Check ball ISUZU TF SERIES 2004 User Guide

MANUAL TRANSMISSION 7B1-101

Clutch Hub Spline Play

Set a dial indicator to the clutch hub to be
measured.

226RS042


Move the clutch hub as far as possible to both the
right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit,
the clutch hub must be replaced.

Clutch Hub Spline Play
Standard Limit
1st-2nd
3rd-4th 0 - 0.1 mm
(0 - 0.004 in) 0.2 mm
(0.008 in)
Rev. 5th 0 - 0.2 mm
(0 - 0.008 in) 0.3 mm
(0.012 in)
Ball Bearing Play


Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit: 0.2 mm (0.008 in)




226RS043

Reassembly
1. Install center roller bearing (29) to counter gear
shaft (30).


Apply engine oil to the bearing inner and outer
circumferences.


Install the roller bearing in the proper direction.
NOTE: Check that outer race moves only in the
direction of arrow.

226RS044
2. Install front roller bearing (28) by performing the
following steps.


Use bearing installer 5-8840-2194-0 to install the
front roller bearing inner race to the counter gear
shaft (30).


Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.

MANUAL TRANSMISSION 7B1-115

3. WALKING OR JUMPING OUT OF GEAR

Checkpoint Trouble Cause Countermeasure

Shift rod and quadrant box
sliding faces
Detent ball
Replace the shift rod and/or
the quadrant box
Replace the detent ball
Worn shift rod and/or sliding
faces
Worn detent ball
Detent springRepair or replace the detent
spring
Replace the worn parts
Detent spring weak or broken
Insufficient stroke caused by
sliding position wear and
excessive play
OK
OKNG NG NG NG
OK OK
Change lever play
Continued on the next page
Mainshaft and countershaft
thrust playReplace the worn partsWorn thrust washer, collar,
and/or gear thrust faces
Replace the worn partsWorn shift arm and/or
synchronizer sleeve groove
NG NG
OKShift arm and synchronizer
sleeve

3B-14 POWER-ASSISTED STEERING SYSTEM


Tie-rod End
If looseness or play is found when checked by moving
the end of ball joint at tie-rod end, replace tie-rod end.

Tie-rod Assembly
If the resistance is insufficient or play is felt when
checked by moving the ball on the tie-rod, replace the
tie-rod assembly.

Rubber Parts
If wear or damage is found through inspection, replace
with new ones.

Reassembly
1. Install mounting rubber and dust cover (If removed).
2. Install oil line.
Torque: 10 - 15 N




m (1.0 – 1.5 kg




m/87 - 130 lb in)
3. Install tie-rod assembly with tab washer.
Apply grease to ball joint, install tie-rod and tab
washer, then tighten to specified torque.
Torque: 69 - 98 N




m (7.0 – 10.0 kg




m/51 - 72 lb ft)
After tightening, bend tab washer against width
across flat of inner ball joint.
4.
Apply a thin coat of grease to the shaft for smooth
installation. Then install bellows.
5. Install band and clip.
6. Install tie-rod end and tighten lock nut.
Torque:
92 - 104 N




m (9.4 – 10.6 kg




m/68 - 77 lb ft)

Main Data and Specifications
General Specifications
2WD 4WD
Power steering Without With
Type Rack and pinion
Rack stroke mm (in) 138 (5.43) 138 (5.43) 152 (5.98)
Steering unit
Lock to lock 4.84 3.38 3.26

FRONT SUSPENSION 3C-11

NOTE: Paint mark to be outer side of after assembly to
vehicle.
2. Install nut (2), then tighten it to the specified
torque.
Torque: 55N





m (5.6kg





m/41lb ft)
3. Install bolt (7) and nut (4), then tighten to the
specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137N




m (14.0kg




m/101 lb ft)


NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.




RTW340SH001301-X
4. Install nut (6), then tighten it to the specified
torque.
Torque: 50N




m (5.1kg




m/37 lb ft)
5. Tighten the cam bolt (8) and nut (3), it to the
interim torque, then turn the cam bolt to the setting
mark applied during disassembly.
6. Install ball joint nut, then tighten it to the specified
torque with just enough additional torque to align
cotter pin holes. Install new cotter pin (5).
Torque: 147N




m (15.0kg




m/108 lb ft)


NOTE: Check the trim height. Refer to Front Alignment
Inspection and Adjustment.

7. Nut (3) tighten it to the specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 186N




m (19.0kg




m/137 lb ft)


NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.





RTW340SH001301-X
8. Install wheel and tire assembly. Refer to wheel in
this section.

3C-16 FRONT SUSPENSION

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 :


Stabilizer bar


Rubber bushing


Link ball joint
Installation
1. Install rubber bushing.
2. Install stabilizer bar.
3. Install bracket and bolt (5), then tighten it to the
specified torque.
Torque: 25 N




m (2.5kg




m/18 lb ft)
4. Install link.
5. Install nut (3), (4), then tighten it to the specified
torque.
Torque: 50 N




m (5.1kg




m/37 lb ft)

3C-18 FRONT SUSPENSION
6. Remove the stabilizer link nut. Right and left.
7. Remove the wheel speed sensor from the knuckle.
8. Remove back plate.
9. Remove lower ball joint by using remover 5-8840- 2017-0.
CAUTION: Be careful not to damage the ball joint
boot.

