steering wheel ISUZU TF SERIES 2004 Owner's Manual

4C1-14 FRONT WHEEL DRIVE
FRONT DRIVE AXLE ASSEMBLY
Front Drive Axle Assembly and Associated Parts


RTW440LF000501

Legend
1. Propeller Shaft
2. Front Axle Case Assembly and Front Drive
Shaft Assembly
3. Washer

4. Mounting Bolt
5. Tie-rod End ; Steering Unit
6. Knuckle and Back Plate
7. Hub and Disc Assembly
8. Suspension Crossmember

FRONT WHEEL DRIVE 4C1-15

Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
3. Remove the stone guard.
4. Remove the brake caliper fixing bolt and hang the caliper.
Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front Wheel Speed Sensor in Brake section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to Front Propeller Shaft in
this section.
8. Loosen the height control arm of the torsion bar, then
remove the torsion bar from lower control arm.
Refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock absorber.

12. Remove the tie-rod end from the knuckle.
Refer to Power Steering Unit in Steering Section.
13. Disconnect the breather hose of the front axle.
14. Disconnect the actuator connector. (With shift on the fly)
15. Remove the bolts and nuts of the lower control arm (Frame
side), then disconnect the lower control arm from frame.
16. Disconnect between the right side upper control arm and
the knuckle, then remove the knuckle with lower control
arm.
CAUTION :
When removing the knuckle, be careful not to damage the
oil seal inside of the knuckle.

4C1-16 FRONT WHEEL DRIVE
17. Support the differential case by the jack.
18. Remove the front axle mounting bolts and nuts, lower the
jack slowly. Remove the left side drive shaft end from the
knuckle, then lower the axle assembly from the vehicle.
CAUTION :
1. During the work, be sure that the axle assembly is
supported securly.
2. Be careful not to damage the bellows of the power
steering unit by interference.
3. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.


Installation
1. Support the differential case by the jack.
2. Jack up the front drive axle assembly, install the left side
drive shaft to the knuckle, then install the mount bolts and
nuts.
CAUTION :
1. Be careful not to damage the bellows of the power
steering unit by interference.
2. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.
3. When installing the drive shaft to the knuckle, be
careful not to damage the oil seal inside of the knuckle.

RTW34CSH000101
3. Tighten the mounting bolts and nuts to the specified torque.
Torque : 169 N·m (17.2kg·m/124 lb ft)



4. Install the right side knuckle with lower control arm to the
upper control arm.
Refer to Knuckle in Suspension section.
CAUTION :
When insert the drive shaft to the knuckle, be careful not
to damage the oil seal inside of the knuckle.

5. Align the bolt hole of the lower control arm, install the bolts
and nuts.

FRONT WHEEL DRIVE 4C1-17
NOTE :
Adjust the buffer clearance before tighten the bolts and nuts of
the lower control arm.

6. Install the breather hose of the front axle.
7. Install the actuator connector of the shift on the fly. (With
shift on the fly)
8. Install the tie-rod end of the power steering unit to the
knuckle, tighten the nut to the specified torque.
Torque : 98 N·m (10.0kg·m/73 lb ft)

9. Install lower bolts and nuts of the shock absorber, tighten it
to the specified torque.
Torque : 93 N·m (9.5kg·m/69 lb ft)
10. Install lower nuts of the stabilizer link, tighten it to the
specified torque.
Torque : 50 N·m (5.1kg·m/37 lb ft)
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the bearing
preload.
Refer to Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake
system.
16. Install the brake caliper. Tighten the bolt of the caliper
bracket to the specified torque.
Torque : 155 N·m (15.8kg·m/115 lb ft)
17. Install the stone guard.
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Steering section.
20. Tighten the bolts and nuts of the lower control arm to the
specified torque.
Refer to Lower Control Arm in Suspension section.

4C1-68 FRONT WHEEL DRIVE
4





2 Model
1. WANDERS AND PULLS

Checkpoint Trouble Cause Countermeasure


Adjust the wheel bearing
preload

Too tight
NG

Adjust the front alignment

Front alignment

Incorrect


Steering unit

Tighten or replace

Loose or worn
NG NG

Suspension

Tighten or replace


Replace or adjust the inflation


Front or rear suspension parts
loose or broken


Tire

Worn or improperly inflated

OK
NG NG OK OK
OK

Wheel bearing preload

FRONT WHEEL DRIVE 4C1-69
2. FRONT WHEEL SHIMMY

Checkpoint Trouble Cause Countermeasure



Ball joint or bush

Replace the ball joint or bush

Worn


Front alignment

Adjust the front alignment


Adjust or replace


Incorrect


Worn or improperly adjusted

OK
OK NG NG NG
OK
Wheel bearing

Tighten or replace

Loose or worn
NO

Shock absorber

Replace the shock absorber

Worn


Tire

Replace or adjust the inflation

Worn or improperly inflated

OK
NG NG OK

Steering unit

4C1-72 FRONT WHEEL DRIVE
5. WANDERS AND PULLS

Checkpoint Trouble Cause Countermeasure


Adjust the wheel bearing
preload

Too tight
NG

Adjust the front alignment

Front alignment

Incorrect


Tighten or replace

Steering unit

Loose or worn
NG NG
OK OK

Tighten or replace


Replace or adjust the inflation


Suspension

Front or rear suspension parts
loose or broken


Tab

Worn or improperly inflated

NG NG
OK OK

Wheel bearing preload

FRONT WHEEL DRIVE 4C1-73
6. FRONT WHEEL SHIMMY

Checkpoint Trouble Cause Countermeasure



Ball joint or bush

Replace the ball joint or bush

Worn


Front alignment

Adjust the front alignment


Adjust or replace


Incorrect


Worn or improperly adjusted

OK
OK NG NG NG
OK
Wheel bearing

Tighten or replace

Loose or worn
NO

Shock absorber

Replace the shock absorber

Worn


Tire

Replace or adjust the inflation

Worn or improperly inflated

OK
NG NG OK

Steering unit

5D-2 PARKING BRAKE SYSTEM

Parking Brake Lever
Parking Brake Lever Assembly and Associated Parts (Bench Seat)



This illustration is based on RHD model.
740R300010

Legend

(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 Piller Trim Cover

(10)
Instrument Panel Assembly & Cross Beam

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