ISUZU TF SERIES 2004 Workshop Manual

FRONT SUSPENSION 3C-29

Special Tools (4





2 Except High Ride Suspension)

ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION
PART NO.
PART NAME

5-8840-0595-0
Support; fixture 5-8840-2327-0
Installer; Upper and
lower arm bushing
5-8840-0596-0
Adapter; lower
5-8840-0597-0
Adapter; Upper
5-8840-0003-0
Base
5-8840-2017-0
Ball joint remover
5-8840-0257-0
Installer; Upper and
lower arm bushing

3C-30 FRONT SUSPENSION


FRONT SUSPENSION
(4





2 High Ride Suspension, 4





4)
CONTENTS

Service Precaution............................................. 3C - 29
Shock Absorber ................................................. 3C - 30
Shock Absorber and Associated Parts ........... 3C - 30
Removal ......................................................... 3C - 30
Inspection and Repair..................................... 3C - 30
Installation....................................................... 3C - 30
Stabilizer Bar ..................................................... 3C - 31
Stabilizer Bar and Associated Parts ............... 3C - 31
Removal ......................................................... 3C - 31
Inspection and Repair..................................... 3C - 31
Installation....................................................... 3C - 32
Torsion Bar ........................................................ 3C - 33
Torsion Bar and Associated Parts .................. 3C - 33
Removal ......................................................... 3C - 33
Inspection and Repair..................................... 3C - 34
Installation....................................................... 3C - 34
Knuckle .............................................................. 3C - 36
Knuckle and Associated Parts........................ 3C - 36
Removal ......................................................... 3C - 36
Inspection and Repair..................................... 3C - 38
Installation....................................................... 3C - 38
Upper Control Arm ............................................. 3C - 39
Upper Control Arm and Associated Parts ...... 3C - 39
Removal ......................................................... 3C - 39

Inspection and Repair..................................... 3C - 40
Installation ...................................................... 3C - 41
Lower Control Arm ............................................. 3C - 43
Lower Control Arm and Associated Parts ...... 3C - 43
Removal ......................................................... 3C - 44
Inspection and Repair..................................... 3C - 45
Installation ...................................................... 3C - 45
Upper Ball Joint ................................................. 3C - 47
Upper Ball Joint and Associated Parts ........... 3C - 47
Removal ......................................................... 3C - 47
Inspection and Repair..................................... 3C - 48
Installation ...................................................... 3C - 48
Lower Ball Joint ................................................. 3C - 49
Lower Ball Joint and Associated Parts ........... 3C - 49
Removal ......................................................... 3C - 49
Inspection and Repair..................................... 3C - 50
Installation ...................................................... 3C - 50
Bump Rubber .................................................... 3C - 51
Bump Rubber and Associated Parts .............. 3C - 51
Removal ......................................................... 3C - 51
Inspection and Repair..................................... 3C - 51
Installation ...................................................... 3C - 51
Special Tools .................................................... 3C - 52



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.

FRONT SUSPENSION 3C-31

Shock Absorber
Shock Absorber and Associated Parts
RTW340MF000901
Legend

(1)
Nut

(2)
Rubber Bushing and Washer

(3) Bolt and Nut

(4)
Shock Absorber
(5) Rubber Bushing and Washer


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 bolt and nut.
4. Remove nut.
5. Remove rubber bushing and washer.
6. Remove shock absorber.
7. Remove rubber bushing and washer.
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 :


Shock absorber


Rubber bushing
Installation
1. Install rubber bushing and washer.
2. Install shock absorber.
3. Install rubber bushing and washer.
4. Install nut (1), then tighten it to the specified
torque.
Torque: 20 N




m (2.0kg




m/14 lb ft)
5. Install bolt and nut (3), then tighten to the specified
torque.
Torque: 93 N




m (9.5kg




m/69 lb ft)

3C-32 FRONT SUSPENSION

Stabilizer Bar
Stabilizer Bar and Associated Parts


RTW340MF000401
Legend

(1)
Rubber Bushing

(2)
Bracket and Bolt
(3) Link



(4)
Nut
(5) Stabilizer Bar
(6) Nut

Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove the stone guard.
3. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.
4. Remove nut (4) and (6).
CAUTION: Be careful not to break the ball joint
boot.
5. Remove link.
6. Remove bracket.
7. Remove stabilizer bar.
8. Remove rubber bushing.

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

FRONT SUSPENSION 3C-33

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




m (2.5kg




m/18 lb ft)
4. Install link.
5. Install nut (4), (6), then tighten it to the specified
torque.
Torque: 50 N





m (5.1kg





m/37 lb ft)

3C-34 FRONT SUSPENSION
Torsion Bar
Torsion Bar and Associated Parts


RTW340MF000501
Legend
(1)
Adjust Bolt, End Piece and Seat
(2)
Height Control Arm


(3) Torsion Bar


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Apply the setting marks (1) to the adjust bolt and end piece, then remove adjust bolt, end piece and
seat.








410RS004

FRONT SUSPENSION 3C-35

3. Apply the setting marks(2) to the height control
arm and torsion bar, then remove height control
arm.
NOTE: “Besco chassis grease” shall be applied on
contact area of height control arm with frame.
(RH & LH Both side)





410RS005
4. Apply the setting marks (3) to the torsion bar and
lower control arm, then remove torsion bar.


RTW340SH000301
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:

Torsion bar


Height control arm


Adjust bolt
Installation
1. Apply grease to the serrated portions, then install
torsion bar. Make sure the bars are on their correct
respective sides and align the setting marks (3).






410RS007



RTW340SH000301

3C-36 FRONT SUSPENSION


Rubber seat


2.
Apply grease to the portion that fits into the bracket
then install height control arm and align the setting
marks (2).





410RS005
3. Apply grease to the bolt portion of the end piece
(4). Apply grease to the portion of the seat (5) that
fits into the bracket.





410RS008

4. Apply grease to the serrated portions.
5. Install adjust bolt and seat, then turn the adjust bolt
to the setting mark (1) applied during disassembly.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering
section.






410RS004

FRONT SUSPENSION 3C-37

Knuckle
Knuckle and Associated Parts


RTW340LF001301
Legend
(1) Torsion Bar
(2 )Lower Ball Joint, Nut and Cotter Pin
(3) Back Plate
(4) Knuckle Assembly
(5) Knuckle


(6) Needle Bearing (44 Model Only)
(7) Thrust Washer (44 Model Only)
(8) Oil Seal (4
4 Model Only)
(9) Upper Ball Joint, Nut and Cotter Pin
(10) Speed Sensor harness


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.

3C-38 FRONT SUSPENSION

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.
6. Remove the speed sensor from the knuckle.
7. Loosen torsion bar by height control arm adjust
bolt, then remove torsion bar. Refer to Torsion Ba
r
in this section.
8. Remove speed sensor harness.
9. Remove back plate.
10. Remove lower ball joint by using remover 5-8840-
2005-0.
CAUTION: Be careful not to damage the ball joint
boot.



901RW271

11. Remove upper ball joint by using remover 5-8840-
2121-0.
CAUTION: Be careful not to damage the ball joint
boot.

901RW272
12. Remove knuckle assembly.
13. Remove oil seal. If replacement required.
(4
4 Model Only)
14. Remove washer. If replacement required.
(4
4 Model Only)
15. Remove needle bearing by using remover 5-8840-
2000-0 and sliding hammer 5-8840-0019-0.
If replacement required. (4
4 Model Only)





(4

4 Model Only)
RTW340SH00401