lock ISUZU TF SERIES 2004 Repair Manual

4C1-54 FRONT WHEEL DRIVE

Important Operations
1. 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.


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



3. 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.


4. 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)

4C1-56 FRONT WHEEL DRIVE


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.



9. 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.












11. Snap ring, shims (4





4 model only)
Adjust the clearance between the flange 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)




RTW440SH000901
13.
Bolt
Torque Nm (kgfm/lbft
)
59 (6.0 / 43)

FRONT WHEEL DRIVE 4C1-57
FRONT HUB AND DISC
(4




4 Manual Locking Hub Model)
DISASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure



RTW440LF000301

Disassembly Steps


1. Bolt
2. Cover assembly
3. Snap ring and shim
4. Body assembly
5. Lock washer


6. Hub nut


7. Hub and disc assembly
8. Outer bearing
9. Oil seal
10. Inner bearing
11. ABS sensor rotor


12. Bolt


13. Wheel pin




14. Clutch assembly
15. Snap ring
16. Knob
17. Compression spring
18. Follower


19. Retaining spring
20. X-ring
21. Snap ring
22. Inner assembly
23. Snap ring
24. Ring
25. Spacer

4C1-58 FRONT WHEEL DRIVE



Important Operations
1. Bolt
Before removal, shift transfer lever into “2H” position and set
free wheeling hub knob into “FREE” position.


6. Hub nut
Wrench : 5-8840-2117-0
(J-36827)



7. Hub and disc assembly
Before disassembly, remove the disc brake caliper assembly
and hang it on the frame with wires.
Refer to Section “Brake” for disc brake caliper removal
procedure.


14. Clutch Assembly
While pushing follower knob, turn clutch assembly clockwise
and then remove clutch assembly from knob.



19. Retaining Spring
Remove retaining spring from clutch assembly by turning it
counterclockwise.

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)

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.

FRONT WHEEL DRIVE 4C1-77
ITEM NO. ILLUSTRATION PART NO. PART NAME


FAL-58

5-8522-0054-0
(J-29015)
Inner bearing installer
(for 2WD)


FAL-54

5-8522-0051-0
(J-33161)
Hub oil seal installer
(for 2WD)


FAL-62

5-8840-2117-0
(J-36827)

Hub nut wrench


FAL-17

5-8840-2119-0
(J-36829)
Outer bearing inner race
installer (for 4WD)


FAL-19

5-8840-2120-0
(J-36830)

Oil seal installer (for 4WD)


FAL-18

5-8522-0054-0
(J-29015)
Outer bearing outer race
installer (for 4WD)


FAL-61

5-8840-2137-0
(J-38194)

Inner cam installer


FAL-39


5-8840-2126-0
Auto locking shim gauge
(for 4WD)


FAL-60


5-8840-2125-0
Snap ring installer
(for 4WD)

SHIFT ON THE FLY SYSTEM 4C2-1

DRIVELINE/AXLE
SHIFT ON THE FLY SYSTEM
CONTENTS

Service Precaution............................................. 4C2-1
Shift On The Fly System .................................... 4C2-2
Outline of Shift on The Fly System ................. 4C2-2
Shift On The Fly Electrical Equipment ............... 4C2-3
Axle Shaft Connection and Disconnection ..... 4C2-3
Actuator Assembly.......................................... 4C2-3

Shift On The Fly System and Association
Parts ................................................................. 4C2-4
Disassembly ................................................... 4C2-5
Inspection and Repair..................................... 4C2-6
Reassembly .................................................... 4C2-9
Torque Specifications ..................................... 4C2-12
Special Service Tool ....................................... 4C2-13



Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners o
r
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.