wheel bolts ISUZU TF SERIES 2004 Workshop Manual

SUPPLEMENTAL RESTRAINT SYSTEM 9A-41

7. Remove the driver knee bolster assembly.


RTW49JSH000401
Legend
(1) RHD
(2) LHD

8. Remove the steering column cover.
9. Disconnect the wiring harness connectors located
at the base of steering column.
CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as
an energy absorbing unit.
10. Remove the combination switch assembly with
SRS coil.
SRS coil is a part of combination switch assembly,
which cannot be replaced separately. Therefore, be
sure not to remove the SRS coil from the combination
switch assembly.
11.Remove the snap ring.
12. Remove the cushion rubber.
13. Disconnect shift lock cable (A/T only).
14.Disconnect the starter switch harness connecto
r
located base of steering column.
15. Remove steering lock cylinder assembly.



16.Apply a setting mark across the universal joint and
steering shaft to reassemble the parts in thei
r
original position.
060R300038
17.Remove steering column assembly.

Installation
1. Install the steering column assembly and align the
setting marks on the universal joint and steering
shaft made during removal.
060R300038
2. Tighten the steering column fixing bolts (dash
panel side) to the specified torque.
Torque: 20 N




m (2.0 kg




m/14 lb ft)
3. Tighten the steering column fixing bolts (Pedal
bracket) to the specified torque.
Torque: 20 N





m (2.0 kg





m/14 lb ft)

9A-44 SUPPLEMENTAL RESTRAINT SYSTEM

Passenger Air Bag Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AI
R
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION,
THAT IS IRRITATING TO THE SKIN AND EYES.
MOST OF THE POWER ON THE AIR BAG
ASSEMBLY IS HARMLESS. AS A PRECAUTION,
WEAR GLOVES AND SAFETY GLASSES WHEN
HANDLING A DEPLOYED AIR BAG ASSEMBLY,
AND WASH YOUR HANDS WITH MILD SOAP AND
WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVE
R
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE.
IN THE CASE OF AN ACCIDENTAL DEPLOYMENT,
THE BAG WILL THEN DEPLOY WITH MINIMAL
CHANCE OF INJURY. WHEN PLACING ALIVE AI
R
BAG ASSEMBLY ON A BENCH OR OTHER
SURFACE, ALWAYS FACE BAG AND RIM COVER
UP, AWAY FROM THE SURFACE. NEVER REST A
STEERING COLUMN ASSEMBLY ON THE
STEERING WHEEL WITH THE AIR BAG
ASSEMBLY FACE DOWN AND COLUMN
VERTICAL. THIS IS NECESSARY SO THAT A FREE
SPACE IS PROVIDED TO ALLOW THE AIR BAG
ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT
OF ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY COULD RESULT.
WARNING: IN THE EVENT DEPLOYMENT HAS
OCCURRED, INSPECT COIL ASSEMBLY WIRE
FOR ANY SIGNS OF SCORCHING, MELTING O
R
ANY OTHER DAMAGE DUE TO EXCESSIVE HEAT.
IF THE COIL HAS BEEN DAMAGED, REPLACE IT.

Removal
1. Disable the SRS. (Refer to “Disabling the SRS”in
this section)
2. Remove glove box.
3. Remove glove box cover.


4. Remove passenger air bag assembly fixing bolts
and nuts. Universal joint is used when removing a
nut.
060R300043
060R300044
5. Remove passenger air bag assembly.
6. Disconnect passenger air bag assembly harness
connector.

SUPPLEMENTAL RESTRAINT SYSTEM 9A-47

Main Data and Specifications
Fastener Tightening Specification
Application N




m kg




m Ft.lb
SRS control unit 7 0.7 5
Steering wheel fixing bolt 35 3.5 25
Steering column (dash panel side fixing bolts) 20 2.0 14
Steering column (Pedal bracket fixing bolt) 20 2.0 14
Steering column (Universal joint fixing bolt) 31 3.2 23
Passenger Air Bag fixing bolt & nut 8 0.8 5.8
Pretensioner seat belt bolt 55 5.6 40

