reverse ISUZU TF SERIES 2004 User Guide

FRONT WHEEL DRIVE 4C1-65


Preload Adjustment
Tighten the hub nut at 29.4 Nm (3 kgfm / 21.716 lb.ft), then
loosen the nut to the full.
Tighten the hub nut at the value given below, using a spring
scale on the wheel pin.
Bearing Preload N(lb)

New bearing and New oil seal 20 - 25 (4.4 - 5.5)
Used bearing and New oil seal 12 - 18 (2.68 - 4.0)
If the measured bearing preload is outside the specifications,
adjust it by loosening or tightening the bearing nut.



21. Lock Washer
Turn the side with larger diameter of the tapered bore to the
vehicle outer side, and attach the washer.
If the bolt holes in the lock plate are not aligned with the
corresponding holes in the nut, reverse the lock plate.
If the bolt holes are still out of alignment, turn in the nut just
enough to obtain alignment,. Screw is to be fastened tightly so
its head may come lower than the surface of the washer.


22. Body Assembly
Apply adhesive (Loctite 15 or equivalent) to the both joining
faces.


23. Snap Ring and Shims
Adjust the clearance between the free wheeling hub body and
the snap ring.
Clearance mm(in)
0 - 0.2 (0 - 0.08)
Adjust Shims Available mm(in)
0.2, 0.3, 0.5, 1.0
(0.008, 0.011, 0.020, 0.039)


24. Cover Assembly
Align stopper nails to grooves of body.

4C2-4 SHIFT ON THE FLY SYSTEM
Shift On The Fly System and Association Parts







RTW440LF000701
Disassembly steps
1. Filler plug
2. Bolt
3. Front axle drive shaft (LH side)
4. Bolt
5. Actuator assembly
6. Bolt
7. Housing
8. Sleeve
9. Clutch gear
10. Snap ring
11. Inner shaft
12. Snap ring
13. Inner shaft bearing
14. Needing bearing
15. Oil seal
Reassembly steps
To reassemble, follow the disassembly steps in
the reverse order.

BRAKES 5C-51
BRAKE CONTROL
REMOVAL AND INSTALLATION

BRAKE PEDAL ASSEMBLY

This illustration shows RHD model
LHD model is opposite.
310R300001

Removal Steps
1. Nut ; fulcrum pin
2. Pin ; fulcrum, pedal to bracket
3. Pedal arm
4. Return spring
5. Pedal pad

Installation steps
To install, follow the removal procedure in
reverse order.
Before installation, apply grease to the entire
circumference of the fulcrum pin (2).
Refer to "SERVICING" in this section for
adjustment procedure of brake pedal.

CAB 10-69


Important Operation - Installation
1. Fuel Filler Lid Cable Assembly


Install the cable holder of cable assembly to the recess
and push the grommet in to the back panel. Fix the clips
to the pointed places.
Note:
To install, follow the removal steps in the reverse order,
noting the following points.





Do not make extreme curve on the cable.





Install the cable from inside of the cab.

CLUTCH 7C-21
CLUTCH
REMOVAL AND INSTALLATION



RTW37CLF000201-X

Removal Steps
1. Transmission assembly


2. Pressure Plate assembly


3. Driven plate assembly
4. Release bearing
5. Shift fork


6. Flywheel assembly and crank bearing

Installation Steps
To install, follow the removal steps in the
reverse order.

CLUTCH 7C-23
015RW053
6. Flywheel Assembly and Crank Bearing (6VE1)
(1) Remove flywheel assembly and crankshaft bearing. Do no
t
remove except for replacement.
(2) Use the remover 5-8840-2000-0 (J-5822) and sliding
hammer 5-8840-0019-0 (J-23907) to remove the crankshaf
t
bearing



Important Operations - Installation
Follow the removal procedure in reverse order to perform the
installation procedure.
Pay careful attention to the important points during the
installation procedure.

015RW054
6. Flywheel Assembly and Crank Bearing (6VE1)
(1) Install flywheel assembly and crankshaft bearing. Use the
installer 5-8840-0125-0 (J-26516-A) and driver handle 5-
8840-0007-0 (J-8092) to install the crankshaft bearing then
clean and lubricate with grease.
015RS047
(2) Install new flywheel fixing bolts in the order illustrated and
tighten them to the specified torque.
N
m (kg
m/lb ft)

6VE1 54 (5.5/40)
NOTE: Do not reuse the bolt and do not apply oil or thread lock
to the bolt.

7C-40 CLUTCH
REASSEMBLY
To reassemble, follow the disassembly steps in the reverse order, noting the following points:


206RS006
1. Before installing the parts, apply a thin coat of rubber
grease.
2. Install cup in groove in piston with the lip turned to the fron
t
of cylinder. Use care so as not to scratch the cylinder.

ELECTRICAL-BODY AND CHASSIS 8A-5
NOTES FOR WORKING ON ELECTRICAL ITEMS
Battery

BATTERY CABLE
Disconnecting the Battery Cable
1. All switches should be "OFF" position.
2. Disconnect the battery ground cable.
3. Disconnect the battery positive cable.
CAUTION:
It is important that the battery ground cable be
disconnected first.
Disconnecting the battery positive cable first can result in
a short circuit.














Connecting the Battery Cable
Follow the disconnecting procedure in the reverse order to
connect the battery cables.
CAUTION:
Clean the battery terminal and apply light coat of grease to
prevent terminal corrosion.




CONNECTOR HANDLING
Disconnecting the Connectors
Some connectors have a tang lock to hold the connectors
together during vehicle operation.
Some tang locks are released by pulling them towards you
1.
Other tang locks are released by pressing them forward
2.
Determine which type of tang lock is on the connector being
handled.



Firmly grasp both sides (male and female) of the connector.
Release the tang lock and carefully pull the two halves of the
connector apart.
Never pull on the wires to separate the connectors.
This will result in wire breakage.

ELECTRICAL-BODY AND CHASSIS 8A-17
DIODE
Diode Specifications and Configurations

SHAPE
MARK/
COLOR
CONSTRUCTION CHECKING
THERE SHOULD BE CONTINUITY IN
EITHER A OR B WHEN A CIRCUIT
TESTER IS CONNECTED WITH
DIODE TERMINAL



BLACK

21
CONNECTION A+-
PATTERN B-+
TERMINAL NO.




BLACK
321
-+
CONNECTION+-
PATTERN+-
-+B A TERMINAL NO.




BLACK

321
-+
CONNECTION+-
PATTERN+-
-+B A TERMINAL NO.




BLACK


4321
+-
A-+
CONNECTION-+
PATTERN-+
B+-
+-
TERMINAL NO.


Maximum Rating (Temp.=25




C)
Items Rating Remarks
Peak reverse voltage 400V
Transient peak reverse voltage 500V
Average output current 1.5A Temp.=40C
Working ambient temperature -30C80C
Storage temperature -40C100ßC

ELECTRICAL-BODY AND CHASSIS 8A-21

Caution:
Do not attach the booster cable to the discharged battery
negative terminal.

11. Start the engine of the vehicle with the booster battery.
Check that all unnecessary electrical accessories are off.
12. Start the engine of the vehicle with the discharged battery.
13. Remove the jumper cables in the reverse order to which
they were attached.
Caution:
Be absolutely sure to remove the negative jumper cable
from the vehicle with the discharged battery first.