ISUZU TF SERIES 2004 Workshop Manual

FRONT SUSPENSION 3C-9

Shock Absorber
Shock Absorber and Associated Parts


RTW440LF001201

Legend

(1)
Shock Absorber ASM with coil

(2)
Nut

(3)
Nut

(4)
Nut


(5)
Lower ball joint Nut and cot ter pin

(6)
Nut

(7)
Bolt

(8)
Cam bolt


Removal
1. Raise the vehicle and support it with suitable
safety stands.

2. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.
3. Remove nut (6).
CAUTION: Be careful not o break the ball joint boot.

3C-10 FRONT SUSPENSION
4. Support lower control arm with a jack.
5. Remove the bolt (7) and nut (4).
6. Remove lower ball joint nut and cotter pin(5), then use remover 5-8840-2017-0 to remove the lowe
r
ball joint from the knuckle.

P1010003
7. Apply the setting marks to the front and rear cam
bolt and cross member, then loosen nut, and cam
bolt.
8. Remove the nut (2).
9. Remove to Shock Absorber ASM.


Installation
1. Install shock absorber.

RTW340MF000801

FRONT SUSPENSION 3C-11

NOTE: Paint mark to be outer side of after assembly to
vehicle.
2. Install nut (2), then tighten it to the specified
torque.
Torque: 55N





m (5.6kg





m/41lb ft)
3. Install bolt (7) and nut (4), then tighten to the
specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137N




m (14.0kg




m/101 lb ft)


NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.




RTW340SH001301-X
4. Install nut (6), then tighten it to the specified
torque.
Torque: 50N




m (5.1kg




m/37 lb ft)
5. Tighten the cam bolt (8) and nut (3), it to the
interim torque, then turn the cam bolt to the setting
mark applied during disassembly.
6. 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 (5).
Torque: 147N




m (15.0kg




m/108 lb ft)


NOTE: Check the trim height. Refer to Front Alignment
Inspection and Adjustment.

7. Nut (3) tighten it to the specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 186N




m (19.0kg




m/137 lb ft)


NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.





RTW340SH001301-X
8. Install wheel and tire assembly. Refer to wheel in
this section.

3C-12 FRONT SUSPENSION
Shock Absorber with Coil Spring

RTW340LF002101

Legend

1. Nut
2. Washer

3. Bushing ; Rubber

4. Mounting Bracket

5. Coil Spring


6. Bushing ; Rubber

7. Washer

8. Shock Absorber ASM

FRONT SUSPENSION 3C-13
Disassembly





1. Install the support fixture (5-8840-0595-0) to the base (5-
8840-003-0).
2. Install the upper adapter (5-8840-0597-0) and the lower
adapter (5-8840-0596-0) to the base and support fixture
assembly.
3. Install the shock absorber assembly to the support fixture.
4. Remove the nut with spring in place.
CAUTION:
Take care not to apply excessive force to the nut during
removal.


CAUTION :
The shock absorbers have been charged with gas at the
factory. Exposure to high temperatures or an open flame
can result in a dangerous explosion.
Keep the shock absorbers away from high temperatures
and open flames.



INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspections.




Visual Check
Inspect the following parts for wear, damage or other abnormal
conditions.


Shock absorber


Rubber bushing


Coil spring

3C-14 FRONT SUSPENSION

Reassembly
1. Reassemble the parts inside the support fixture.
2. When tightening the bolt, compress the spring so that i
t
does not apply pressure to the spring seat.
3. Install the nut (1), then tighten to the specified torque.
Torque : 25 N





m (2.5 kg





m/19 lb ft)

FRONT SUSPENSION 3C-15

Stabilizer Bar
Stabilizer Bar and Associated Parts



RTW340LF000901
Legend

(1)
Stabilizer Bar

(2)
Link

(3)
Nut


(4)
Nut

(5)
Bracket and Bolt

(6)
Rubber Bushing


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.

3. Remove nut (3) and (4).
CAUTION: Be careful not to break the ball joint
boot.

4. Remove link.
5. Remove bracket and bolt.
6. Remove stabilizer bar.
7. Remove rubber bushing.

3C-16 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 :


Stabilizer bar


Rubber bushing


Link ball joint
Installation
1. Install rubber bushing.
2. Install stabilizer bar.
3. Install bracket and bolt (5), then tighten it to the
specified torque.
Torque: 25 N




m (2.5kg




m/18 lb ft)
4. Install link.
5. Install nut (3), (4), then tighten it to the specified
torque.
Torque: 50 N




m (5.1kg




m/37 lb ft)

FRONT SUSPENSION 3C-17

Knuckle
Knuckle and Associated Parts


450R300037
Legend

(1)
Nut and Cotter Pin

(2)
Back Plate

(3)
Nut and Cotter Pin


(4)
Nut and Cotter Pin

(5)
Knuckle

(6)
Bolt


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
in this section.

3. Remove the brake caliper. Refer to Disc Brakes in
Brake section.
4. Remove the hub assembly. Refer to Front Hub
and Disk in this section.
5. Remove tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.

3C-18 FRONT SUSPENSION
6. Remove the stabilizer link nut. Right and left.
7. Remove the wheel speed sensor from the knuckle.
8. Remove back plate.
9. Remove lower ball joint by using remover 5-8840- 2017-0.
CAUTION: Be careful not to damage the ball joint
boot.

P1010009
10. Remove upper ball joint by using remover 5-8840-
2017-0.
CAUTION: Be careful not to damage the ball joint
boot.

P1010011
11. Remove knuckle.

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
Installation
1. Install knuckle assembly.
2. 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 (1).
Torque: 98 N






m (10.0kg






m/72 lb ft)
3. 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 (4).
Torque: 147N






m (15.0kg






m/108 lb ft)
4. Install back plate.
5. Install wheel speed sensor.
6. Install stabilizer link nut. Right and left.