tow ISUZU TF SERIES 2004 Repair Manual

7B1-32 MANUAL TRANSMISSION

2. Install bearing snap ring (29).
3. Apply recommended thread locking agents
(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install bearing plate and screw (28).
Tighten the screws to the specified torque by using
torx bit wrench 5-8840-0047-0.
Torque: 15 N




m (1.5 kg




m/11 lb




ft)

220RW137
4. Install needle bearing (27), reverse gear (26), and
reverse block ring (25). 5. Assemble rev-5th synchronizer assembly (24) by
performing the following steps.
1. Turn the clutch hub face (1) toward the sleeve
groove (2) (rear side) on the outer
circumference.
2. Check that the inserts (3) fit snugly into the
clutch hub (5) ring insert grooves.
3. Check that the inserts springs (4) are fitted to
the inserts as shown in the illustration.
4. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
5. Install the synchronizer assembly (24) to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the reverse gear side.

226RS013

226RS049

7B1-68 MANUAL TRANSMISSION

19. Remove engine rear mount bolts fixing
transmission.
220R300009
20. Remove the middle part of transmission
crossmember (15) by removing four fixing bolts and
nuts.
501R30007
21. Take out the rear support rubber. 22. Remove starter (16). (Diesel engine only)
060L100070
23. Use the clutch release bearing remover 5-8840-
2291-0 (J-39207) to disconnect the clutch release
bearing from the clutch pressure plate. (6VE1 only)
220RW109
Release bearing disconnection
1. Pull the shift fork toward the transmission to
press the clutch release bearing against the
clutch.
2. Insert the clutch release bearing remover
between the wedge collar and the release
bearing.
3. Turn the remover to separate the release
bearing.

7B1-72 MANUAL TRANSMISSION




RTW37BLF000201

5. Apply a force of about 113N (26 Ib) to the tip of the
shift fork in the direction of the transmission to
engage the clutch pressure plate and release
bearing. (6VE1 only)
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage
each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine while applying
a force of about 25 N (5.5 lb). If the shift fork will not
move, then they are securely engaged.

220RS006

7B1-88 MANUAL TRANSMISSION

13. Use screw drivers between the reverse gear (23)
and bearing plate (25) to remove the Rev-5th
synchronizer assembly (21) together with reverse
block ring (22) and reverse gear (23).

226RS010
14. Remove needle bearing (24).
15. Use the torx bit wrench (T45) 5-8840-0047-0 to
remove the bearing plate and screw(25) from the
intermediate plate.

220RW137
16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (26).


226RS011
17. Hold the snap ring open with the pliers.
Push the intermediate plate (27) toward the rear of
the transmission to remove it.
The bearing snap ring will come free.

Inspection and Repair
Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.

Reassembly
1. Mesh the counter gear with the mainshaft assembly.
Set the holding fixture 5-8840-2160-0 to the
mainshaft and the counter gear and then install it on
the base 5-8840-0003-0.
Install the intermediate plate (27) on the gear
assembly.
226RW212

MANUAL TRANSMISSION 7B1-89

2. Install bearing snap ring (26).
3. Apply recommended thread locking agents
(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install bearing plate and screw (25).
Tighten the screws to the specified torque by using
torx bit wrench 5-8840-0047-0.
Torque: 15 N




m (1.5 kg




m/11 lb




ft)

220RW137
4. Install needle bearing (24), reverse gear (23), and
reverse block ring (22). 5. Assemble rev-5th synchronizer assembly (21) by
performing the following steps.
1. Turn the clutch hub face (1) toward the sleeve
groove (2) (rear side) on the outer
circumference.
2. Check that the inserts (3) fit snugly into the
clutch hub (5) ring insert grooves.
3. Check that the inserts springs (4) are fitted to
the inserts as shown in the illustration.
4. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
5. Install the synchronizer assembly (21) to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the reverse gear side.

226RS013

226RS049

3A-2 FRONT ALIGNMENT

Front End Alignment Inspection and
Adjustment
General Description
“Front End Alignment” refers to the angular
relationshipbetween the front wheels, the front suspension
attachingparts and the ground.
Proper front end alignment must be maintained in order
toinsure efficient steering, good directional stability and
toprevent abnormal tire wear.
The most important factors of front end alignment arewheel
toe-in, wheel camber and axle caster.



Camber:
This illustration shows view from the front of the vehicle.
Camber is the vertical tilting inward or outward of the front
wheels. When the wheels tilt outward at the top, the camber is
positive (+). When the wheels tilt inward at the top, the camber
is negative (-). The amount of tilt measured in degrees from
the vertical is called the camber angle (1). If camber is extreme
or unequal between the wheels, improper steering and
excessive tire wear will result. Negative camber causes wear
on the inside of the tire, while positive camber causes wear to
the outside.

Caster:
This illustration shows view from the side of the vehicle.
Caster (1) is the vertical tilting of the wheel axis either
forward or backward (when viewed from the side of the
vehicle). A backward tilt is positive (+) and a forward tilt is
negative (-). On the short and long arm type suspension
you cannot see a caster angle without a special instrument, but
if you look straight down from the top of the upper control arm
to the ground, the ball joints do not line up (fore and aft) when
a caster angle other than 0 degree is present. With a positive
angle, the lower ball joint would be slightly ahead (toward the
front of the vehicle) of the upper ball joint center line.


