oil ISUZU TF SERIES 2004 Workshop Manual

FRONT SUSPENSION 3C-9

Shock Absorber
Shock Absorber and Associated Parts


RTW440LF001201

Legend

(1)
Shock Absorber ASM with coil

(2)
Nut

(3)
Nut

(4)
Nut


(5)
Lower ball joint Nut and cot ter pin

(6)
Nut

(7)
Bolt

(8)
Cam bolt


Removal
1. Raise the vehicle and support it with suitable
safety stands.

2. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.
3. Remove nut (6).
CAUTION: Be careful not o break the ball joint boot.

FRONT SUSPENSION 3C-11

NOTE: Paint mark to be outer side of after assembly to
vehicle.
2. Install nut (2), then tighten it to the specified
torque.
Torque: 55N





m (5.6kg





m/41lb ft)
3. Install bolt (7) and nut (4), then tighten to the
specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137N




m (14.0kg




m/101 lb ft)


NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.




RTW340SH001301-X
4. Install nut (6), then tighten it to the specified
torque.
Torque: 50N




m (5.1kg




m/37 lb ft)
5. Tighten the cam bolt (8) and nut (3), it to the
interim torque, then turn the cam bolt to the setting
mark applied during disassembly.
6. Install ball joint nut, then tighten it to the specified
torque with just enough additional torque to align
cotter pin holes. Install new cotter pin (5).
Torque: 147N




m (15.0kg




m/108 lb ft)


NOTE: Check the trim height. Refer to Front Alignment
Inspection and Adjustment.

7. Nut (3) tighten it to the specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 186N




m (19.0kg




m/137 lb ft)


NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.





RTW340SH001301-X
8. Install wheel and tire assembly. Refer to wheel in
this section.

3C-12 FRONT SUSPENSION
Shock Absorber with Coil Spring

RTW340LF002101

Legend

1. Nut
2. Washer

3. Bushing ; Rubber

4. Mounting Bracket

5. Coil Spring


6. Bushing ; Rubber

7. Washer

8. Shock Absorber ASM

FRONT SUSPENSION 3C-13
Disassembly





1. Install the support fixture (5-8840-0595-0) to the base (5-
8840-003-0).
2. Install the upper adapter (5-8840-0597-0) and the lower
adapter (5-8840-0596-0) to the base and support fixture
assembly.
3. Install the shock absorber assembly to the support fixture.
4. Remove the nut with spring in place.
CAUTION:
Take care not to apply excessive force to the nut during
removal.


CAUTION :
The shock absorbers have been charged with gas at the
factory. Exposure to high temperatures or an open flame
can result in a dangerous explosion.
Keep the shock absorbers away from high temperatures
and open flames.



INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspections.




Visual Check
Inspect the following parts for wear, damage or other abnormal
conditions.


Shock absorber


Rubber bushing


Coil spring

3C-20 FRONT SUSPENSION
5. Remove nut (8).
6. Remove upper ball joint by using remover 5-8840-
2017-0.
CAUTION: Be careful not to damage the ball joint
boot.

P1010005
7. Remove nut (3).
8. Remove bolt(1).
9. Remove bolt (10) and nut (9).
10. Remove upper ball joint.
11. Remove upper control arm assembly.
12. Remove bushing.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:


Upper control arm


Bushing
Installation
1. Install bushing by using installer 5-8840-0257-0
and 5-8840-2327-0.


P1010062
2. Install upper ball joint and tighten it to the specified
torque (9).
Torque: 31 N






m (3.2kg






m/23 lb ft)
3. Install nut (6) and cotter pin then tighten the nut to the specified torque, with just enough additional
torque to align cotter pin holes. Install new cotte
r
pin.
Torque: 98 N






m (10.0kg







m/72 lb ft)
4. Install upper control arm assembly.
5. Install bolt (1) and nut (3).
NOTE: Apply oil to the thread.
NOTE: Tighten the bolt (1) with the parts in the position
shown in the illustration below.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137 N






m (14.0kg






m/101 lb ft)





RTW340SH001301-X
6. Install nut (12).
7. Install nut (11).

3C-22 FRONT SUSPENSION
4. Support lower control arm with a jack.
5. Remove the nut (10).
6. Remove the nut (8).
7. Remove the shock absorber lower end from the
lower control arm.
8. Remove the lower ball joint from the lower control arm.
9. Remove nut (4) and cam plate.
10. Remove cam bolt.
11. Remove lower control arm.
12. Remove bushing.
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:


Lower control arm


Bushing
Installation
1. Install rear bushing by using installer 5-8840-
0257-0 and 5-8840-2327-0.


