torque ISUZU TF SERIES 2004 Repair Manual

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.

4C2-10 SHIFT ON THE FLY SYSTEM



412RS044





















13. Inner Shaft Bearing


Place a new snap ring in inner shaft.


Force a new inner shaft bearing into the inner shaft.
Installer : 5-8840-2197-0 (J-37452)


12. Snap Ring
NOTE;
Be careful not to damage the inner shaft.

11.inner Shaft


Clean the housing contact surface of the front axle
case.


Insert inner shaft assembly into the front axle case.
NOTE:
Be careful not to damage oil seal.




412RW017

10. Snap Ring
Install snap ring in the groove of front axle case.
NOTE:
Be sure to install the snap ring properly.


9. Clutch Gear
Apply differential gear oil to clutch oil.
8. Sleeve
Apply differential gear oil to sleeve.




412RW023


7. Housing


Clean contact surface with the front axle and sctuator
mounting surface.

Apply liquid gasket to the contact surface on the front
axle case and install in the housing.

6. Bolt
Tighten bolts to specified tightening torque.
Housing Bolt Torque N m (kg m/lb ft)
75 (7.6/55)

SHIFT ON THE FLY SYSTEM 4C2-11






5. Actuator


Clean the actuator contact surface with the housing.


Apply liquid gasket to the contact surface on the
actuator side.


Align shift arm with the groove of sleeve and install the
actuator.

4. Bolt
Tighten bolts to specified torque.
Actuator Bolt Torque N m (kg m/lb ft)
9 (0.95/78)














3. Front Axle Drive Shaft (LH side)
2. Bolt


Install front axle drive shaft and mounting bracket.


Tighten fitting bolts to specified tightening torque.
Bolt Torque N m (kg m/lb ft)
116 (11.8/85)
1. Filler Plug


Pour specified amount of differential gear oil.
Front Differential Oil Capacity liter (US/UK gal)
1.4 (0.37/0.31)
Actuator Housing Oil Capacity liter (US/UK gal)
0.12 (0.03/0.03)


Install filler plug through packing and tighten to
specified torque.
Filler Plug Torque Nm (kgm/lbft)
78 (8.0/58)

4C2-12 SHIFT ON THE FLY SYSTEM
Torque Specifications N





m (kgf





m / lb ft)






RTW440LF000801

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.

ANTI-LOCK BRAKE SYSTEM 5B-1

SECTION 5B
BRAKES
ANTI-LOCK BRAKE SYSTEM
TABLE OF CONTENTS
PAGE
Service Precaution ...................................................................................................................... 5B – 2
Torque Specifications ................................................................................................................ 5B – 3
Electronic Hydraulic Control Unit ........................................................................................... 5B – 7
Electronic Hydraulic Control Unit and Associated Parts ............................................ 5B – 7
Removal .................................................................................................................................... 5B – 7
Installation ................................................................................................................................ 5B – 7
Front Wheel Speed Sensor ....................................................................................................... 5B – 8
Front Wheel Speed Sensor and Associated Parts ........................................................ 5B – 8
Removal .................................................................................................................................... 5B – 9
Inspection and Repair ........................................................................................................... 5B – 9
Installation ................................................................................................................................ 5B – 10
Rear Wheel Speed Sensor ........................................................................................................ 5B – 11
Rear Wheel Sensor and Associated Parts ....................................................................... 5B – 11
Removal .................................................................................................................................... 5B – 11
Inspection and Repair ........................................................................................................... 5B – 11
Installation ................................................................................................................................ 5B – 12
Front Speed Sensor Rotor ........................................................................................................ 5B – 13
Front Sensor Rotor and Associated Parts ....................................................................... 5B – 13
Removal .................................................................................................................................... 5B – 13
Inspection and Repair ........................................................................................................... 5B – 14
Installation ................................................................................................................................ 5B – 14
Rear Speed Sensor Rotor .......................................................................................................... 5B – 16
Rear Sensor Rotor and Associated Parts ........................................................................ 5B – 16
Removal .................................................................................................................................... 5B – 16
Inspection and Repair ........................................................................................................... 5B – 17
Installation ................................................................................................................................ 5B – 17
G-Sensor ........................................................................................................................................ 5B – 19
G-Sensor and Associated Parts ......................................................................................... 5B – 19

5B -2 ANTI-LOCK BRAKE SYSTEM

Removal .................................................................................................................................... 5B – 19
Installation ................................................................................................................................ 5B – 19
Special Tools ........................................................................................................................... 5B – 20


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.

ANTI-LOCK BRAKE SYSTEM 5B-3

Torque Specifications
Electronic Hydraulic Control Unit

This illustration is based
on RHD model
E05R300007

ANTI-LOCK BRAKE SYSTEM 5B-7

Electronic Hydraulic Control Unit
Electronic Hydraulic Control Unit and Associated Parts



RHD model LHD model
350R300001-X

Legend


1.
Flare Nut from master cylinder front

2.
Flare Nut to front right wheel cylinder

3. Flare Nut to front left wheel cylinder

4.
Flare Nut to rear wheel cylinder


5.
Electronic Hydraulic Control Unit (EHCU)

6.
Flare Nut from master cylinder rear

7.
Bolt

8.
Front

Removal
1. Disconnect the harness connector.
2. Loosen five flare nuts and remove brake pipes.


After disconnecting brake pipe, cap or tape the
openings of the brake pipe to prevent the entry o
f
foreign matter.
3. Remove three bracket fixing bolts.

Installation
1. Install EHCU and tighten the bolt to the specified
torque.

Torque : 8 N
m (0.8 kg
m /69 lb in)
2. Tighten the flare nuts to the specified torque.

Torque : 16 N
m (1.6 kg
m /12 lb ft)

3. Connect the harness connector.

5B -10 ANTI-LOCK BRAKE SYSTEM

Installation
1. Install the speed sensor in the knuckle and take care
not to hit the speed sensor head during installation.
2. Install speed sensor fixing bolt and tighten the fixing
bolt to the specified torque.

Torque: 8 Nm (0.8 kgm /69 lb in)
3. Connect the cable clips at the arrow mark places.
4. Install the cable fixing bolt and nut (4
2) and tighten
the fixing bolt and nut to the specified torque.

Torque :

Bolt
8 N
m (0.8 kg
m /69 lb in)

Nut
20 N
m (2.0 kg
m /14 lb ft)
NOTE: Confirm that the cable is not twisted when
connecting the speed sensor cable.
5. Connect the speed sensor connector.