tow ISUZU TF SERIES 2004 Repair Manual

SHEET METAL 2B-5
ENGINE HOOD LOCK
REMOVAL AND INSTALLATION



This illustration is based on the RHD model.
RTW42BMF000101

Removal Steps
Installation Steps


1. Radiator grille


4. Control cable


2. Engine food lock assembly
3. Hood lock control lever
3. Hood lock control lever


2. Engine food lock assembly


4. Control cable
1. Radiator grille



Important Operations - Removal
1. Radiator Grille
Refer to the Radiator Grille in this section.


2. Engine Hood Lock Assembly

Apply setting marks (1) to the hood lock assembly and the
body prior to removal.

4. Control Cable
Pull out the control cable toward the passenger compartment.

GENERAL INFORMATION 0A-5

7. Measurement criteria are defined by the terms "standard" and "limit".

A measurement falling within the "standard" range indicates that the applicable part or parts are serviceable.
"Limit" is an absolute value.

A measurement falling outside the "limit" indicates that the applicable part or parts must be repaired or replaced.
8. Components are parts are listed in the singular form throughout the Workshop Manual.
9. The following directional criteria are used throughout the Workshop Manual:

Front:

The cooling fan side of the engine.
Right:

The right-hand side of the engine viewed from the flywheel.

Left:
The left-hand side of the engine viewed from the flywheel.

Rear:

The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine towards the rear.

The engine's rotation is clockwise viewed from the front of the engine.

MAINTENANCE AND LUBRICATION 0B-11
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For GENERAL EXPORT)

Severe driving conditions
A : Repeated short trips
G : Gasoline engine
B : Driving on rough roads
4JA1-T : 4JA1-T Diesel engine
C : Driving on dusty roads
4JA1-TC : 4JA1-TC Diesel engine
D : Driving in extremely cold weather and/or on salted roads
4JH : 4JH1-TC Diesel engine
E : Towing trailer or climbing mountain frequently
D
: Diesel engine
MT : Manual transmission

AT : Automatic transmission

4WD
Four wheel drive


Condition
A B C D E A+D
Engine oil G : Change every 5,000 km (3,000 miles) or 3 month4JA1-T : Change every 2,500 km (1,500 miles) 4JA1-TC : Change every 5,000 km (3,000 miles) 4JH : Change every 7,500 km (4,500 miles)



G Replace every 5,000 km (3,000 miles) or 3 month



Engine oil filter
D Replace every 5,000 km (3,000 miles)




Exhaust system Inspect every 5,000 km (3,000 miles)







Air cleaner element Replace every 20,000 km (12,000 miles) D : Inspect every 2,500 km (1,500 miles)


Steering system for looseness
or damage Inspect every 5,000 km (3,000 miles)



Universal joints and sleeves Inspect for wear and lubricate every 5,000 km (3,000
miles)



Transmission or transfer case
oil MT Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


AT Transmission:
Change every 20,000 km (12,000 miles)






4WD Transfer:
Change every 20,000 km (12,000 miles)


Differential oil Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


Front brake pads and discs Inspect every 5,000 km (3,000 miles)




Rear brake lining and drum
wear Inspect every 5,000 km (3,000 miles)






Interval Item

0B-12 MAINTENANCE AND LUBRICATION
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For EUROPE)


Severe driving conditions
4JA1-TC : 4JA1-TC Diesel engine
A: Repeated short trips
4JH : 4JH1-TC Diesel engine
B: Driving on rough roads
D : Diesel engine
C: Driving on dusty roads
MT : Manual transmission
D: Driving in extremely cold weather and/or on salted roads
AT : Automatic transmission
E: Towing trailer or climbing mountein frequently
4WD : Four wheel drive


Condition
Item Interval
A B C D A+D
Engine oil 4JH : Change every 5,000 km (3,000 miles) 4JA1-TC : Change every 7,500 km (4,500 miles)



Engine oil filter 4JH : Replace every 5,000 km (3,000 miles) 4JA1-TC : Replace every 7,5000 km (4,500 miles)




Exhaust pipes and mounting Inspect every 10,000 km (6,000 miles)





Air cleaner element Replace every 20,000 km (12,000 miles)



Steering system for looseness or
damage Inspect every 5,000 km (3,000 miles)




Universal joints and sleeves Inspect for wear and lubricate every 10,000 km (6,000 miles)



Transmission or transmission
with transfer case oil MT Change every 30,000 km (18,000 miles)
after changing at initial 10,000 km (6,000 miles)



AT
Transmission:
Inspection every 20,000 km (12,000 miles)





4WD Transfer:
Change every 30,000 km (18,000 miles)
After changing at initial 10,000 km (6,000 miles)



Differential oil Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


Front brake pads and discs Inspect every 5,000 km (3,000 miles)




Rear brake lining and drum wear Inspect every 5,000 km (3,000 miles)

7B-8 MSG MODEL


Exhaust Pipe
1. Remove the exhaust pipe bracket from the transmission
case.
2. Remove the exhaust pipe.