P1010063
2. Install lower control arm.
3. Install cam bolt.
4. Install lower ball joint and tighten it to the specified
torque (9).
Torque: 127 N






m (12.9kg






m/94 lb ft)
5. Install shock absorber and tighten it to the specified torque (5).

NOTE: Apply oil to the thread.
NOTE: Tighten the nut (4) with the parts in the position
shown in the illustration below.
Torque: 137 N






m (14.0kg






m/101 lb ft)




RTW340SH001301-X
6. Install stabilizer link and tighten it to the specified
torque (10).
Torque: 50 N






m (5.1kg






m/37 lb ft)
7. Install nut (4) and cam plate and tighten lower link nut finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut (4) with the parts in the position
shown in the illustration below.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 186 N






m (19.0kg






m/137 lb ft)





RTW340SH001301-X
8. Install nut (8) and cotter pin then tighten the nut to
the specified torque, with just enough additional
torque to align cotter pin holes. Install new cotte
r

FRONT SUSPENSION 3C-37

Knuckle
Knuckle and Associated Parts


RTW340LF001301
Legend
(1) Torsion Bar
(2 )Lower Ball Joint, Nut and Cotter Pin
(3) Back Plate
(4) Knuckle Assembly
(5) Knuckle


(6) Needle Bearing (44 Model Only)
(7) Thrust Washer (44 Model Only)
(8) Oil Seal (4
4 Model Only)
(9) Upper Ball Joint, Nut and Cotter Pin
(10) Speed Sensor harness


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.

2. Remove wheel and tire assembly. Refer to Wheel
in this section.
3. Remove the brake caliper. Refer to Disc Brakes in
Brake section.

3C-38 FRONT SUSPENSION

4. Remove the hub assembly. Refer to Front Hub
and Disk in this section.
5. Remove tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
6. Remove the speed sensor from the knuckle.
7. Loosen torsion bar by height control arm adjust
bolt, then remove torsion bar. Refer to Torsion Ba
r
in this section.
8. Remove speed sensor harness.
9. Remove back plate.
10. Remove lower ball joint by using remover 5-8840-
2005-0.
CAUTION: Be careful not to damage the ball joint
boot.



901RW271

11. Remove upper ball joint by using remover 5-8840-
2121-0.
CAUTION: Be careful not to damage the ball joint
boot.

901RW272
12. Remove knuckle assembly.
13. Remove oil seal. If replacement required.
(4
4 Model Only)
14. Remove washer. If replacement required.
(4
4 Model Only)
15. Remove needle bearing by using remover 5-8840-
2000-0 and sliding hammer 5-8840-0019-0.
If replacement required. (4
4 Model Only)





(4

4 Model Only)
RTW340SH00401

FRONT SUSPENSION 3C-39

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:


Knuckle


Knuckle arm

Thrust washer (44 Model Only)
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g) and
install needle bearing by using installer 5-8840-
2128-0 and grip 5-8840-0007-0. (4
4 Model Only)





(4
4 Model Only)
901RW275
2. Apply multipurpose type grease to the thrust
washer, and install washer with chamfered side
facing knuckle. (44 Model Only)

3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2
g). Then use installer 5-8840-2127-0 and grip 5-
8840-0007-0 to install oil seal. After fitting the oil
seal to the installer, drive it to the knuckle using a
hammer or bench press until the tool front face
contacts with the thrust washer. (4
4 Model Only)




(4
4 Model Only)
901RW274
4. Install knuckle assembly.
5. Install upper ball joint and tighten the nut to the
specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin (9).
Torque: 98 N




m (10.0kg




m/72 lb ft)
6. Install lower ball joint and tighten the nut to the
specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin (2).
Torque: 147 N





m (15.0kg





m/108 lb ft)
7. Install back plate.
8. Install speed sensor harness.
9. Install torsion bar, refer to Torsion Bar in this
section.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering.

3C-42 FRONT SUSPENSION

Installation
1. Install fulcrum pin.
2. Install bushing by using installer 5-8840-0256-0
and 5-8840-2307-0.


RTW340SH000701



RTW340SH000801
3. Install upper ball joint and tighten it to the specified
torque (12).
Torque: 57 N




m (5.8kg




m/42 lb ft)
4. Install nut and cotter pin then tighten the nut to the
specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin (11).
Torque: 98 N




m (10.0kg




m/72 lb ft)
5. Install plate (8).

6. Install nut (9) and tighten fulcrum pin nut finger-
tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut with the parts in the position
shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 108 N




m (11.0kg




m/80 lb ft)


450R100002
7. Install upper control arm assembly with the fulcrum
pin projections turned inward.


RTW340SH000901

Legend
(1) Projection
(2) Outward

8. Install the caster shims (2) between the chassis