wheel ISUZU TF SERIES 2004 Repair Manual

FRONT WHEEL DRIVE 4C1-15

Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
3. Remove the stone guard.
4. Remove the brake caliper fixing bolt and hang the caliper.
Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front Wheel Speed Sensor in Brake section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to Front Propeller Shaft in
this section.
8. Loosen the height control arm of the torsion bar, then
remove the torsion bar from lower control arm.
Refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock absorber.

12. Remove the tie-rod end from the knuckle.
Refer to Power Steering Unit in Steering Section.
13. Disconnect the breather hose of the front axle.
14. Disconnect the actuator connector. (With shift on the fly)
15. Remove the bolts and nuts of the lower control arm (Frame
side), then disconnect the lower control arm from frame.
16. Disconnect between the right side upper control arm and
the knuckle, then remove the knuckle with lower control
arm.
CAUTION :
When removing the knuckle, be careful not to damage the
oil seal inside of the knuckle.

4C1-16 FRONT WHEEL DRIVE
17. Support the differential case by the jack.
18. Remove the front axle mounting bolts and nuts, lower the
jack slowly. Remove the left side drive shaft end from the
knuckle, then lower the axle assembly from the vehicle.
CAUTION :
1. During the work, be sure that the axle assembly is
supported securly.
2. Be careful not to damage the bellows of the power
steering unit by interference.
3. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.


Installation
1. Support the differential case by the jack.
2. Jack up the front drive axle assembly, install the left side
drive shaft to the knuckle, then install the mount bolts and
nuts.
CAUTION :
1. Be careful not to damage the bellows of the power
steering unit by interference.
2. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.
3. When installing the drive shaft to the knuckle, be
careful not to damage the oil seal inside of the knuckle.

RTW34CSH000101
3. Tighten the mounting bolts and nuts to the specified torque.
Torque : 169 N·m (17.2kg·m/124 lb ft)



4. Install the right side knuckle with lower control arm to the
upper control arm.
Refer to Knuckle in Suspension section.
CAUTION :
When insert the drive shaft to the knuckle, be careful not
to damage the oil seal inside of the knuckle.

5. Align the bolt hole of the lower control arm, install the bolts
and nuts.

FRONT WHEEL DRIVE 4C1-17
NOTE :
Adjust the buffer clearance before tighten the bolts and nuts of
the lower control arm.

6. Install the breather hose of the front axle.
7. Install the actuator connector of the shift on the fly. (With
shift on the fly)
8. Install the tie-rod end of the power steering unit to the
knuckle, tighten the nut to the specified torque.
Torque : 98 N·m (10.0kg·m/73 lb ft)

9. Install lower bolts and nuts of the shock absorber, tighten it
to the specified torque.
Torque : 93 N·m (9.5kg·m/69 lb ft)
10. Install lower nuts of the stabilizer link, tighten it to the
specified torque.
Torque : 50 N·m (5.1kg·m/37 lb ft)
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the bearing
preload.
Refer to Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake
system.
16. Install the brake caliper. Tighten the bolt of the caliper
bracket to the specified torque.
Torque : 155 N·m (15.8kg·m/115 lb ft)
17. Install the stone guard.
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Steering section.
20. Tighten the bolts and nuts of the lower control arm to the
specified torque.
Refer to Lower Control Arm in Suspension section.

4C1-18 FRONT WHEEL DRIVE
FRONT AXLE DRIVE SHAFT
Front Axle Drive Shaft and Associated Parts
RTW34CLF000401
Legend
1. Axle Case and Differential
2. Snap Ring
3. Bearing
4. Snap Ring
5. Oil Seal
6. Bracket
7. DOJ Case
8. Circlip
9. Bolt
10. Drive shaft Joint Assembly
11. Ball


12. Snap Ring
13. Ball Retainer
14. Ball Guide
15. Band
16. Bellows
17. Band
18. Band
19. Bellows
20. Band
21. UJ Shaft
22. Dust Seal

FRONT WHEEL DRIVE 4C1-19

Disassembly
NOTE :
For the left side, follow the same steps as right side.


