content ISUZU TF SERIES 2004 Workshop Manual

ACCESSORIES 9-1

SECTION 9
ACCESSORIES
TABLE OF CONTENTS
PAGE
Parts Location ................................................................................................................... 9-2
Circuit Diagram ................................................................................................................. 9-6
Connector List .................................................................................................................. 9-10
Radio .................................................................................................................................. 9-12
Front Speaker .................................................................................................................... 9-13
Tweeter .............................................................................................................................. 9-14
Rear Speaker (Extend Cab)............................................................................................... 9-15
Rear Speaker (Crew Cab) .................................................................................................. 9-16
Clock ................................................................................................................................... 9-17
Antenna ............................................................................................................................. 9-18

PROPELLER SHAFT 4A-1
SECTION 4A
PROPELLER SHAFT
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4A- 3
Rear Propeller Shaft...................................................................................................... 4A- 3
Torque Specifications ....................................................................................................... 4A- 5
Front Propeller Shaft ................................................................................................... 4A- 6
Torque Specifications ....................................................................................................... 4A- 7
Rear Propeller Shaft .......................................................................................................... 4A- 8
General Description ...................................................................................................... 4A- 8
Removal and Installation .............................................................................................. 4A-11
Universal Joint Disassembly........................................................................................ 4A-12
Inspection and Repair .................................................................................................. 4A-14
Universal Joint Reassembly ........................................................................................ 4A-16
Rear Propeller Shaft Assembly ........................................................................................ 4A-17
Disassembly and Reassembly .................................................................................... 4A-18
Front Propeller Shaft ........................................................................................................ 4A-19
Removal and Installation .............................................................................................. 4A-19
Disassembly ................................................................................................................. 4A-21
Universal Joint Disassembly and Reassembly ......................................................... 4A-23
Reassembly .................................................................................................................. 4A-27

REAR AXLE 4B-1

SECTION 4B
REAR AXLE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4B- 3
Torque Specifications....................................................................................................................4B- 4
Recommended Liquid Gasket .......................................................................................... 4B- 6
Recommended Thread Locking Agents .......................................................................... 4B- 6
Rear Axle Assembly .......................................................................................................... 4B- 7
General Description ...................................................................................................... 4B- 7
Servicing............................................................................................................................. 4B- 8
Rear Axle ............................................................................................................................ 4B- 9
Disassembly .................................................................................................................. 4B- 10
Inspection and Repair................................................................................................... 4B- 13
Reassembly ................................................................................................................... 4B- 14
Differential Assembly.....................................................................................................................4B- 19
Disassembly .................................................................................................................. 4B- 20
Reassembly ................................................................................................................... 4B- 22
Differential Cage Assembly..........................................................................................................4B- 32
Disassembly .................................................................................................................. 4B- 33
Inspection and Repair...............................................................................................................4B- 33
Reassembly.................................................................................................................................4B- 35
Limited Slip Differential (LSD) .......................................................................................... 4B- 36
Disassembly................................................................................................................................4B- 37
Inspection and Repair................................................................................................... 4B- 38
Reassembly ................................................................................................................... 4B- 40
Troubleshooting ............................................................................................................ 4B- 43
Special Service Tool..................................................................................................................4B- 54

FRONT WHEEL DRIVE 4C1-1
SECTION 4C1
FRONT WHEEL DRIVE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4C1- 3
Special Parts Fixing Nuts and Bolts ................................................................................ 4C1- 4
Recommended Liquid Gasket .......................................................................................... 4C1- 6
Recommended Thread Locking Agents .......................................................................... 4C1- 6
Servicing............................................................................................................................. 4C1- 7
General Description........................................................................................................... 4C1- 8
Front Drive Axle Assembly ............................................................................................. 4C1- 14
Front Drive Axle Assembly and Associated Parts ................................................... 4C1- 14
Removal ....................................................................................................................... 4C1- 15
Installation ...................................................................................................................4C1- 16
Front Axle Drive Shaft ..................................................................................................... 4C1- 18
Front Axle Drive Shaft and Associated Parts ........................................................... 4C1- 18
Disassembly ................................................................................................................ 4C1- 19
Inspection and Repair................................................................................................. 4C1- 20
Bushing Replacement ............................................................................................... 4C1- 21
Reassembly ................................................................................................................. 4C1- 21
Standard caulk Measure ............................................................................................ 4C1- 22
Differential ...................................................................................................................4C1- 24
Disassembly ................................................................................................................ 4C1- 24
Major Components ................................................................................................ 4C1- 24
Minor Components................................................................................................ 4C1- 27
Inspection and Repair................................................................................................. 4C1- 29
Reassembly ................................................................................................................ 4C1- 31
Minor Components ................................................................................................. 4C1- 31
Major Components ................................................................................................. 4C1- 33

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.