P1010009
10. Remove upper ball joint by using remover 5-8840-
2017-0.
CAUTION: Be careful not to damage the ball joint
boot.

P1010011
11. Remove knuckle.

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
Installation
1. Install knuckle assembly.
2. 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 (1).
Torque: 98 N






m (10.0kg






m/72 lb ft)
3. 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 (4).
Torque: 147N






m (15.0kg






m/108 lb ft)
4. Install back plate.
5. Install wheel speed sensor.
6. Install stabilizer link nut. Right and left.

3C-20 FRONT SUSPENSION
5. Remove nut (8).
6. Remove upper ball joint by using remover 5-8840-
2017-0.
CAUTION: Be careful not to damage the ball joint
boot.

P1010005
7. Remove nut (3).
8. Remove bolt(1).
9. Remove bolt (10) and nut (9).
10. Remove upper ball joint.
11. Remove upper control arm assembly.
12. Remove bushing.
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
Installation
1. Install bushing by using installer 5-8840-0257-0
and 5-8840-2327-0.


P1010062
2. Install upper ball joint and tighten it to the specified
torque (9).
Torque: 31 N






m (3.2kg






m/23 lb ft)
3. Install nut (6) and cotter pin then tighten the nut to the specified torque, with just enough additional
torque to align cotter pin holes. Install new cotte
r
pin.
Torque: 98 N






m (10.0kg







m/72 lb ft)
4. Install upper control arm assembly.
5. Install bolt (1) and nut (3).
NOTE: Apply oil to the thread.
NOTE: Tighten the bolt (1) with the parts in the position
shown in the illustration below.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137 N






m (14.0kg






m/101 lb ft)





RTW340SH001301-X
6. Install nut (12).
7. Install nut (11).

3C-22 FRONT SUSPENSION
4. Support lower control arm with a jack.
5. Remove the nut (10).
6. Remove the nut (8).
7. Remove the shock absorber lower end from the
lower control arm.
8. Remove the lower ball joint from the lower control arm.
9. Remove nut (4) and cam plate.
10. Remove cam bolt.
11. Remove lower control arm.
12. Remove bushing.
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
Installation
1. Install rear bushing by using installer 5-8840-
0257-0 and 5-8840-2327-0.


P1010063
2. Install lower control arm.
3. Install cam bolt.
4. Install lower ball joint and tighten it to the specified
torque (9).
Torque: 127 N






m (12.9kg






m/94 lb ft)
5. Install shock absorber and tighten it to the specified torque (5).

NOTE: Apply oil to the thread.
NOTE: Tighten the nut (4) with the parts in the position
shown in the illustration below.
Torque: 137 N






m (14.0kg






m/101 lb ft)




RTW340SH001301-X
6. Install stabilizer link and tighten it to the specified
torque (10).
Torque: 50 N






m (5.1kg






m/37 lb ft)
7. Install nut (4) and cam plate and tighten lower link nut finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut (4) with the parts in the position
shown in the illustration below.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 186 N






m (19.0kg






m/137 lb ft)





RTW340SH001301-X
8. Install nut (8) and cotter pin then tighten the nut to
the specified torque, with just enough additional
torque to align cotter pin holes. Install new cotte
r

3C-32 FRONT SUSPENSION

Stabilizer Bar
Stabilizer Bar and Associated Parts


RTW340MF000401
Legend

(1)
Rubber Bushing

(2)
Bracket and Bolt
(3) Link



(4)
Nut
(5) Stabilizer Bar
(6) Nut

Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove the stone guard.
3. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.
4. Remove nut (4) and (6).
CAUTION: Be careful not to break the ball joint
boot.
5. Remove link.
6. Remove bracket.
7. Remove stabilizer bar.
8. Remove rubber bushing.

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 :


Stabilizer bar


Rubber bushing


Link ball joint

FRONT SUSPENSION 3C-39

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

Thrust washer (44 Model Only)
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g) and
install needle bearing by using installer 5-8840-
2128-0 and grip 5-8840-0007-0. (4
4 Model Only)





(4
4 Model Only)
901RW275
2. Apply multipurpose type grease to the thrust
washer, and install washer with chamfered side
facing knuckle. (44 Model Only)

3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2
g). Then use installer 5-8840-2127-0 and grip 5-
8840-0007-0 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. (4
4 Model Only)




(4
4 Model Only)
901RW274
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 (9).
Torque: 98 N




m (10.0kg




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 (2).
Torque: 147 N





m (15.0kg





m/108 lb ft)
7. Install back plate.
8. Install speed sensor harness.
9. Install torsion bar, refer to Torsion Bar in this
section.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering.