power ISUZU TF SERIES 2004 Owner's Guide

REAR AXLE 4B-43

TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair
rear axle problems.
Each troubleshooting chart has three headings
arranged from left to right.
(1) Checkpoint
(2) Trouble Cause
(3) Countermeasure
This Section is divided into five sub-sections:
1. Abnormal Rear Axle Noise
1) Noise when the engine is driving the vehicle
2) Noise when the vehicle is coasting
3) Intermittent noise
4) Noise when the vehicle is turning
5) Constant noise
2. Vibration
3. Oil Leakage
1) Differential carrier leakage
2) Axle case leakage
3) Axle case to inside hub leakage
4) Axle case to inside brake drum leakage
4. Power Not Being Transmitted to the Wheels
(Propeller Shaft Operation is Normal)

REAR AXLE 4B-53

4. POWER NOT BEING TRANSMITTED TO THE WHEELS
(PROPELLER SHAFT OPERATION IS NORMAL)

Checkpoint Trouble Cause Countermeasure

Replace the rear axle shaftBroken rear axle shaft NG
Replace the drive pinion and
the ring gear as a setDrive pinion and ring gearBroken drive pinion and/or ring
gear
Replace the differential gears
and/or the spiderDifferential cage gearsBroken differential cage gears
and/or spider NG NG
OK OK
Rear axle shaft

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.

5A-4 BRAKE CONTROL SYSTEM

DTC C0277 (Flash Code 77) Power Supply Low Input .................................................... 5A-84
DTC C0278 (Flash Code 78) Power Supply High Input ................................................... 5A-84
DTC C0282 (Flash Code 82) 4 Wheel Drive State Input Signal Failure .......................... 5A-86
DTC C0285 (Flash Code 85) Assembly Error (G-sensor) ................................................ 5A-88
Special Tools ...................................................................................................................... 5A-90


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, REFER
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, or
other corrosion inhibitors) on threaded fasteners or
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.

BRAKE CONTROL SYSTEM 5A-17

EHCU Pin-outs


C05L300005

EHCU Side
Pin No.
(Harness
side
Pin No.) Pin Function Wire
Color Typical Value Note
1
(C67-11) Power Supply WHT/GRN Battery Voltage Solenoid
2
(C67-10) Ground 1 BLK 0V
(Less than 0.1V) Solenoid, Control Unit
3
(C67-28) Ground 2 BLK 0V
(Less than 0.1V) Motor
4
(C67-27) Power Supply WHT/RED Battery Voltage Motor
5
(C67-9) Stop Light Switch RED Open : 0V
Close : Battery Voltage Close Condition :
Step on the Brake Pedal
6
(C67-8) Serial ORN/WHT - J1850 Class 2
Communication
7
(C67-7) Serial GRN - J1850 Class 2
Communication
8
(C67-6) Not Used - -
9
(C67-5) Not Used - -
10
(C67-4) G-Sensor Ground BLK 0V
(Less than 0.1V) 4WD Only
DTC C0276, C0285
11
(C67-3) Front Right Wheel Speed Sensor (-) GRY High Level: 1.28~2.2V
Low Level: 0.5~0.86V DTC C0221,C0222,
C0223
12
(C67-2) Front Right Wheel Speed Sensor (+) GRY/RED 12

1.5V DTC C0221,C0222,
C0223
13
(C67-1) Rear Right Wheel Speed Sensor (-) BLK High Level: 1.28~2.28V
Low Level: 0.5~0.86V DTC C0231,C0232,
C0233

5A-18 BRAKE CONTROL SYSTEM

EHCU Side
Pin No.
(Harness
side
Pin No.) Pin Function Wire
Color Typical Value Note
14
(C67-17) ABS Warning Lamp YEL More than 10V
15
(C67-16) Not Used - -
16
(C67-15) Not Used - -
17
(C67-14) G-Sensor Signal YEL/BLK 2.0~3.0V
(MAX4.0V,MIN1.0V) 4WD Only
It checks in a flat place
(0G:2.5V)
DTC C0276, C0285
18
(C67-13) Front Left Wheel Speed Sensor (+) RED 12

1.5V DTC C0225, C0226,
C0227
19
(C67-12) Rear Right Wheel Speed Sensor (+) ORN 12

1.5V DTC C0231,C0232,
C0233
20
(C67-26) EBD (Brake) Warning Lamp LT BLU More than 10V
21
(C67-25) Starter Switch ON
(Power Supply and Switch Position) BLU/WHT Battery Voltage Control Unit
DTC C0277,C0278
22
(C67-22) Not Used - -
23
(C67-23) Not Used - -
24
(C67-22) Not Used - -
25
(C67-21) Transfer (2-4WD Control Unit) GRY Pulse Signal
(High 4.5V, Low 1.5V) 4WD Only
DTC C0282
26
(C67-20) Front Left Wheel Speed Sensor (-) WHT High Level: 1.28~2.2V
Low Level: 0.5~0.86V DTC C0225, C0226,
C0227
27
(C67-19) Rear Left Wheel Speed Sensor (+) GRY/BLU 12

1.5V
DTC C0235, C0236,
C0237
28
(C67-18) Rear Left Wheel Speed Sensor (-) WHT/BLU High Level: 1.28~2.2V
Low Level: 0.5~0.86V DTC C0235, C0236,
C0237

BRAKE CONTROL SYSTEM 5A-19

System Components
Electronic Hydraulic Control Unit (EHCU), four Wheel
Speed Sensors, two Warning Lamps, and G-sensor.

