ISUZU TF SERIES 2004 Workshop Manual

FRONT WHEEL DRIVE 4C1-71
4. NOISES IN FRONT AXLE

Checkpoint Trouble Cause Countermeasure

Replenish the gear oilInsufficient gear oil NG
Replace the wheel bearing
Replace the pinion shaft
bearing
Replace the ring gear pinion
gear or side gear
Replace the gear oil
Wheel bearingWorn
Pinion shaft bearingWorn
Worn or chipped
Wrong or poor grade gear oil
Ring gear, pinion gear or side
gear
Adjust the backlashDrive pinion to ring gear
backlashToo much or too little backlash
NG NG NG NG NG
OK OK
OK
OK
Oil level
Tighten or replaceDifferential bearingLoose or worn NG OK

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

4C1-74 FRONT WHEEL DRIVE
PROPELLER SHAFT
1. NOISE

Checkpoint Trouble Cause Countermeasure

Spider bearingReplaceWorn or jammed
ReplaceDamaged or worn
NG NG
OKYoke spline



2. VIBRATION

Shaft balanceAdjustUnbalance
ReplaceIncorrect
NG NG
OKShaft runout
Transmission rear housing
bushing, transfer case
housing bushing
ReplaceWorn NG OK
Yoke splineReplaceJammed NG OK

FRONT WHEEL DRIVE 4C1-75
SPECIAL SERVICE TOOL
ITEM NO. ILLUSTRATION PART NO. PART NAME


FAL-1

5-8840-0013-0
(J-22888)


Side bearing puller



FAL-14

9-8521-1743-0
(J-8107-2)

Side bearing plug adapter


FAL-3

5-8840-0133-0
(J-8614-01)

Pinion flange holder


FAL-8


9-8521-5032-0

Final pinion spindle


FAL-10

5-8840-0015-0
(J-22912-01)

Separator


FAL12

9-8522-1141-0
(J-24256)
Outer bearing outer race
installer


OTL-1

5-8840-0007-0
(J-8092)

Driver handle


FAL-16

9-8522-1274-0
(J-24252)
Inner bearing outer race
installer


FAL-34

5-8840-2085-0
(J-21777-42)

Pilot

4C1-76 FRONT WHEEL DRIVE
ITEM NO. ILLUSTRATION PART NO. PART NAME


FAL-41

5-8840-2089-0
(J-23597-9)

Nut & bolt


FAL-36

5-8840-2087-0
(J-23597-7)

Gauge plate


FAL-42

5-8840-0126-0
(J-8001)

Dial indicator



FAL-43

5-8840-0128-0
(J-23597-1)

Arbor



FAL-38

5-8840-2088-0
(J-23597-8)

Disc (2 pcs. required)



FAL-59

9-8522-1165-0
(J-6133-01)
Pinion bearing installer
(for 4WD)


FAL-52

9-8522-1275-0
(J-24250)

Pinion oil seal installer



FAL-56

9-8522-1164-0
(J-24244)

Side bearing installer



FAL-57

5-8522-0053-0
(J-29016)
Outer bearing installer
(for 2WD)

FRONT WHEEL DRIVE 4C1-77
ITEM NO. ILLUSTRATION PART NO. PART NAME


FAL-58

5-8522-0054-0
(J-29015)
Inner bearing installer
(for 2WD)


FAL-54

5-8522-0051-0
(J-33161)
Hub oil seal installer
(for 2WD)


FAL-62

5-8840-2117-0
(J-36827)

Hub nut wrench


FAL-17

5-8840-2119-0
(J-36829)
Outer bearing inner race
installer (for 4WD)


FAL-19

5-8840-2120-0
(J-36830)

Oil seal installer (for 4WD)


FAL-18

5-8522-0054-0
(J-29015)
Outer bearing outer race
installer (for 4WD)


FAL-61

5-8840-2137-0
(J-38194)

Inner cam installer


FAL-39


5-8840-2126-0
Auto locking shim gauge
(for 4WD)


FAL-60


5-8840-2125-0
Snap ring installer
(for 4WD)

4C1-78 FRONT WHEEL DRIVE
ITEM NO. ILLUSTRATION PART NO. PART NAME





5-8840-2789-0

ABS sensor rotor installer

SHIFT ON THE FLY SYSTEM 4C2-1

DRIVELINE/AXLE
SHIFT ON THE FLY SYSTEM
CONTENTS

Service Precaution............................................. 4C2-1
Shift On The Fly System .................................... 4C2-2
Outline of Shift on The Fly System ................. 4C2-2
Shift On The Fly Electrical Equipment ............... 4C2-3
Axle Shaft Connection and Disconnection ..... 4C2-3
Actuator Assembly.......................................... 4C2-3

Shift On The Fly System and Association
Parts ................................................................. 4C2-4
Disassembly ................................................... 4C2-5
Inspection and Repair..................................... 4C2-6
Reassembly .................................................... 4C2-9
Torque Specifications ..................................... 4C2-12
Special Service Tool ....................................... 4C2-13



Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners o
r
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

4C2-2 SHIFT ON THE FLY SYSTEM

Shift On The Fly System
Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2WD) and 4 wheel drive (4WD) electrically b
y
driver's pressing the 4WD switch (push button type) on
instrument panel.
This system controls below operations.
1.
Shifting the transfer front output gear (Connecting to,
and disconnecting from, front propeller shaft b
y
motor actuator).
2. Retrial of shifting the transfer front output gear.
3. Connecting front wheels to, and disconnecting them
from, the front axles by axle motor actuator.
4. Indicator on instrument panel.
5. 4WD out signal to other Electronic Hydraulic Control
Unit.

System Diagrams
RUW34BLF000201