ISUZU AXIOM 2002 Service Repair Manual

3C±10FRONT SUSPENSION
Knuckle
Knuckle and Associated Parts
410RW006
Legend
(1) Torsion Bar
(2) Lower Ball Joint, Nut and Cotter Pin
(3) Back Plate
(4) Knuckle Assembly
(5) Knuckle(6) Needle Bearing (4WD MODEL)
(7) Thrust Washer (4WD MODEL)
(8) Oil Seal (4WD MODEL)
(9) Upper Ball Joint, Nut and Cotter Pin
(10) Wheel Speed Sensor
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.
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 Bar in this
section.
8. Remove wheel speed sensor.

FRONT SUSPENSION3C±11
9. Remove back plate.
10. Remove lower ball joint by using remover J±29107.
CAUTION: Be careful not to damage the ball joint
boot.
901RW163
11. Remove upper ball joint by using remover J±36831.
CAUTION: Be careful not to damage the ball joint
boot.
901RW162
12. Remove knuckle assembly.
13. Remove oil seal (Except 2WD model).
14. Remove washer (Except 2WD model).15. Remove needle bearing by using remover J±23907
(Except 2WD model).
901RW044
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

Needle bearing

Thrust washer
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g) and install
needle bearing by using installer J±36838 and
J±8092 (Except 2WD model).
901RW045

3C±12FRONT SUSPENSION
2. Apply multipurpose type grease to the thrust washer,
and install washer with chamfered side facing knuckle
(Except 2WD model).
3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2 g).
Then use installer J±36837 and J±8092 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 (Except
2WD model).
901RW167
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.
Torque: 98 N´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.
Torque: 147 N´m (108 lb ft)
7. Install back plate.
8. Install wheel speed sensor.
9. Install torsion bar, refer to
Torsion Bar in this section.
NOTE: A d j u s t t h e t r i m h e ight. Refer to Front End
Alignment Inspection and Adjustment in Steering.

FRONT SUSPENSION3C±13
Upper Control Arm
Upper Control Arm and Associated Parts
450R200004
Legend
(1) Bolt and Plate
(2) Camber Shims
(3) Caster Shims
(4) Nut Assembly
(5) Upper Control Arm Assembly
(6) Fulcrum Pin(7) Bushing
(8) Plate
(9) Nut
(10) Speed Sensor Cable
(11) Nut and Cotter Pin
(12) Upper Ball Joint
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 and disconnect brake pipe.
Refer to
Disc Brakes in Brake section.
4. Support lower control arm with a jack.
5. Remove speed sensor cable.
6. Remove nut and cotter pin then use remover
J±36831.

3C±14FRONT SUSPENSION
CAUTION: Be careful not to damage the ball joint
boot.
901RW162
7. Remove upper ball joint.
8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and
number of shims.
11. Remove caster shims and note the positions and
number of shims.
12. Remove upper control arm assembly.
13. Remove nut.
14. Remove plate.
15. Remove bushing by using remover J±29755.
901RW161
901RW160
16. Remove fulcrum pin.
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

Fulcrum pin
Installation
1. Install fulcrum pin.
2. Install bushing by using installer J±29755 and
J±39376.
901RW164

FRONT SUSPENSION3C±15
901RW159
3. Install plate.
4. Install nut and tighten fulcrum pin nut finger±tight.
NOTE: Torque fulcrum pin nut after adjusting buffer
clearance.
Buffer clearance: 15 mm (0.59 in)
Torque: 108 N´m (80 lb ft)
450R200002
5. Install upper control arm assembly with the fulcrum
pin projections turned inward.
450RS013
Legend
(1) Projection
(2) Outward
6. Install the caster shims(2) between the chassis frame
and fulcrum pin.
7. Install the camber shims(1) between the chassis
frame and fulcrum pin.
450RS014
8. Install nut assembly.
9. Install bolt and plate, then tighten the bolt to the
specified torque.
Torque: 152 N´m (112 lb ft)
10. Install upper ball joint and tighten it to the specified
torque.
Torque: 57 N´m (42 lb ft)
11. 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.
Torque: 98 N´m (72 lb ft)
12. Install speed sensor cable.

3C±16FRONT SUSPENSION
Lower Control Arm
Lower Control Arm and Associated Parts
450R200003
Legend
(1) Nut, Front
(2) Bush, Front
(3) Bolt, Front
(4) Nut, Rear
(5) Bush, Rear
(6) Bolt, Rear
(7) Bolt, Lower Ball Joint(8) Bolt, Torsion Bar Arm
(9) Torsion Bar Arm Bracket and Nut
(10) Torsion Bar
(11) Lower Control Arm
(12) Lower Ball Joint and Nut
(13) Shock Absorber
(14) Stabilizer Link
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 tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle driving
shaft to release the shaft from hub(Except 2WD
model). Refer to
Front Hub and Disc in Driveline/Axle
section.
5. Support lower control arm with a jack.

FRONT SUSPENSION3C±17
6. Remove front nut.
7. Remove rear nut.
8. Remove torsion bar, refer to
Torsion Bar in this
section.
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control arm.
11. Remove the shock absorber lower end from the lower
control arm.
12. Remove the lower ball joint from the lower control
arm.
13. Remove front bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover J±36833.
901RW154
901RW155
19. Remove rear bushing by using remover J±36834.
901RW051
901RW052
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

3C±18FRONT SUSPENSION
Installation
1. Install rear bushing by using installer J±36834.
901RW053
2. Install front bushing by using installer J±36833.
901RW156
3. Install lower ball joint bolt.
4. Install torsion bar arm bolt.
5. Install lower control arm.
6. Install rear bolt.
7. Install front bolt.
8. Install lower ball joint and tighten it to the specified
torque.
Torque: 116 N´m (85 lb ft)
9. Install shock absorber and tighten it to the specified
torque.
Torque: 93 N´m (69 lb ft)
10. Install stabilizer link and tighten it to the specified
torque.
Torque: 50 N´m (37 lb ft)11. Install torsion bar arm bracket and tighten it to the
specified torque.
Torque: 116 N´m (85 lb ft)
12. Install Torsion bar, refer to
Torsion Bar in this section.
13. Install rear nut and tighten lower link nut finger±tight.
NOTE: Torque lower control arm nut after adjusting buffer
clearance.
Buffer clearance: 15 mm (0.59 in)
Torque: 235 N´m (174 lb ft)
450R200002
14. Install front nut then tighten lower link nut finger-tight.
NOTE: Torque lower control arm nut after adjusting buffer
clearance .
Buffer clearance: 15 mm (0.59 in)
Torque: 186 N´m (137 lb ft)
NOTE: A d j u s t t h e t r i m h e ight. Refer to
Front End
Alignment Inspection and Adjustment in Steering section.
450R200002

FRONT SUSPENSION3C±19
Upper Ball Joint
Upper Ball Joint and Associated Parts
450RW004
Legend
(1) Bolt and Nut(2) Upper Ball Joint
(3) Nut and Cotter Pin
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove the speed sensor from the knuckle.