Rear Propeller Shaft (Single Shaft Type)
1. Remove the propeller shaft flange yoke at the drive pinion
side

1.
2. Remove the propeller shaft from the transmission main
shaft spline

2.





Rear Propeller Shaft (Dual Shaft Type)
1. Apply setting marks to the 2nd propeller shaft flange yoke.
This will prevent mispositioning during the installation
procedure.
2. Remove the 2nd propeller shaft flange yoke bolts at the
drive pinion side

1.
3. Remove the center bearing retainer bolts

2 .
4. Remove the 1st propeller shaft with the center bearing and
the 2nd propeller shaft.
Pull the 1st propeller shaft toward the rear of the vehicle
until the spline yoke is free of the transmission main shaft.



Harness Connector
Disconnect the back up light switch connector and the
speedometer sensor connector.




Slave Cylinder
Remove the slave cylinder from the transmission case.

7B-10 MSG MODEL




3) Manually move the transmission as far as possible toward
the rear of the vehicle (into the space between the No.3
crossmember
3 and the floor panel 4 .
4) Lower the clutch housing end of the transmission toward the
transmission jack.
The rear of the transmission is supported by the No.3
crossmember at this time.
5) Firmly grasp the transmission rear cover (1st mechanic).
Raise the transmission jack toward the transmission (2nd
mechanic).
Carefully lower the transmission onto the transmission jack.
The transmission must be centered on the transmission
jack.




8. Carefully pull the transmission jack with the transmission
from beneath the vehicle.

7B-22 MSG MODEL




27. Bearing Snap Ring
28. Intermediate Plate
1) Insert the snap ring pliers into the mainshaft bearing snap
ring hole.
The snap ring hole is in the intermediate plate

1.
2) Use the snap ring pliers
2to force open the mainshaft
bearing snap ring
3.
Hold the snap ring open with the pliers.
3) Push the intermediate plate toward the rear of the
transmission to remove it.
The ball bearing snap ring will come free.

MANUAL TRANSMISSION 7B1-11

17. Remove the middle part of transmission
crossmember (12) by removing four fixing bolts and
nuts.
501R300008
18. Take out the rear mount rubber (14).
19. Remove starter (15) (Diesel engine only).
060L100070
20. Use the clutch release bearing remover 5-8840-
2291-0 (J-39207) to disconnect the clutch release
bearing from the clutch pressure plate. (6VE1 only)
220RW109
Release bearing disconnection
1. Pull the shift fork toward the transmission to
press the clutch release bearing against the
clutch.
2. Insert the clutch release bearing remover
between the wedge collar and the release
bearing.
3. Turn the remover to separate the release
bearing.

MANUAL TRANSMISSION 7B1-15

C24NE
RTW37BLF0002
220RS006
5. Apply a force of about 113N (26 Ib) to the tip of the
shift fork in the direction of the transmission to
engage the clutch pressure plate and release
bearing. (6VE1 only)
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage
each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine while applying
a force of about 25 N (5.5 lb). If the shift fork will not
move, then they are securely engaged.

MANUAL TRANSMISSION 7B1-31

13. Use screw drivers between the reverse gear (26)
and bearing plate (28) to remove the Rev-5th
synchronizer assembly (24) together with reverse
block ring (25) and reverse gear (26).

226RS010
14. Remove needle bearing (27).
15. Use the torx bit wrench (T45) 5-8840-0047-0 to
remove the bearing plate and screw(28) from the
intermediate plate.

220RW137
16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (29).


226RS011
17. Hold the snap ring open with the pliers.
Push the intermediate plate (30) toward the rear of
the transmission to remove it.
The bearing snap ring (29) will come free.

Inspection and Repair
Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.

Reassembly
1. Mesh the counter gear with the mainshaft assembly.
Set the holding fixture 5-8840-2160-0 to the
mainshaft and the counter gear and then install it on
the base 5-8840-0003-0.
Install the intermediate plate (30) on the gear
assembly.
226RW212