ISUZU TF SERIES 2004 Workshop 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.

3C-40 FRONT SUSPENSION

Upper Control Arm
Upper Control Arm and Associated Parts


RTW440LF001301
Legend
(1)Bolt and Plate
(2)Camber Shims
(3)Caster Shims
(4)Nut Assembly
(5)Upper Control Arm Assembly
(6)Fulcrum Pin


(7)Bushing
(8)Plate
(9)Nut
(10)Speed Sensor harness
(11)Nut and Cotter Pin
(12)Upper Ball Joint, Bolt and Nut


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 and disconnect brake
pipe. Refer to Disc Brakes in Brake section.

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-42 FRONT SUSPENSION

Installation
1. Install fulcrum pin.
2. Install bushing by using installer 5-8840-0256-0
and 5-8840-2307-0.


RTW340SH000701



RTW340SH000801
3. Install upper ball joint and tighten it to the specified
torque (12).
Torque: 57 N




m (5.8kg




m/42 lb ft)
4. 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 (11).
Torque: 98 N




m (10.0kg




m/72 lb ft)
5. Install plate (8).

6. Install nut (9) and tighten fulcrum pin nut finger-
tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut with the parts in the position
shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 108 N




m (11.0kg




m/80 lb ft)


450R100002
7. Install upper control arm assembly with the fulcrum
pin projections turned inward.


RTW340SH000901

Legend
(1) Projection
(2) Outward

8. Install the caster shims (2) between the chassis

FRONT SUSPENSION 3C-43

frame and fulcrum pin.
9. Install the camber shims (1) between the chassis
frame and fulcrum pin.





450R100004
10. Install nut assembly.
11. Install bolt and plate (1), then tighten the bolt to the
specified torque.
Torque: 152 N




m (15.5kg




m/112 lb ft)
NOTE: Apply oil to the thread.
12. Install speed sensor harness.

3C-44 FRONT SUSPENSION

Lower Control Arm
Lower Control Arm and Associated Parts
RTW33CLF000201
Legend
(1) Cam Bolt
(2)Bush, Front
(3) Cam Plate and Nut
(4) Nut, Rear
(5) Bush, Rear
(6) Bolt, Rear
(7) Bolt, Lower Ball Joint


(8) Bolt, Torsion Bar Arm
(9) Torsion Bar Arm Bracket and Nut
(10) Torsion Bar
(11) Lower Control Arm
(12) Lower Ball Joint and Nut
(13) Shock Absorber, Bolt and Nut
(14) Stabilizer Link and Nut

FRONT SUSPENSION 3C-45

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 tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle
driving shaft to release the shaft from hub. Refer to
Front Hub and Disc in Driveline/Axle section.
5. Support lower control arm with a jack.
6. Remove cam plate and nut.
7. Remove rear nut.
8. Remove torsion bar, refer to Torsion Bar in this
section.
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control
arm.
11. Remove the shock absorber lower end from the
lower control arm.
12. Remove the lower ball joint from the lower control
arm.
13. Remove cam bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover 5-8840-
2123-0.



Front
901RW154



Front
901RW155
19. Remove rear bushing by using remover 5-8840-
2124-0.


Front
901RW051




Front
901RW052

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-47

14. Install cam plate and nut then tighten lower link nut
finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut (3) or bolt with the parts in the
position shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 186 N




m (19.0kg




m/137 lb ft)
NOTE: Adjust the trim height. Refer to Front En
d
Alignment Inspection and Adjustment in Steering
section.



450R100002

3C-48 FRONT SUSPENSION

Upper Ball Joint
Upper Ball Joint and Associated Parts


RTW440LF001401
Legend

(1)
Bolt and Nut

(2)
Upper Ball Joint


(3) Nut and Cotter Pin


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove the speed sensor from the knuckle.
3. Remove upper ball joint nut and cotter pin, then
use remover 5-8840-2121-0 to remove the uppe
r
ball joint from the knuckle.