air suspension ISUZU TF SERIES 2004 Owner's Manual

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.

FRONT SUSPENSION 3C-41

4. Support lower control arm with a harness.
5. Remove speed sensor harness.
6. Remove nut and cotter pin then remove knuckle
using remover 5-8840-2121-0.
CAUTION: Be careful not to damage the ball joint
boot.

RTW340SH000401
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 (9).
14. Remove plate (8).

15. Remove bushing (7) by using remover 5-8840-
0256-0.

RTW340SH000501



RTW340SH000601
16. Remove fulcrum pin (6).
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

3C-46 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:


Lower control arm


Bushing
Installation
1. Install rear bushing by using installer 5-8840-2124-
0.



Front
901RW053
2. Install front bushing by using installer 5-8840-
2123-0.



Front
901RW156



3. Install lower ball joint bolt.
4. Install torsion bar arm bolt.
5. Install lower control arm.
6. Install rear bolt.
7. Install cam bolt the hole and projection are
upward.
8. Install lower ball joint and tighten it to the specified
torque (12).
Torque: 127 N




m (12.9kg




m/94 lb ft)
9. Install shock absorber and tighten it to the
specified torque (13).
Torque: 93 N




m (9.5kg




m/69 lb ft)
10. Install stabilizer link and tighten it to the specified
torque (14).
Torque: 50 N




m (5.1kg




m/37 lb ft)
11. Install torsion bar arm bracket and tighten it to the
specified torque.
Torque: 116 N





m (11.8kg





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 (4).
NOTE: Apply oil to the thread.
NOTE: Tighten the nut or bolt with the parts in the
position shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 235 N




m (24.0kg




m/174 lb ft)



450R100002

FRONT SUSPENSION 3C-49

CAUTION: Be careful not to damage the ball joint
boot.


RTW340SH000401
4. Remove bolt and nut.
5. Remove upper ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.


Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.


Inspect screw/taper area of ball for damage.


If any defects are found by the above inspections,
replace the ball joint assembly with new one.





450RS023



After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 1.3–3.2 N




m (0.13-0.33kg




m/0.9-
2.4 lb ft)







450RS024
If the above limits specified are exceeded, replace the
ball joint assembly.
Installation
1. Install upper ball joint.
2. Install bolt and nut (1), then tighten them to the
specified torque.
Torque: 57 N




m (5.8kg




m/42 lb ft)
3. 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 (3).
Torque: 98 N




m (10.0kg




m/72 lb ft)

FRONT SUSPENSION 3C-51

CAUTION: Be careful not to damage the ball joint
boot.




901RW271
7. Remove nut.
8. Remove bolt.
9. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found
through inspection.


Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement .


Inspect screw/taper area of ball for damage.

If any defects are found by the above inspections,
replace the ball joint assembly with new one.




450RS026


After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 2.5-6.4 N




m (0.25-0.65kg




m/1.8-
4.7 lb ft)






450RS024


If the above limits specified are exceeded, replace
the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install bolt.
3. Install nut (3) and tighten it to the specified torque.
Torque: 127 N




m (12.9kg




m/94 lb ft)
4. 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 (4).
Torque: 147 N




m (15.0kg




m/108 lb ft)

3C-52 FRONT SUSPENSION

Bump Rubber
Bump Rubber and Associated Parts
RTW340MF001001
Legend

(1)
Bolt

(2)
Bump Rubber




Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove bolt.
3. Remove bump rubber.
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 :

Bump Rubber

Installation
1. Install bump rubber.
NOTE: Arrow points to be vehicle outer side of afte
r
assembly to vehicle.
2. Install bolt (1), then tighten it to the specified
torque.
Torque: 42 N




m (4.3kg




m/31 lb ft)

REAR SUSPENSION 3D-1
SECTION 3D
REAR SUSPENSION
TABLE OF CONTENTS
PAGE
Main Data and Specifications...........................................................................................3D- 2
Torque Specifications........................................................................................................ 3D- 3
Rear Suspension................................................................................................................3D- 4
General Description ...................................................................................................... 3D- 4
Leaf Spring and Shock Absorber ..................................................................................... 3D- 5
Leaf Spring and Associated Parts ............................................................................... 3D- 5
Removal .........................................................................................................................3D- 6
Inspection and Repair ................................................................................................... 3D- 7
Installation ..................................................................................................................... 3D- 8
Leaf Spring Assembly ....................................................................................................... 3D- 9
Disassembly .................................................................................................................. 3D- 9
Inspection and Repair ................................................................................................... 3D- 9
Reassembly ................................................................................................................... 3D- 10
Troubleshooting................................................................................................................. 3D- 11

REAR SUSPENSION 3D-7
INSPECTION AND REPAIR
Make correction or parts replacement if wear, damage or their abnormal conditions are found through inspection.





Visual Check
Inspect the following parts for wear, damage, nuts or other
abnormal conditions.
 Leaf spring assembly
 Clip
 Center bolt
 U-bolt
 Spring pin
 Shackle pin
 Shock absorber
 Rubber bumper
 Rubber bushing
 Bump rubber seat



Shackle Pin
Shackle Pin diameter mm (in)
17.93 - 18.00 (0.706 - 0.709)



Spring Pin
Spring Pin Diameter mm (in)
13.8 - 14.0 (0.543 - 0.551)



Shock Absorber
Inspection operation of shock absorber
If no resistance is felt while expanding the shock absorber, that
indicates the absorber is faulty.

REAR SUSPENSION 3D-9

LEAF SPRING ASSEMBLY

F03L100004

Disassembly
1. Remove the bushing using a bench press and a suitable
metal fitting.



RTW430SH000101

2. Apply a setting mark across the springs before
disassembling the leaf spring assembly.

F03L100006

3. Use a bench press and remove the center bolt.
 Discard center bolt and install a new one.

465R300001

4. Disassemble the leaf spring assembly.


Inspection and Repair
Inspect leaf spring, bush, clips, liners and center spacer for
wear, damage, rust or other abnormal conditions and if
necessary, repair or replace it.