service ISUZU TF SERIES 2004 Owner's Guide

REAR AXLE 4B-1

SECTION 4B
REAR AXLE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4B- 3
Torque Specifications....................................................................................................................4B- 4
Recommended Liquid Gasket .......................................................................................... 4B- 6
Recommended Thread Locking Agents .......................................................................... 4B- 6
Rear Axle Assembly .......................................................................................................... 4B- 7
General Description ...................................................................................................... 4B- 7
Servicing............................................................................................................................. 4B- 8
Rear Axle ............................................................................................................................ 4B- 9
Disassembly .................................................................................................................. 4B- 10
Inspection and Repair................................................................................................... 4B- 13
Reassembly ................................................................................................................... 4B- 14
Differential Assembly.....................................................................................................................4B- 19
Disassembly .................................................................................................................. 4B- 20
Reassembly ................................................................................................................... 4B- 22
Differential Cage Assembly..........................................................................................................4B- 32
Disassembly .................................................................................................................. 4B- 33
Inspection and Repair...............................................................................................................4B- 33
Reassembly.................................................................................................................................4B- 35
Limited Slip Differential (LSD) .......................................................................................... 4B- 36
Disassembly................................................................................................................................4B- 37
Inspection and Repair................................................................................................... 4B- 38
Reassembly ................................................................................................................... 4B- 40
Troubleshooting ............................................................................................................ 4B- 43
Special Service Tool..................................................................................................................4B- 54

4B-2 REAR AXLE

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 REFORMING 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 prope
r
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 o
r
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 specification.
Following these instructions can help you avoid
damage to parts and systems.

4B-54 REAR AXLE

SPECIAL SERVICE TOOL
ITEM NO. ILLUSTRATION PART NO. PART NAME





5-8840-0079-0


Wheel Pin Remover





9-8522-1269-0

Oil Seal Installer



5-8840-2202-0

Oil Seal Installer



9-8522-1271-0

Support Stand



5-8840-0275-0

Holding Fixture



5-8840-0003-0

Holding Fixture Base



5-8840-0013-0

Remover



5-8840-0014-0

Remover



5-8840-2196-0

Adapter

4C1-2 FRONT WHEEL DRIVE
PAGE
Front Hub and Disc (4





2 Except High Ride Suspension Model) ................................. 4C1- 42
Disassembly ................................................................................................................ 4C1- 42
Inspection and Repair................................................................................................. 4C1- 45
Reassembly ................................................................................................................. 4C1- 46
Front Hub and Disc (4




4, 4




2 High Ride Suspension, 4




4 Rigid Hub,
4




4 Shift On The Fly Model) ........................................................................................... 4C1- 50
Disassembly ................................................................................................................ 4C1- 50
Inspection and Repair................................................................................................. 4C1- 52
Reassembly ................................................................................................................. 4C1- 53
Front Hub and Disc (4





4 Manual Locking Hub Model) ................................................. 4C1- 57
Disassembly ................................................................................................................ 4C1- 57
Inspection and Repair................................................................................................. 4C1- 60
Reassembly ................................................................................................................. 4C1- 61
Troubleshooting .............................................................................................................. 4C1-67
Special Service Tool ................................................................................................... 4C1-75

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

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.

SHIFT ON THE FLY SYSTEM 4C2-13
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME

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

Grip


5-8840-2407-0
(J-41693)



Installer: Oil seal



5-8840-2408-0
(J-41694)



Installer: Bearing needle



5-8840-0027-0
(J-26941)

Remover: Bearing needle


5-8840-0084-0
(J-2619-01)

Hammer: Sliding



5-8840-2197-0
(J-37452)

