height ISUZU TF SERIES 2004 Service 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.

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-54 FRONT SUSPENSION
TROUBLESHOOTING
1. VIBRATION, SHOCK, AND SHIMMY OF STEERING WHEEL

Checkpoint Trouble Cause Countermeasure



Check front axle


Check wheel alignment


Check suspension ball joint


Check shock absorber or
attaching nut and bolt


Replace


Adjust


Replace


Replace or retighten


Check steering unit and
linkage


Faulty


Worn


Malfunction or loose


Check upper and lower link
bushings
Replace


Adjust


Worn


Incorrect

OK OK OK
NG NG NG NG NG NG
OK OK
Check vehicle trim height





Improperly adjusted or worn front
wheel bearing.


Worn or incorrectl
y adjusted wheel
bearing.
Replace; refer to Section 4C "Front
Wheel Drive"


Insufficientl
y tightened steeringgear housing.


Wear of steering linkage.


Excessive backlash due to
improper ad
justment of the steeringgear box.

Worn column bearing weakened
column bearing spring, or loose
clamp.
Replace; refer to Section 3B
"Steering"


Improper tire pressure.

Imbalance and deformation of frond
wheel.


Unevenl
y worn tire or insufficient
tightening of wheel nuts.
Replace; refer to Section 3E "Wheel
and Tires"

FRONT SUSPENSION 3C-55
2. VEHICLE PULLS TO RIGHT OR LEFT

Checkpoint Trouble Cause Countermeasure



Steering linkage, and upper
and lower link


Rubber bushing for upper and
lower link


Wheel alignment


Vehicle trim height


Replace


Replace


Adjust


Adjust


Deformed


Worn


Incorrect


Incorrect


Brake adjustment (binding)

Adjust


Replace


Incorrect

Collapsed or break (4

2
Except high ride suspension)
Collapsed or twisted (4

4, 4

2
High ride suspension)
Continued on the next pageOK OK OK OK
NG NG NG NG NG NG
OK OK Coil spring (4
2 Except high
ride suspension)
Torsion bar (4

4, 4

2 High
ride suspension)

Front wheel bearing

Adjust or replace

Incorrect adjustment or
abrasion
NG

FRONT SUSPENSION 3C-57
3. INSTABILITY OF VEHICLE

Checkpoint Trouble Cause Countermeasure



Tire pressure


Wheel alignment

Rubber bushings for upper
and lower links. (4
2 Except
high ride suspension)


Adjust


Adjust


Replace


Incorrect



Incorrect


Worn


Steering linkage and upper
and lower links

Replace


Adjust


Worn or deformed


Incorrect

OK OK OK
NG NG NG NG NG
OK OK
Vehicle trim height


Road wheel

Adjust

Deformed or unbalanced
NG

TRANSFER CASE 7D-23

Detent Spring Free Length
1.
Use a vernier caliper to measure the detent spring
free length.
2.
If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Standard :23.4 mm (0.92 in)
Limit :22.8 mm (0.90 in)


220RW035

Detent Spring Tension
1.
Use a spring tester to measure the detent spring
tension.
2.
If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent ball

Compressed height : 18.7 mm (0.736 in)
Standard : 68.6 ~ 88.2 N (7.0 ~ 9.0 kg/ 15.4 ~ 19.8
lb)




220RS013

Shift Arm
1.
Inspect the shift arms for wear, distortion or scoring.
Replace if these conditions are present.

Shift Arm Thickness
1.
Use a micrometer to measure the shift arm
thickness.
2.
If the measured value is less than the specified limit,
the shift arm must be replaced.
H-L Shift arm thickness
Standard : 7.6-7.85 mm (0.299-0.309 in)
Limit : 7.0 mm (0.276 in)

2-4 Shift arm thickness
Standard : 9.6-9.85 mm (0.378-0.388 in)
Limit : 9.0 mm (0.354 in)

7A4–12 UNIT REPAIR (AW30–40LE)
5. Install the second brake drum gasket.
Install a new second brake drum gasket to the
transmission case.
24 0RY 0 001 3
6. Individual piston operation inspection.
Check for the sound of operation while injecting
compressed air into the oil hole indicated in the
figure.
24 0RY 0 001 4
E nd OFCa llou t
NOTE: When inspecting the direct clutch, check with
the C–0 accumulator piston hole closed. If there is no
noise, disassemble and check the condition of the parts.7. Install the accumulator pistons.
Coat the O–ring with ATF and install it to the
piston.
Install the three springs and four accumulator
pistons to the bore as shown in th figure.
24 0RY 0 0027
mm (in)
Legend
(1) OD direct clutch
(2) Direct clutch
(3) Forward clutch
(4) OD brake
(5) Second coast brake
(6) Second brake
(7) First and reverse brake
(A) C–0 Accumulator piston hole
Piston Outer diameter Height
B–2 36.8 mm (1.449 in) 62.5 mm (2.461 in)
C–2 36.8 mm (1.449 in) 56.6 mm (2.228 in)
B–0 31.8 mm (1.252 in) 52.0 mm (2.047 in)
C–0 29.8 mm (1.173 in) 44.0 mm (1.732 in)
Spring Free length Outer
diameterColor
B–2 74.6 (2.93) 19.7 (0.78) BROWN
C–2
(Outer)68.5 (2.7) 20.2 (0.80) BLUE
C–2 (Inner) 42.1 (1.658) 14.7 (0.579) PINK
B–0 63.6 (2.504) 16.0 (0.630) RED
C–0
(Outer)74.6 (2.937) 20.9 (0.823) ORANGE
C–0 (Inner) 46.0 (1.811) 14.0 (0.551) YELLOW

7A4–30 UNIT REPAIR (AW30–40LE)
17. Align the spline of the front planetary gear with the
flukes of the discs and install the front planetary
gear to the forward clutch.
24 7RY 0 001 7
18. Coat the bearing and race with petroleum jelly and
install them onto the ring gear.
Bearing and race diameter (Reference)
24 7RY 0 001 9
19. Install the assembled direct clutch, forward clutch
and front planetary ring gear into the transmission
case.
24 7RY 0 0018
Using vernier calipers, measure the distance
between the sun gear input drum and direct
clutch drum as shown in the figure.
Height: 2.5– 4.5 mm (0.098 – 0.177 in)
If the values are nonstandard, check for an
improper installation.
24 8RY 0 0024
Inside Outside
Bearing 35.15 mm (1.384 in) 53.65 mm (2.112 in)
Race 35.15 mm (1.384 in) 53.65 mm (2.112 in)