BRAKE CONTROL SYSTEM 5A-1


SECTION 5A
BRAKE CONTROL SYSTEM
CONTENTS

Service Precaution ............................................................................................................. 5A-4
General Description ........................................................................................................... 5A-5
EHCU, Brake Pipe Diagram .......................................................................................... 5A-6
Hydraulic Unit (H/U)....................................................................................................... 5A-7
Normal Braking ......................................................................................................... 5A-8
Pressure Isolation (Pressure Maintain) .................................................................. 5A-9
Pressure Reduction .................................................................................................. 5A-10
Brake Release ........................................................................................................... 5A-11
Circuit Diagram.............................................................................................................. 5A-12
Connector List ............................................................................................................... 5A-13
Part Location ................................................................................................................. 5A-15
EHCU Pin-outs ............................................................................................................... 5A-17
System Components ..................................................................................................... 5A-19
Electronic Hydraulic Control Unit (EHCU) .............................................................. 5A-19
ABS Warning Lamp .................................................................................................. 5A-19
Wheel Speed Sensor (WSS)..................................................................................... 5A-19
G-Sensor ................................................................................................................... 5A-19
Normal and Anti-lock Braking ................................................................................. 5A-19
Electronic Brake-force Distribution (EBD) System ................................................ 5A-20
Brake Pedal Travel.................................................................................................... 5A-20
Acronyms and Abbreviations ....................................................................................... 5A-20
General Diagnosis ............................................................................................................. 5A-20
General Information ...................................................................................................... 5A-20
ABS Service Precautions.............................................................................................. 5A-20
Computer System Service Precautions....................................................................... 5A-21
General Service Precautions........................................................................................ 5A-21
Note on Intermittents .................................................................................................... 5A-21
Test Driving ABS Complaint Vehicles ......................................................................... 5A-21
"ABS and Brake" Warning Lamp ................................................................................. 5A-22
Normal Operation .......................................................................................................... 5A-22

ANTI-LOCK BRAKE SYSTEM 5B-1

SECTION 5B
BRAKES
ANTI-LOCK BRAKE SYSTEM
TABLE OF CONTENTS
PAGE
Service Precaution ...................................................................................................................... 5B – 2
Torque Specifications ................................................................................................................ 5B – 3
Electronic Hydraulic Control Unit ........................................................................................... 5B – 7
Electronic Hydraulic Control Unit and Associated Parts ............................................ 5B – 7
Removal .................................................................................................................................... 5B – 7
Installation ................................................................................................................................ 5B – 7
Front Wheel Speed Sensor ....................................................................................................... 5B – 8
Front Wheel Speed Sensor and Associated Parts ........................................................ 5B – 8
Removal .................................................................................................................................... 5B – 9
Inspection and Repair ........................................................................................................... 5B – 9
Installation ................................................................................................................................ 5B – 10
Rear Wheel Speed Sensor ........................................................................................................ 5B – 11
Rear Wheel Sensor and Associated Parts ....................................................................... 5B – 11
Removal .................................................................................................................................... 5B – 11
Inspection and Repair ........................................................................................................... 5B – 11
Installation ................................................................................................................................ 5B – 12
Front Speed Sensor Rotor ........................................................................................................ 5B – 13
Front Sensor Rotor and Associated Parts ....................................................................... 5B – 13
Removal .................................................................................................................................... 5B – 13
Inspection and Repair ........................................................................................................... 5B – 14
Installation ................................................................................................................................ 5B – 14
Rear Speed Sensor Rotor .......................................................................................................... 5B – 16
Rear Sensor Rotor and Associated Parts ........................................................................ 5B – 16
Removal .................................................................................................................................... 5B – 16
Inspection and Repair ........................................................................................................... 5B – 17
Installation ................................................................................................................................ 5B – 17
G-Sensor ........................................................................................................................................ 5B – 19
G-Sensor and Associated Parts ......................................................................................... 5B – 19