Toe-in:
This illustration shows view from the top of the vehicle.
Toe-in is the measured amount the front wheels are turned in.
The actual amount of toe-in is normally a fraction of a degree.
Toe-in is measured from the center of the tire treads or from
the inside of the tires. The purpose of toe-in is to insure parallel
rolling of the front wheels and to offset any small deflections of
the wheel support system which occurs when the vehicle is
rolling forward. Incorrect toe-in results in excessive toe-in and
unstable steering. Toe-in is the last alignment to be set in
the front end alignment procedure.

3A-4 FRONT ALIGNMENT
Alignment for 4





2 (Except High Ride Suspension)
Caster and camber Adjustment
The lower links of the 4 X2 vehicle front suspension have an adjusting cam at either end (front and rear). This
permits simultaneous adjustment of camber and caster angle.

Front
Front
RTW340LF000301

Legend

1. Lower link ASM RH
2. Adjust cam RR
3. Adjust cam FRT
4. -direction The lower link ASM protrudes
toward the inside
5. +direction The lower link ASM protrudes
toward the outside
6. Lower link ASM LH
7. Adjust cam RR
8. Adjust cam FRT
9. -direction The lower link ASM protrudes
toward the inside
10. +direction The lower link ASM protrudes
toward the outside

3B-8 POWER-ASSISTED STEERING SYSTEM

6. Fully close the shutoff valve. Record the highest
pressures.


If the pressure recorded is within 9300-9800 kPa
(95-100 kg/cm
2/1350-1420 psi), the pump is
functioning within its specifications.


If the pressure recorded is higher than 9800 kPa
(100 kg/cm
2/1420 psi), the valve in the pump is
defective.


If the pressure recorded is lower than 9300 kPa (95
kg/cm
2/1350 psi), the valve or the rotating group in
the pump is defective.
7. If the pump pressures are within specifications,
leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built in either side of the powe
r
steering unit, the power steering unit is leaking
internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and fron
t
suspension must be thoroughly examined.

Maintenance
The hydraulic system should be kept clean and fluid
level in the reservoir should be checked at regula
r
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. When a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding the
Power Steering System in this section.


Inspect belt for tightness.


Inspect pulley for looseness or damage. The pulle
y
should not wobble with the engine running.


Inspect hoses so they are not touching any othe
r
parts of the vehicle.


Inspect fluid level and fill to the proper level.

Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55
C (130
F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from
the system. Refer to Bleeding the Power Steering
System in this section.

Bleeding The Power Steering System
When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the powe
r
steering fluid system, noisy and unsatisfactory operation
of the system may result.

Bleeding Procedure
When bleeding the system, and any time fluid is added
to the power steering system, be sure to use only powe
r
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and
let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so
that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right
and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to
set a few minutes, then repeat the above procedure.

Flushing The Power Steering System
1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch
the draining fluid.
3. While running the engine at idle, fill the reservoi
r
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which ma
y
cause a sudden fluid overflow at the reservoir.

POWER-ASSISTED STEERING SYSTEM 3B-13

Power Steering Unit Disassembled View

This illustration is based on the RHD model. 440R300003
Legend
(1) Tie-rod End
(2) Lock Nut
(3) Clip
(4) Bellows
(5) Band
(6) Tie-rod Assembly
(7) Oil Line
(8) Inner Ball Joint Assembly
(9) Tab Washer
(10) Mounting Rubber
(11) Housing Assembly



Disassembly
NOTE: The valve housing is made of aluminum and
care should be exercised when clamping in a vise, etc.
to prevent distortion or damage.
1. Loosen lock nut and remove tie-rod end.
2. Remove clip and band, then remove bellows.
3. Remove tie-rod assembly.
To remove, move the boot toward the tie-rod end,
then remove tab washer.
4. Remove oil line, mounting rubber and dust cover.
Inspection and Repair
Inspect the following parts for wear, damage or any
abnormal conditions.

3D-8 REAR SUSPENSION

Installation
1. Install the bump rubber (15) and bolt and tighten it to the
specified torque.
Torque Nm (kgm/lbft)
42 (4.3/31)
2. Install the leaf spring (14).
 The leaf spring assembly should be installed so that the
built-in rubber bush is toward the front.
 Align the holes of the spring eye and frame bracket.
 Insert the spring pin (13) toward vehicle inner side
through the frame bracket holes and the spring bush
hole.
 Tighten the nut (12) a little and after the vehicle is
lowered, tighten it to the specified torque.
Torque N
m (kg
m/lb
ft)
152 (15.5/112)
RTW340LF000101

 Apply rubber grease to inside and outside of the rubber
bushing.
 Install the rubber bushings (11) into the hole of the
frame side bracket and the spring rear eye.
 Install the shackle pin (10) and shackle plate (9).
 Tighten the nuts (8) a little and after vehicle is lowered,
tighten it to the specified torque.
Torque Nm (kgm/lbft)
98 (10/72)
3. Support the lower clamp (7) under the leaf spring.
4. Apply oil to the thread portion of U bolt (6).
Install the U bolt and seat on the rear axle and insert the U
bolt in the lower clamp holes.
5. Tighten the nut (5) to the specified torque.
Torque Nm (kgm/lbft)
78 (8.0/58)
6. Install the shock absorber (4) and inner washer on the
lower clamp pin and frame side pin.
7. Install the washer and nut (3) on the frame side pin and
tighten the nut to the specified torque.
Torque Nm (kgm/lbft)
39 (4.0/29)
8. Install the washer and nut (2) on the lower clamp pin and
tighten the nut to the specified torque.
Torque Nm (kgm/lbft)
39 (4.0/29)
9. Install the parking brake cable (1) on the leaf spring and
tighten the nut at its bracket.
Torque N
m (kg
m/lb
ft)
7 (0.7/5)