instrument panel ISUZU TF SERIES 2004 User Guide

PARKING BRAKE SYSTEM 5D-3







This illustration shows RHD model
LHD model is opposite.
RTW35DLH000101

Legend

(1)
Nut

(2)
Bolt and Washer

(3)
Adjust Nut

(4)
Bolt


(5)
Front Parking Brake Cable

(6)
Clip

(7)
Switch

(8)
Bolt

(9)
Parking Lever Assembly


Removal
1. Remove instrument panel assembly & cross beam
in legend numbers order.

Refer to section 10.
2. Bolts (2)(8) are already removed in step 1.
3. Remove adjust nut (3).
4. Pull out clip (6) and take out front parking brake
cable (5) from parking lever assembly (9).
5. Remove bolts (4) and nut (1) and take out parking
lever assembly (9).
6. Remove switch (7).
Installation
1. Install switch (7).
Torque: 1.5 N




m (0.15 kg




m/13 lb in)
2. Set parking lever assembly (9).
3. Install bolts (4) and nut (1) and tighten them to the
specified torque.
Torque: 15 N





m (1.5 kg





m/11 lb ft)
4. Set front parking brake cable (5) in parking leve
r
assembly (9).
5. Drive clip (6) into the outer cable groove of front
parking brake cable (5) at the outside of parking
lever assembly (9).

5D-4 PARKING BRAKE SYSTEM

6. Drive adjust nut (3) on the front end of front
parking brake cable (5) so that front ends of rea
r
parking brake fit into the rear end (equalizer) of
front cable (5).
7. Install instrument panel assembly & cross beam.

Refer to section 10.
8. Install bolts (2) (8) and tighten them to the
specified torque.
Torque: 15 N




m (1.5 kg




m/11 lb ft)
9. Install all parts removed when removal steps.

Refer to section 10.
10. When a parking cable is replaced, pull parking
brake lever with a force equivalent to operating
force: 490N (50 kg/110 lb), 10 times fo
r
conditioning.
11. Adjust nut (3) so that lever (9) goes through 8

14
notches, when pulled with a operation force o
f
294N (30 kg/66 lb) and check brake for no drag.

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

10-2 CAB
WINDSHIELD
REMOVAL


RTW4A0LF000901

Removal Steps
1. Interior trim panels (Front side)
/Headlining/Instrument panel assembly
2. Wiper arm assembly

3. Room mirror
4. Side moulding
5. Vent cowl cover
6. Windshield stopper
7. Upper moulding

8. Windshield glass
9. Engine hood rear seal

10-4 CAB

INSTALLATION


RTW4A0LF001201

Installation Steps


1. Engine hood rear seal
2. Upper moulding

3. Windshield glass
4. Windshield stopper
5. Vent cowl cover
6. Side moulding
7. Room mirror

8. Wiper arm assembly
9. Interior trim panels (Front side)
/Headlining/Instrument panel assembly

10-28 CAB
INSTRUMENT PANEL
REMOVAL


This illustration is based on RHD model
RTW4A0LF001001

Disassembly Steps

1. Front console assembly

2. Glove box

3. Instrument panel driver lower cover
assembly

4. Driver knee bolster assembly

5. Driver air bag

6. Steering wheel/ steering cowl

7. Meter cluster assembly
8. Dash side trim cover
9. Front pillar trim cover
10. Front cover
11. Side cover

12. Instrument panel & Cross beam
assembly


13. Ashtray case

14. Center cluster assembly

15. Control lever assembly
16. Storage box assembly

17. Ashtray bracket
18. Meter assembly
19. Passenger lower bracket
20. Glove box cover

21. Passenger air bag (if so equipped)

22. Side ventilation grille

23. Vent duct assembly/Defroster nozzle
assembly
24. Instrument harness assembly

25. Instrument panel

26. Cross beam

CAB 10-29

Important Operations
1. Front Console Assembly


Refer to Floor Consol in this section.



2. Glove Box


Remove 2 fixing screws and pulling the handle.



3. Instrument Panel Driver Lower Cover Assembly
1) Remove the engine hood opener 2 fixing screws.
2) Remove the lower cover one fixing screw.
3) Pull out the cover (Stick type parking brake only).
4) Pull out the lower cover assembly.




4. Driver Knee Bolster Assembly


Remove 4 fixing bolts.
Caution:
For precaution on installation or removal of SRS-air bag
system, refer to section 9 “Supplemental Restraint System
(SRS) - AIR BAG”

5. Driver Air Bag
6. Steering Wheel/Steering Cowl


Refer to Section 3B “STEERING COLUMN” for steering
lock assembly removal steps.




7. Meter Cluster Assembly


Pull out the 4 clip positions.

10-30 CAB


12. Instrument Panel & Cross Beam Assembly
1) Remove the two bolts fixing the steering column to the
cross beam and the two bolts fixing the brake pedal
bracket to the cross beam.



2) Remove the two bolts fixing the parking brake bracket to
the cross beam (Stick type parking brake only).



3) Disconnect the control cables at the blower unit and
heater unit.
Remove the front & side cover from the instrumen
t
panel.
4) Remove the fasteners fixing the instrument panel &
cross beam assembly to the body panel.


5) Disconnect the instrument harness connectors.

CAB 10-31



13.Ashtray Case

Pull out the ashtray case.
14. Center Cluster Assembly
1) Pull out the cluster at the 6 clip positions.
2) Disconnect the cigarette lighter, accessory socket,
hazard switch and clock connectors.
15. Control Lever Assembly


Remove the 2 fixing screws.
17.Ashtray Bracket


Remove the 3 fixing screws and illumination connector.


Caution:
For precautions on installation or removal of SRS-air bag
system, refer to section 9 "Supplemental Restraint System
(SRS) - AIR BAG".
21. Passenger Air Bag



Remove 2 fixing bolts, 2 fixing nuts and connector.
22. Side Ventilation Grille.

Pull out the grilles and disconnect switch connecto
r
(Driver’s side).
23. Vent Duct Assembly/Defroster Nozzle Assembly


Refer to section 1 “HVAC” for defroster nozzle and
ventilation duct removal steps.




25. Instrument Panel


Remove the clip and 6 fixing bolts.
26. Cross Beam

10-32 CAB
INSTALLATION


This illustration is based on RHD model
RTW4A0LF001101

Installation Steps
1. Cross beam
2. Instrument panel
3. Instrument harness assembly
4. Vent duct assembly/Defroster nozzle
assembly
5. Side ventilation grille
6. Passenger air bag
7. Glove box cover
8. Passenger lower bracket
9. Meter assembly
10. Ashtray bracket
11. Storage box assembly
12. Control lever assembly
13. Center cluster assembly


14. Ashtray case

15. Instrument panel & Cross beam
assembly
16. Side cover
17. Front cover
18. Front pillar trim cover
19. Dash side trim cover
20. Meter cluster assembly

21. Steering wheel/Steering cowl
22. Driver air bag
23. Driver knee bolster assembly
24. Instrument panel driver lower cover assembly
25. Glove box
26. Front console assembly