oil ISUZU TF SERIES 2004 Manual PDF

4C1-34 FRONT WHEEL DRIVE




Important Operations
2. Outer Bearing Outer Race
Installer : 9-8522-1141-0
(J-24256)
Grip : 5-8840-0007-0
(J-8092)


3. Inner Bearing Outer Race
Installer : 9-8522-1274-0
Grip : 5-8840-0007-0
(J-8092)







4. Adjust Shim
Adjustment of drive pinion mounting distance
(1) Apply gear oil to the inner and outer drive pinion bearing.
Clean the pinion setting gage set.
Then install the gage set together with the inner and oute
r
bearings.

1. Pilot : 5-8840-2085-0
(J-21777-42)
2. Nut and bolt : 5-8840-2089-0
(J-23597-9)
3. Gage plate : 5-8840-2087-0
(J-23597-7)

FRONT WHEEL DRIVE 4C1-37
(7) Select the shim using the chart;

mm(i n)
Pi ni on
marki ng

+10 +8 +6 +4 +2 0 -2 -4 -6 -8 -10 Dial indicator
reading (inches)
0.081 2.18 (0.0858)0.082 2.18 (0.0858) 2.20 (0.0866)0.083 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882)0.084 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890)0.085 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898)0.086 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914)0.087 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921)0.088 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929)0.089 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937)0.090 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937)2.42 (0.0953)0.091 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961)0.092 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969)0.093 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977)0.094 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992)0.095 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000)0.096 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.097 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.098 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.099 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.001 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.002 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.003 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.004 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.005 2.54 (0.1000) 2.56 (0.1008) 0.006 2.56 (0.1008)
Note :
When ordering shims, find the part number in the Parts Catalog by using the thickness of the shims listed
in the above table.







5. Inner Bearing
Place the shim on the drive pinion, with the chamfered side
turned towards the pinion head then install the inner bearing on
to the pinion using an installer and a press.
Installer : 9-8522-1165-0 (J-6133-01)
Note:
Do not apply pressure to the roller cage.
Apply pressure only to the inner race.



6. Collapsible Spacer
Discard the used collapsible spacer and install a new one.







9. Oil Seal
Use oil seal installer to install a new oil seal that has been
soaked in rear axle lubricant.
Installer : 9-8522-1275-0 (J-24250)
Note :
Take care not to use a rear differential oil seal instead of
the front differential oil seal.

4C1-42 FRONT WHEEL DRIVE
FRONT HUB AND DISC
(4




2 Except High Ride Suspension Model)
DISASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure.

RTW34CLF000801
Disassembly Steps
1. Bolt


2. Brake caliper


3. Hub cap
4. Split pin
5. Nut retainer
6. Hub nut
7. Lock washer


8. Outer bearing


9. Hub and disc assembly
10. Oil seal
11. Inner bearing and outer race
12. ABS sensor rotor


13. Bolt


14. Wheel pin

FRONT WHEEL DRIVE 4C1-43
Important Operations
Before removal, jack up the front of vehicle and support frame
with jack stands.



2. Brake Caliper
(1) Remove the two bolts from the rear side of the knuckle arm,
then remove the brake caliper, with the brake hose
attached.
(2) Use a wire etc., for attaching the brake caliper to the uppe
r
link.
Refer to the section Brake.



3. Hub Cap
When removing hub cap, exercise care so as not to scratch or
distort hub fitting face.



9. Hub and Disc Assembly
Using a brass bar to remove the outer bearing outer race (1),
oil seal, inner bearing and inner bearing outer race (2) from the
hug.



If necessary, replace the wheel pin in the following manner.

13. Bolt
14. Wheel Pin ; Front Hub
(1) Scribe mark on hub to disc before disassembly to insure
proper assembly.
(2) Drive out the ABS sensor rotor using a metal bar and
hammer through the two bolt holes.

Discard the used ABS sensor rotor
Refer to the section Brake.

FRONT WHEEL DRIVE 4C1-45
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found
through inspection.
For inspection and servicing of disc caliper, and relative parts, and ABS parts, refer to section 5 Brakes.



Hub

Hub bearing

Bearing outer race


Disc


Oil seal


Knuckle spindle


ABS sensor rotor


Caliper



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

4C1-46 FRONT WHEEL DRIVE
REASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure.

RTW34CLF000901
Reassembly Steps


1. Wheel pin


2. Bolt


3. ABS sensor rotor


4. Inner bearing and outer race


5. Oil seal


6. Hub and disc assembly
7. Outer bearing


8. Lock washer


9. Hub nut
10. Nut retainer
11. Split pin


12. Hub cap
13. Brake caliper


14. Bolt

FRONT WHEEL DRIVE 4C1-47

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 and Outer Race
5. Oil Seal

Outer Bearing Outer Race
(1) Install the bearing outer race by driving into the hub.
Installer (Outer) : 5-8822-0053-0 (J-29016)
Installer (Inner) : 5-8822-0054-0 (J-29015)
Drive handle : 5-8840-0007-0 (J-8092)

4C1-48 FRONT WHEEL DRIVE


(2) Install the outer and inner bearing into the hub with fingers.


(3) Install oil seal using special tools.
Discard the used oil seal and install a new one.
Installer : 5-8522-0051-0
(J-33161)
Grip : 5-8840-0007-0
(J-8092)


Hub cap Hub

6. Hub and Disc Assembly
12. Hub Cap
Apply grease in the hub and hub cap.
Description Amount g(oz)
Hub 50 (1.76)
Hub cap 20 (0.70)
Outer bearing 6.5 (0.23)
Inner bearing 12 (0.42)


9. Hub nut
Adjustment of front wheel hub bearing preload
1. Tighten spindle nut to 3.0 kg
m (21.7 lb.ft/29.4 N
m) torque.
2. Turn the hub 2-3 turns and loosen the nut just enough so
that it can be turned with the fingers.
3. Turn the nut all the way in with the fingers and check to be
sure the hub has no free play.
4. Measure the bearing preload by pulling one of the wheel
hub studs with a spring scale.
5. Tighten the spindle nut until specified bearing preload Is
obtained.
6. Install the split pin in the nut retainer.
Discard the used split pin and install a new one.
After reassembling, install the disc brake caliper assembly.
Bearing Preload N

m (kgf

m/lb

ft)

New bearing and New oil seal 8-12 (0.8-1.2 / 69-104)
Reuse bearing and New oil seal 8-12 (0.8-1.2 / 69-104)

4C1-50 FRONT WHEEL DRIVE
FRONT HUB AND DISC
(4




4, 4




2 High Ride Suspension,
4





4 Rigid Hub, 4





4 Shift On the Fly Model)
DISASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure

411R300011

Disassembly Steps
1. Bolt
2. Hub cap
3. Snap ring and shim (4
4 model only)
4. Flange (4
4 model only)
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

4C1-52 FRONT WHEEL DRIVE
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found
through inspection.
For inspection and servicing of disc caliper, and relative parts, and ABS parts, refer to Section Brakes.




Hub


Hub bearing, oil seal


Knuckle spindle


Disc


Caliper


ABS sensor rotor

Cap, Hub flange, Shim, Snap ring



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