power ISUZU TFS SERIES 1997 Workshop Manual

4B-52 REAR AXLE
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair rear axle problems.
Each troubleshooting chart has three headings arranged from left to right.
(1) Checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into five sub-sections:
1. Abnormal Rear Axle Noise
1) Noise when the engine is driving the vehicle
2) Noise when the vehicle is coasting
3) Intermittent noise
4) Noise when the vehicle is turning
5) Constant noise
2. Vibration
3. Oil Leakage
1) Differential carrier leakage
2) Axle case leakage
3) Axle case to inside hub leakage
4) Axle case to inside brake drum leakage
4. Power Not Being Transmitted to the Wheels (Propeller Shaft Operation is Normal)

4B-62 REAR AXLE
4. POWER NOT BEING TRANSMITTED TO THE WHEELS
(PROPELLER SHAFT OPERATION IS NORMAL)
Checkpoint Trouble Cause Countermeasure
Replace the rear axle shaftBroken rear axle shaft NG
Replace the drive pinion and
the ring gear as a setDrive pinion and ring gearBroken drive pinion and/or ring
gear
Replace the differential gears
and/or the spiderDifferential cage gearsBroken differential cage gears
and/or spider NG NG
OK OK
Rear axle shaft

5-8 BRAKES
MAIN DATA AND SPECIFICATIONS
FRONT DISC BRAKE mm(in.)
Caliper type Pin slide
Disc outside diameter 257 (10.118)
Disc thickness 22 (0.866)
Piston diameter 60.33 (2.375)
Adjustment method Self-adjusting
REAR DRUM BRAKE mm(in.) 4 2 4 4
Type Leading and Trailing
Drum inside diameter 254(10.008) 295 (11.614)
Brake lining dimension 221 50 5 283 45 4
(Length Width Thickness) (8.71 1.97 0.20) (11.14 1.77 0.16)
Adjustment method Self-adjusting
WHEEL CYLINDER mm(in.)
Inside diameter : rear
Europe and South Africa 25.40 (1.000)
Others 22.22 (0.875)
MASTER CYLINDER mm(in.)
TypeSplit
Bore diameter 23.81 (0.938)
Piston stroke (Primary + Secondary) 19 + 12 (0.75 + 0.47)
VACUUM SERVO mm(in.)
Diaphragm diameter
Except Australia 230 (9.055)
For Australia 180 (7.087) + 205 (8.077)
Power cylinder stroke 32.5 (1.281)
PEDAL RATIO 4.04
BALANCE
Type Blend proportioning valve/Load sensing proportioning
valve

BRAKES 5-67
TROUBLESHOOTING
Condition and Cause Correction
Poor Brake Action
Master cylinder faulty Correct or replace
Power cylinder faulty Correct or replace
Level of brake fluid in reservoir too low Replenish and bleed
Air in hydraulic circuit Bleed
Front disc brake caliper faulty Clean or replace
Rear brake wheel cylinder faulty Clean or replace
Water or oil on brake pads or linings Clean or replace
Brake pads or linings hardened Replace
Brake pads or linings in poor contact with rotor or brake drum Correct
Brake pads or linings worn Replace
Brake disc or drum rusted Grind or replace
Check valve in vacuum hose faulty Correct or replace
Brake Squeak
Brake pads or linings worn Replace
Brake pads or linings hardened Replace
Brake pads or linings in poor contact with rotor or brake drum Correct
Brake disc(s) warped, worn or damaged Grind or replace
Disc brake anti-squeak shims fatigued Replace
Front hub bearings loose or preload is incorrect Adjust or replace
Brake disc or drum rusted Grind or replace
Brake Pull
Tire inflation pressures unequal Adjust
Front wheel alignment incorrect Adjust
Water or oil on brake pads or linings Clean or replace
Brake pads or linings hardened Replace
Brake pads or linings worn excessively Replace
Brake drum or rotor worn or scored Grind or replace
Front or rear wheel cylinder or disc brake caliper malfunctioning Clean or replace
Front hub bearing preload incorrect Adjust or replace
Brake pad or lining clearances unequal Adjust or replace
Brake Drag
Parking brake maladjusted Adjust
Brake pad or lining clearance insufficient Adjust
Brake pedal free play insufficient Adjust brake pedal height or power cylinder operating rod
Piston in master cylinder sticking Clean or replace
Pistons in disc brake caliper sticking Replace piston seals
Pistons in rear brake wheel cylinders sticking Clean or replace
Brake pads sticking in caliper Clean
Return springs weakened Replace
Parking brake binding Overhaul rear brakes
Front hub bearing preload incorrect Adjust or replace
Rear brake shoes not returning Correct or replace brake back plate, check automatic adjuster and
replace as necessary
Obstructions in hydraulic circuit Clean
Rotor warped excessively Grind or replace
Rear brake drum distorted Grind or replace
Piston cups swollen Replace brake fluid and piston cups
Check valve ; vacuum hose faulty Replace
Parking cable sticking Clean or replace
Rear disc brake over adjust Adjust or overhaul rear brakes
Excessive Brake Pedal Travel
Air in hydraulic circuit Bleed hydraulic circuit
Level of brake fluid in reservoir too low Replenish brake fluid reservoir to specified level and bleed hydraulic
circuit as necessary.
Master cylinder push rod clearance excessive Adjust
Leakage in hydraulic system Correct or replace defective parts
Rear disc brake autoadjuster malfunction Overhaul rear brakes