BRAKES 5C-1
SECTION 5C
BRAKES
TABLE OF CONTENTS
PAGE
General Description......................................................................................................... 5C- 2
Main Data and Specifications ......................................................................................... 5C- 9
Torque Specifications ..................................................................................................... 5C-10
Servicing........................................................................................................................... 5C-19
Front Brake Assembly ..................................................................................................... 5C-33
Removal and Installation ............................................................................................ 5C-33
Removal and installation of Disc Pad ....................................................................... 5C-37
Disassembly ................................................................................................................ 5C-39
Inspection and Repair................................................................................................. 5C-40
Reassembly ................................................................................................................. 5C-42
Rear Drum Brake Assembly ............................................................................................ 5C-44
Disassembly ................................................................................................................ 5C-44
Inspection and Repair................................................................................................. 5C-45
Reassembly ................................................................................................................. 5C-47
Brake Control ................................................................................................................... 5C-51
Removal and Installation ............................................................................................ 5C-51
Master Cylinder ................................................................................................................ 5C-52
Removal and Installation ............................................................................................ 5C-52
Disassembly ................................................................................................................ 5C-53
Inspection and Repair................................................................................................. 5C-55
Reassembly ................................................................................................................. 5C-56
Vacuum Booster .............................................................................................................. 5C-58
Removal and Installation ............................................................................................ 5C-58

PARKING BRAKE SYSTEM 5D-1

SECTION 5D
BRAKES
PARKING BRAKE SYSTEM
CONTENTS

Service Precaution .......................................... 5D-1
Service Precaution ....................................... 5D-1
General Description ...................................... 5D-1
Parking Brake Lever ........................................ 5D-2
Parking Brake Lever Assembly and
Associated Parts (Bench Seat) .................. 5D-2
Removal ....................................................... 5D-3
Installation............................................................
5D-3
Front Parking Brake Cable....................................
5D-5
Front Parking Brake Cable and Associated
Parts (Bench Seat).........................................
5D-5
Removal...............................................................
5D-6
Installation............................................................
5D-6
Parking Brake Lever...............................................
5D-8
Parking Brake Lever Assembly and Associated
Parts (Buckle Seat)....................................... 5D-8
Removal ....................................................... 5D-8
Installation .................................................... 5D-8
Parking Brake Rear Cable ............................... 5D-9
Parking Brake Rear Cable and Associated
Parts ............................................................ 5D-9
Removal ....................................................... 5D-10
Installation .................................................... 5D-10
Inspection and Repair ................................... 5D-11
Parking Brake Adjustment ............................ 5D-11
Main Data and Specifications........................... 5D-12
Troubleshooting ............................................ 5D-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 or
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.

General Description
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the
lever can be held in that position until it is released. The
position of the lever is transmitted through cable/leve
r
systems to the rear wheels. These parts are designed
to obtain sufficient braking force even when parking on
slopes. When the parking brake is set, or when the
ignition SW is in the "ON" position, the brake warning
light illuminates. The rear wheel parking brake is a
leading-trailing brake (mechanical inside expansion
type) built in the rear drum brake. Parking brake
adjustment is made through the adjusting hole (bored
through back plate). Parking brake lever stroke should
be adjusted to 8

14 notches with 30kg (bench seat) o
r
6

8 notches with 30kg (bucket seat). Refer to “Parking
Brake Adjustment" in this section.

CAB 10-1
SECTION 10
CAB
TABLE OF CONTENTS
PAGE
Windshield.......................................................................................................................... 10- 2
Rear Window Assembly .................................................................................................... 10- 7
Front Door Assembly ........................................................................................................ 10- 10
Rear Door Assembly (Crew Cab) ...................................................................................... 10- 20
Instrument Panel................................................................................................................ 10- 28
Floor Console..................................................................................................................... 10- 34
Console Box (Without Floor Console) ............................................................................. 10- 38
Headlining .......................................................................................................................... 10- 39
Interior Trim Panels ...........................................................................................................10- 44
Fuel Filler Lid Opener Lever/Cable................................................................................... 10- 55
Quarter Glass (Extend Cab) .............................................................................................. 10- 70
Font Seat ............................................................................................................................ 10- 71
Rear Seat (Crew Cab) ........................................................................................................ 10- 74
Jump Seat (Extend Cab) ................................................................................................... 10- 75
Front Seat Belt ................................................................................................................... 10- 76
Rear Seat Belt (Crew Cab) ................................................................................................ 10- 80
Rear Seat Belt (Extend Cab) ............................................................................................. 10- 84
Front Wheel Extension ...................................................................................................... 10- 87
Rear Wheel Extension ....................................................................................................... 10- 88
Tail Gate Assembly ............................................................................................................ 10- 89