Electronic Hydraulic Control Unit (EHCU)

The EHCU consists of ABS control circuits, fault
detector, and a fail-safe. It drives the EHCU according
to the signal from each sensor, cancelling ABS to return
to normal braking when a malfunction has occurred in
the ABS.
The EHCU has a self-diagnosing function which can
indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment rear
left side. It consists of a motor, solenoid valves fail safe
relay.
Solenoid Valves: Reduces or holds the caliper fluid
pressure for each front brake or both rear brakes
according to the signal sent from the EHCU.
Buffer chamber: Temporarily holds the brake fluid that
returns from the front and rear brake so that pressure
of front brake can be reduced smoothly.
Motor: Drives the pump according to the signal from
EHCU.
Fail safe Relay: When failure occurs in ABS.
The power supply to solenoid Valve is cut.

ABS Warning Lamp


825L300001
Vehicles equipped with the Anti-lock Brake System
have an amber “ABS” warning lamp in the instrument
panel. The “ABS” warning lamp will illuminate if a
malfunction in the Anti-lock Brake System is detected
by the Electronic Hydraulic Control Unit (EHCU). In
case of an electronic malfunction, the EHCU will turn
“ON” the “ABS” warning lamp and disable the anti-lock
braking function.

The “ABS” warning lamp will turn “ON” for
approximately three seconds after the ignition switch is
to the “ON” position.
If the “ABS” warning lamp stays “ON” after the ignition
switch is the “ON” position, or comes “ON” and stays
“ON” while driving, the Anti-lock Brake System should
be inspected for a malfunction according to the
diagnosis procedure.

Wheel Speed Sensor (WSS)
It consists of a sensor and a rotor. The sensor is
attached to the knuckle on the front wheels and to the
rear wheels.
The rotor is press-fit in the axle shaft.

G-Sensor
The G-sensor detects the vehicle deceleration speed
and sends a signal to the EHCU. In 4WD operation, all
four wheels may be decelerated in almost the same
phase, since all wheels are connected mechanically.
This tendency is noticeable particularly on roads with
low friction coefficient, and the ABS control is adversely
affected.
The G-sensor judges whether the friction coefficient of
road surface is low or high, and changes the EHCU's
operating system to ensure ABS and EBD control.

Normal and Anti-lock Braking
Under normal driving conditions, the Anti-lock Brake
System functions the same as a standard power
assisted brake system. However, with the detection of
wheel lock-up, a slight bump or kick-back will be felt in
the brake pedal. This pedal “bump” will be followed by a
series of short pedal pulsations which occurs in rapid
succession. The brake pedal pulsation will continue
until there is no longer a need for the anti-lock function
or until the vehicle is stopped. A slight ticking or
popping noise may be heard during brake applications
when the anti-lock features is being used.
When the anti-lock feature is being used, the brake
pedal may rise even as the brakes are being applied.
This is also normal. Maintaining a constant force on
the pedal will provide the shortest stopping distance.

5A-20 BRAKE CONTROL SYSTEM

Electronic Brake-force Distribution (EBD) System

ABS has the EBD function. EBD is a function which
controls braking force distribution of a front wheel and a
rear wheel, and makes brake fluid pressure of a rear
wheel the optimal. If the rate of a slip of a rear wheel
becomes large more than fixed compared with a front
wheel about the rate of a slip in order to perform
braking force distribution of a front wheel and a rear
wheel, the brake fluid pressure of a rear wheel will be
controlled. EBD enables it to always utilize the braking
power of a rear wheel for the maximum according to
the load change concerning the back axis by vehicles
loading states (No luggage, loading, etc.), deceleration,
etc. Brake fluid pressure control to a rear wheel is
performed by the EBD function which used the ABS
function without the mechanical proportioning valve.
C05L300016
Brake Pedal Travel
Vehicles equipped with the Anti-lock Brake System may
be stopped by applying normal force to the brake pedal.
Although there is no need to push the pedal beyond the
point where it stops or holds the vehicle, by applying
more force the pedal will continue to travel toward the
floor.
This extra brake pedal travel is normal.

Acronyms and Abbreviations
Several acronyms and abbreviations are commonly
used throughout this section:
ABS
Anti-lock Brake System
CKT
Circuit
DLC
Data Link Connector
EBD
Electronic Brake-force Distribution
EHCU
Electronic Hydraulic Control Unit
FL
Front Left
FR
Front Right
GEN
Generator
H/U
Hydraulic Unit
MV
Millivolts
RR
Rear
RPS
Revolution per Second
VDC
DC Volts
VAC
AC Volts
W/L
Warning Lamp
WSS
Wheel Speed Sensor

General Diagnosis
General Information
ABS troubles can be classified into two types, those
which can be detected by the ABS warning lamp and
those which can be detected as a vehicle abnormality
by the driver.
In either case, locate the fault in accordance with the
“BASIC DIAGNOSTIC FLOWCHART” and repair.
Please refer to Section 5C for the diagnosis of
mechanical troubles such as brake noise, brake judder
(brake pedal or vehicle vibration felt when braking),
uneven braking, and parking brake trouble.

ABS Service Precautions
Required Tools and Items:

Box Wrench
 Brake Fluid

Special Tool
Some diagnosis procedures in this section require the
installation of a special tool.

5-8840-0366-0 High Impedance Multimeter
When circuit measurements are requested, use a
circuit tester with high impedance.