REAR AXLE 4B-7

REAR AXLE ASSEMBLY
General Description
A03R300001

The rear axle assembly is of the semi–floating type in
which the vehicle weight is carried on the axle
housing .
The center line of the pinion gear is below the center
line of the ring gear (hypoid drive).
All parts necessary to transmit power from the
propeller shaft to the rear wheels are enclosed in a
banjo type axle housing.
The 220 mm (8.6 in) ring gear rear axle uses a
conventional ring and pinion gear set to transmit the
driving force of the engine to the rear wheels. This
gear set transfers this driving force at a 90 degree
angle from the propeller shaft to the drive shafts.
The axle shafts are supported at the wheel end of the
shaft by a double tapered roller bearing.
The pinion gear is supported by two tapered roller
bearings. The pinion depth is set by a shim pack
located between the gear end of the pinion and the
roller bearing that is pressed onto the pinion. The
pinion bearing preload is set by crushing a collapsible
spacer between the bearings in the axle housing.
The ring gear is bolted onto the differential cage with
12 bolts.
The differential cage is supported in the axle housing
by two tapered roller bearings. The differential and ring
gear are located in relationship to the pinion by using
selective shims and spacers between the bearing and
the differential cage. To move the ring gear, shims are
deleted from one side and an equal amount are added
to the other side. These shims are also used to
preload the bearings which are pressed onto the
differential cage. Two bearing caps are used to hold
the differential into the rear axle housing.
The differential is used to allow the wheels to turn at
different rates of speed while the rear axle continues
to transmit the driving force. This prevents tire
scuffing when going around corners and prevents
premature wear on internal axle parts.
The rear axle is sealed with a pinion seal, a seal at
each axle shaft end, and by a liquid gasket between
the differential carrier and the axle housing

4B-12 REAR AXLE

Legend


1.
Offset Box Wrench

10.
Remove wheel cylinder.
11.
Remove bearing holder fixing nuts.
12.
Take out axle shaft assembly with back plate and
set it on a bench press as following illustration.
Put bolt head on thick steel plate.

When axle shaft is extracted, since axle case oil
seal is damaged, axle case oil seal.
13.
Remove snap ring. Use snap ring pliers to
remove. Snap ring is prohibition of reuse.
14.
Remove shim (If so equipped)
15.
Remove sensor rotor (or spacer), double tape
r
roller bearing, oil seal, bearing holder, and back
plate from axle shaft by means of a press.

Discard used oil seal, double taper roller
bearing, snap ring, ABS sensor rotor and
spacer.
A03R300002
Legend

1.
Bench Press Fitting

2. Steel Plate (25-30 mm thickness)
3. Axle Shaft

16. Remove differential assembly fixing bolts and
nuts and take out differential assembly.
17.
Remove wheel pin from axle shaft, using the
remover 5-8840-0079-0.
420L100009
18.
Remove axle case oil seal.

Discard used oil seal.

4B-14 REAR AXLE

Reassembly
1.
Using the oil seal installer 5-8840-2202-0, install
new axle case oil seal.

420R300004

Note :
Confirm that the dimention : A should be 34.5 –
36.1 mm (1.36 – 1.42 in)







A03R300004

2.
Install new oil seal in bearing holder, using the oil
seal installer 9-8522-1269-0.


F04R300002
Legend


1.
Oil Seal

2.
Bearing Holder

3.
Drive wheel pin into axle shaft flange, using a
hammer.
4.
Differential assembly
a.
Clean the mating surface of axle case and
differential carrier.
b.
Apply Three Bond 1215 (TB1215) or
equivalent on the surface of differential
assembly as flowing illustration.




425RS006

c. Tighten bolts and nuts to the specified torque.

Torque : Bolt
64 N
m (6.5 kg
m/47 lb
ft)

Nut
44 N
m (4.5 kg
m/33 lb
ft)

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

4C1-4 FRONT WHEEL DRIVE
SPECIAL PARTS FIXING NUTS AND BOLTS
FRONT DRIVE AXLE AND PROPELLER SHAFT
N
m (kgf
m/lb
ft)




RTW440LF000101

4C1-6 FRONT WHEEL DRIVE
RECOMMENDED LIQUID GASKET

Type Brand Name Manufacture Remarks

RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
Water Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer

Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacture's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying
the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater
than 0.25 mm (0.01 in). Poor adhesion will result.

RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.

LOCTITE 262

Red 2. Apply LOCTITE to the bolts.


LOCTITE 270

Green

LOCTITE 271

Red
3. Tighten the bolts to the specified torque.
4. Wait at least on hour before continuing the installation procedure.

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.