Remover: Bearing inner shaft

BRAKE CONTROL SYSTEM 5A-1


SECTION 5A
BRAKE CONTROL SYSTEM
CONTENTS

Service Precaution ............................................................................................................. 5A-4
General Description ........................................................................................................... 5A-5
EHCU, Brake Pipe Diagram .......................................................................................... 5A-6
Hydraulic Unit (H/U)....................................................................................................... 5A-7
Normal Braking ......................................................................................................... 5A-8
Pressure Isolation (Pressure Maintain) .................................................................. 5A-9
Pressure Reduction .................................................................................................. 5A-10
Brake Release ........................................................................................................... 5A-11
Circuit Diagram.............................................................................................................. 5A-12
Connector List ............................................................................................................... 5A-13
Part Location ................................................................................................................. 5A-15
EHCU Pin-outs ............................................................................................................... 5A-17
System Components ..................................................................................................... 5A-19
Electronic Hydraulic Control Unit (EHCU) .............................................................. 5A-19
ABS Warning Lamp .................................................................................................. 5A-19
Wheel Speed Sensor (WSS)..................................................................................... 5A-19
G-Sensor ................................................................................................................... 5A-19
Normal and Anti-lock Braking ................................................................................. 5A-19
Electronic Brake-force Distribution (EBD) System ................................................ 5A-20
Brake Pedal Travel.................................................................................................... 5A-20
Acronyms and Abbreviations ....................................................................................... 5A-20
General Diagnosis ............................................................................................................. 5A-20
General Information ...................................................................................................... 5A-20
ABS Service Precautions.............................................................................................. 5A-20
Computer System Service Precautions....................................................................... 5A-21
General Service Precautions........................................................................................ 5A-21
Note on Intermittents .................................................................................................... 5A-21
Test Driving ABS Complaint Vehicles ......................................................................... 5A-21
"ABS and Brake" Warning Lamp ................................................................................. 5A-22
Normal Operation .......................................................................................................... 5A-22

5A-2 BRAKE CONTROL SYSTEM

Brake (EBD) Warning Lamp.......................................................................................... 5A-22
Tech 2 Scan Tool ........................................................................................................... 5A-23
DATA LIST (Tech 2) ....................................................................................................... 5A-26
Actuator Test (Tech 2)................................................................................................... 5A-27
Diagnostic Trouble Codes................................................................................................. 5A-30
Diagnosis By "ABS" Warning Lamp Illumination Pattern .............................................. 5A-32
Basic Diagnostic Flow Chart ............................................................................................ 5A-35
Basic Inspection Procedure .............................................................................................. 5A-37
1. Basic Inspection of Service Brake ........................................................................... 5A-37
2. Ground Inspection .................................................................................................... 5A-37
Wheel Speed Sensor Inspection Procedure .................................................................... 5A-38
Symptom Diagnosis........................................................................................................... 5A-39
ABS Works Frequently But Vehicle Does Not Decelerate ......................................... 5A-39
Uneven Braking Occurs While ABS Works ................................................................. 5A-40
The Wheels Are Locked ................................................................................................ 5A-40
Brake Pedal Feed Is Abnormal ..................................................................................... 5A-41
Braking Sound (From EHCU) Is Heard
While Not Braking ....................................................................................................... 5A-42
No ABS Warning Lamp ................................................................................................. 5A-43
DTC C0221 (Flash Code 21) Front Right Wheel Speed Sensor
Short Circuit or Circuit Open ......................................................................................... 5A-44
DTC C0222 (Flash Code 22) Front Right Wheel Speed Sensor Incorrect Signal.......... 5A-46
DTC C0223 (Flash Code 23) Front Right Wheel Speed Sensor
Signal - Tooth Chipping................................................................................................... 5A-48
DTC C0225 (Flash Code 25) Front Left Wheel Speed Sensor Short Circuit or
Circuit Open .................................................................................................................... 5A-50
DTC C0226 (Flash Code 26) Front Left Wheel Speed Sensor Incorrect Signal ............ 5A-52
DTC C0227 (Flash Code 27) Front Left Wheel Speed Sensor Signal - Tooth
Chipping ........................................................................................................................... 5A-54
DTC C0231 (Flash Code 31) Rear Right Wheel Speed Sensor Short Circuit or
Circuit Open .................................................................................................................... 5A-56
DTC C0232 (Flash Code 32) Rear Right Wheel Speed Sensor Incorrect Signal ........... 5A-58
DTC C0233 (Flash Code 33) Rear Right Wheel Speed Sensor Signal - Tooth
Chipping ........................................................................................................................... 5A-60

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.