CAB 10-15
DISASSEMBLY
(Front Door)
87 910
11 6
Disassembly Steps
1. Power window switch/Windows regulator
handle
2. Bezel
3. Speaker grill
4. Speaker assembly
5. Door pull case
6. Door mirror cover/Tweeter
7. Door trim pad
8. Door pocket
9. Power window box
10. Inner waste seal
11. Outer waste seal
12. Door mirror assembly
13. Door mirror bracket
14. Bracket
15. Speaker box
16. Water-proof sheet
17. Window glass
18. Window regulator/Power window motor
19. Glass run
20. Glass run rear channel
21. Inside lever
22. Door lock assembly/Door lock actuator
23. Glass run front channel
24. Door lock cylinder
25. Outside handle

10-16 CAB
Important Operations
1. Power Window Switch/Window Regulator Handle
Prise out the power window switch and remove the
connectors.
To remove the regulator handle, remove the clip at the
root of the handle by using wire.
2. Bezel
Remove the screw while pulling the inside lever toward
you.
3. Speaker Grill
Pull out the clips.
4. Speaker Assembly
Remove 4 screws and disconnect the speaker harness
connector.
5. Door Pull Case
Remove the screw at the bottom of the case.

CAB 10-17
6. Door Mirror Cover/Tweeter
Pull out the upper clip, and then take out the catch at the
lower section.
If so equipped the tweeter, disconnect the speaker
harness connector.
7. Door Trim Pad
Remove the cover bottom of the trim pad (4 pcs), then
remove the screws.
8. Door Pocket
9. Power Window Box
10.Inner Waste Seal
11.Outer Waste Seal
12.Door Mirror Assembly
Remove 3 fixing bolts and then remove the connector.
13.Door Mirror Bracket
Remove 2 bolts at the lower section, and then remove 2
screws in the weather strip.
14.Bracket
15.Speaker Box
Remove 3 fixing bolts.
16.Water Proof Sheet
Take care not to damage the sheet when peeling it off.

10-18 CAB
17.Window Glass
Remove 2 screws through the access hole and pull out
the window glass upward.
18.Window Regulator/Power Window Motor
Disconnect the power window motor connector.
19.Glass Run
Pull it out of the door piller of the channel. (front/rear)
20.Glass Run Rear Channel
Remove 2 screws.
21.Inside Lever
22.Door Lock Assembly/Door Lock Actuator
Disconnect the linkage with the outside handle, the
inside lever and the lock cylinder.
23.Glass Run Front Channel
24.Door Lock Cylinder
Remove the door lock cylinder by applying finger
pressure from inside while depressing the retaining clip.
25.Outside Handle

CAB 10-19
DISASSEMBLY AND REASSEMBLY
(Rear Door)
3
2
910 181219 13
1716
15 14
6
5 4 1611
7
68
Disassembly Steps
1.Power window switch/Window regurator
handle
2. Speaker grill
3. Speaker
4. Bezel
5. Inside pull handole
6. Door trim pad
7. Arm rest sm
8. Bracket
9. Water proof sheet
10. Glass guide
11. Upper cover
12. Window regurator/Power window motor
13. Window glass
14. Bracket15. Inside lever
16. Outside handle
17. Door lock cylinder
18. Outer waste seal
19. Glass run
Reassembly Steps
To reassemble, follow the disassembly steps
in the reverse order.

CAB 10-23
REASSEMBLY
(Front Door)
15
23 21 24 2522 171620
Reassembly Steps
1. Outside handle
2. Door lock cylinder
3. Glass run front channel
4. Door lock assembly/Door lock actuator
5. Inside lever
6. Glass run rear channel
7. Glass run
8. Window regulator/Power window motor
9. Window glass
10. Water proof sheet
11. Speaker box
12. Bracket
13. Door mirror bracket14. Door mirror assembly
15. Outer waste seal
16. Inner waste seal
17. Power window box
18. Door pocket
19. Door trim pad
20. Door mirror cover/Tweeter
21. Door pull case
22. Speaker assembly
23. Speaker grill
24. Bezel
25. Power window switch/Windows regulator
handle