suspension ISUZU TF SERIES 2004 Repair Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 3514 of 4264
3C-22 FRONT SUSPENSION
4. Support lower control arm with a jack.
5. Remove the nut (10).
6. Remove the nut (8).
7. Remove the shock absorber lower end from the
lower control arm.
8. Remove the lower ball joint from the lower control arm.
9. Remove nut (4) and cam plate.
10. Remove cam bolt.
11. Remove lower control arm.
12. Remove 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:
Lower control arm
Bushing
Installation
1. Install rear bushing by using installer 5-8840-
0257-0 and 5-8840-2327-0.
P1010063
2. Install lower control arm.
3. Install cam bolt.
4. Install lower ball joint and tighten it to the specified
torque (9).
Torque: 127 N
m (12.9kg
m/94 lb ft)
5. Install shock absorber and tighten it to the specified torque (5).
NOTE: Apply oil to the thread.
NOTE: Tighten the nut (4) with the parts in the position
shown in the illustration below.
Torque: 137 N
m (14.0kg
m/101 lb ft)
RTW340SH001301-X
6. Install stabilizer link and tighten it to the specified
torque (10).
Torque: 50 N
m (5.1kg
m/37 lb ft)
7. Install nut (4) and cam plate and tighten lower link nut finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut (4) with the parts in the position
shown in the illustration below.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 186 N
m (19.0kg
m/137 lb ft)
RTW340SH001301-X
8. Install nut (8) and cotter pin then tighten the nut to
the specified torque, with just enough additional
torque to align cotter pin holes. Install new cotte
r
Page 3515 of 4264
FRONT SUSPENSION 3C-23
pin.
Torque: 147 N
m (15.0kg
m/108 lb ft)
Page 3516 of 4264
3C-24 FRONT SUSPENSION
Upper Ball Joint
Upper Ball Joint and Associated Parts
RTW340LF001101
Legend
(1)
Bolt
(2)
Upper Ball Joint
(3)
Nut
(4)
Nut and Cotter Pin
(5)
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 nut (5).
4. Remove upper ball joint nut and cotter pin, then
use remover 5-8840-2017-0 to remove the uppe
r
ball joint from the knuckle.
CAUTION: Be careful not to damage the ball joint
boot and brake hose.
Page 3517 of 4264
FRONT SUSPENSION 3C-25
P1010005
5. Remove bolt (1) and nut (3).
6. Remove upper ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.
Inspect screw/taper area of ball for damage.
If any defects are found by the above inspections,
replace the ball joint assembly with new one.
450R300030
After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 1.3-3.2 N
m (0.13-0.33kg
m/0.9-
2.4 lb ft)
450RS024
If the above limits specified are exceeded, replace the
ball joint assembly.
Installation
1. Install upper ball joint.
2. Install bolt (1) and nut (3), then tighten them to the specified torque.
Torque: 31N
m (3.2kg
m/23 lb ft)
3. 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 (4).
Torque: 98 N
m (10.0kg
m/72 lb ft)
4. Install nut (5), then tighten to the specified torque. Torque: 50 N
m (5.1kg
m/37 lb ft)
Page 3518 of 4264
3C-26 FRONT SUSPENSION
Lower Ball Joint
Lower Ball Joint and Associated Parts
RTW340LF002201
Legend
(1)
Lower Ball Joint
(2)
Nut and Cotter Pin
(3)
Nut
(4)
Nut
(5)
Bolt
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 nut (4).
4. Support lower control arm with a jack.
5. Remove lower ball joint nut and cotter pin, then
use remover 5-8840-2017-0 to remove the lowe
r
ball joint from the knuckle.
Page 3519 of 4264
FRONT SUSPENSION 3C-27
CAUTION: Be careful not to damage the ball joint
boot.
P1010003
6. Remove nut (3).
7. Remove bolt (5).
8. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found
through inspection.
Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement .
Inspect screw/taper area of ball for damage.
If any defects are found by the above inspections,
replace the ball joint assembly with new one.
450RS026
After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 2.5-6.4 N
m (0.26-0.65kg
m/1.9-
4.7 lb ft)
450RS024
If the above limits specified are exceeded, replace
the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install bolt (5).
3. Install nut (3) and tighten it to the specified torque. Torque: 127 N
m (12.9kg
m/94 lb ft)
4. Install ball joint nut, then tighten it 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)
5. Install nut (4), then tighten to the specified torque. Torque: 50 N
m (5.1kg
m/37 lb ft)
Page 3520 of 4264
3C-28 FRONT SUSPENSION
Bump Rubber
Bump Rubber and Associated Parts
RTW340LF002601
Legend
(1)
Bolt
(2)
Bump Rubber
Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove bolt.
3. Remove bump rubber.
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 :
Bump Rubber
Installation
1. Install bump rubber.
2. Install bolt (1), then tighten it to the specified
torque.
Torque: 42 N
m (4.3kg
m/31 lb ft)
Page 3521 of 4264
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
Page 3522 of 4264
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.
Page 3523 of 4264
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)