1. Use a hammer and chisel to remove the 3 pawls (above
the large and small boot bands on the DOJ side).
COUTION :
Take care not to damage the bellows during band removal.
2. Remove band (1).



3. Pry off circlip (1) with a screwdriver or equivalent.



4. Remove drive shaft joint assembly.
5. Remove the six balls (1) with a screwdriver or equivalent.

4C1-20 FRONT WHEEL DRIVE
6. Using snap ring pliers, remove the snap ring (1) fastening
the ball retainer to the center shaft.
7. Remove ball retainer, ball guide and bellows.



8. Use a hammer and chisel to remove the 3 pawls (above
the large and small boot bands on the UJ side).
CAUTION :
Take care not to damage the bellows during band removal.

9. Remove band (1).
10. Remove bellows.
11. Remove dust seal from UJ.
12. Remove UJ shaft assembly.
13. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
14. Remove snap ring and bearing.
15. Remove snap ring and oil seal.
16. Remove bracket.


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.
1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal

FRONT WHEEL DRIVE 4C1-21

Bushing Replacement
 Remove the bushings using a remover 5-8840-2309-0 and
hammer.




By using installer and base 5-8840-2309-0, press fit the
bushings into the bracket.

Reassembly
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
Discard the used oil seal, snap ring and install a new one.
3. Install bearing and fix snap ring.
Discard the used snap ring and install a new one.
4. Install bracket to axle case. Tighten the bracket bolt to the
specified torque.
Torque : 116 N·m (11.8kg·m/85 lb ft)
5. Apply 135g of the specified grease in UJ.
6. Install dust seal for UJ.
Discard the used dust seal and install a new one.

Legend
1. Bellows
2. Shaft
7.
Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
CAUTION :
During bellows assembly, be sure to insert both ends of
the bellows into the case and shaft grooves.

4C1-22 FRONT WHEEL DRIVE

Legend
1. UJ Case
2. Bellows



8. Install band. Note the setting direction. After installation,
check Standard Caulk Measure.
Discard the used band and install a new one.
Use the special tool pliers 5-8840-2745-0 to caulk the band
to the specified value.
For both sides on UJ bellows.





Standard Caulk Measure

1.2mm (0.05in) <= (1), (2) <= 4.0mm (0.16in)

(1) - (2) or (2) - (1) <= 0.4mm (0.016in)
9. Install another bellows and fix band.
Discard the used band and install a new one.
10. Install the ball guide with the smaller diameter side ahead
onto the shaft.
11. Install ball retainer.

12. Using snap ring pliers, install the snap ring (1) securing the
ball retainer to the shaft.
Discard the used snap ring and install a new one.

FRONT WHEEL DRIVE 4C1-23
13. Align the track on the ball (1) retainer with the window in
the cage, and install the six balls into position.




14. Pack 150g of the specified grease in DOJ case, then install
drive shaft joint assembly. After reassembly, move the DOJ
longitudinally several times to get to fit.

15. Install the circlip (1) so that open ends are positioned away
from the ball groove.
Discard the used circlip and install a new one.


Legend
1. Outer Case
2. Circlip
3. Open Ends



16. Install band. After installation, check that the bellows is free
from distortion.
Discard the used band and install a new one.
Use the special tool pliers 5-8840-2745-0 to caulk the band
to the specified valve.
For both sides on UJ bellows.

4C1-24 FRONT WHEEL DRIVE
DIFFERENTIAL
DISASSEMBLY
MAJOR COMPONENTS
RTW34CLF000501
Disassembly Steps
1. Bolt
2. Differential assembly
3. Axle case
4. Bolt


5. Bearing cap
6. Diff. cage assembly


7. Side bearing outer race


8. Side bearing


9. Adjust shims


10. Flange nut
11. Flange


12. Dust cover


13. Pinion gear


14. Inner bearing
15. Adjust shim
16. Collapsible spacer


17. Inner bearing outer race
18. Oil seal
19. Outer bearing


20. Outer bearing outer race
21. Diff. carrier