOTE: Confirm SRS and Horn harness connector is
fixed by the steering wheel.
RTW33BSH000601

CAUTION: Never apply force to the steering wheel in
direction of the shaft by using a hammer or othe
r
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
12. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 31 - 39 N




m (3.2 – 4.0 kg




m/23 - 29 lb ft)
13. Support the module and carefully connect the
module connector and horn lead, then install inflato
r
module.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of inflator to prevent lead
wire from being pinched.
14. Tighten bolts to specified torque.
Torque: 2 - 4 N




m (0.2 – 0.4 kg




m/17 - 35 lb in)
15. Install driver knee bolster (reinforcement).
16. Install instrument panel lower cover.
17. Install the engine hood opening lever.
18. Connect the yellow 2-way SRS connector and horn
lead located under the steering column.
19. Connect the battery "-" terminal cable. (with SRS ai
r
bag)

POWER-ASSISTED STEERING SYSTEM 3B-61

System Inspection (with SRS air bag)
Turn the ignition switch to "ON" while watching warning
light.
The light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.

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

TRANSFER CASE 7D-3

General Description

RUW34DLF000701
The transfer case is used to provide a means of
providing power flow to the front axle. The transfer case
also provides a means of disconnecting the front axle,
providing better fuel economy and quieter operation
when the vehicle is driven on improved roads where
four wheel drive is not required. In addition, the transfer
case provides an additional gear reduction when placed
in low range, which is useful when difficult off-road
conditions are encountered.
Use the 4WD switch on the center cluster panel to
select the drive range. The 4WD indicator lamp will be
lit when 4WD is selected.

TRANSFER CASE 7D-7

Removal
NOTE: Before removing transmission and transfer
assembly from vehicle, change the transfer mode to
2WD using the 4WD push button switch on dash panel.
1.
Disconnect battery ground cable.
2.
Raise and support vehicle with suitable stands. Drain
transfer case fluid.
3. Remove the center exhaust pipe(5). (6VE1 only)
4.
Remove rear propeller shaft (1) and front propelle
r
shaft (2)(3).
NOTE: Apply alignment marks on the flange at both
front and rear sides.
5.
Disconnect harness connectors and clip.

Connector: transfer switch, 2WD-4WD actuator,
speed sensor.
NOTE: Avoid turning the vehicle ignition switch to the
ON position when the 2WD-4WD connector is removed
(battery connected).
If the ignition switch must be turned to the ON position,
the controller must first be removed (memory must be
cleared because the CHECK 4WD INDICATOR will
light).
6.
Remove transfer case (4) from the vehicle.
Installation
1.
Apply a thin coat of molybdenum disulfide grease to
the input shaft spline as shown in the figure.

260R300001

TRANSFER CASE 7D-9

For A/T
261R300002

3.
Connect harness connectors and clip.

Connector: transfer switch, 2WD-4WD actuator,
speed sensor.
4. Install center exhaust pipe(5). (6VE1 only)
5.
Install rear propeller shaft (1) and front propelle
r
shaft (2)(3).
Torque: 63 N




m (6.4 kg




m/46 lb ft)