section 1A ISUZU TF SERIES 2004 Manual Online

5D-6 PARKING BRAKE SYSTEM





This illustration is based on RHD model.
RTW35DMF000101

Legend

(1)
Adjust Nut

(2)
Clip

(3)
Bolt


(4)
Bolt

(5)
Parking Brake Cable T-end

(6)
Front Parking Brake Cable


Removal
1. Remove seat assembly and seat adjuster.
Refer to section 10.
2. Turn over the carpet so that front parking brake
cable (6) appears.
3. Remove adjust nut (1).
4. Pull out clip (2) and take out front parking brake
cable (6).
5. Remove bolt (3) (4).
6. Disconect parking brake cable T-ends (5) from
front parking brake cable (6).
7. Take out front parking brake cable through the
floor hole.
Installation
1. Apply grease (multipurpose type grease) to the
connecting portion of parking brake cable T-end
(5) and front parking brake equalizer. (arrow mark)
2. Let rear end (equalizer) of front parking brake
cable (6) enter the floor hole and connect it with
parking brake rear cable T-end (5).
3. Set front parking brake cable (6) in the parking
lever assembly.
4. Drive clip (2) into the outer cable groove of front
parking brake cable (6) at the outside of the
parking lever assembly.
5. Install bolt (3)(4) on the floor and tighten them to
the specified torque.
Torque: 15 N




m (1.5 kg




m/11 lb ft)

PARKING BRAKE SYSTEM 5D-7

6. Drive adjust nut (1) on the front end of front
parking brake cable (6) so that parking brake
cable T-end fits into the rear end (equalizer) o
f
front cable (6).
7. Fit the carpet on the floor.
8. Install seat adjuster and seat assembly.

Refer to section 10.
9. Pull parking brake lever with a force equivalent to
operating force: 490N (50 kg/110 lb), 10 times fo
r
conditioning.
10. Adjust nut (1) so that parking brake lever goes
through 8

14 notches, when pulled with a
operation force of 294N (30 kg/66 lb).
11. Check brake for no drag.

5D-8 PARKING BRAKE SYSTEM

Parking Brake Lever
Parking Brake Lever Assembly and Associated Parts (Bucket Seat)


RTW35DSF000101

Legend

(1)
Rear Floor Console

(2)
Parking Brake Cable T-end

(3)
Adjust Nut


(4)
Switch

(5)
Parking Brake Lever Assembly

(6)
Bolt

(7)
Equalizer


Removal
1. Remove rear floor console (1).

Refer to section 10.
2. Loosen adjust nut (3).
3. Remove bolt (6).
4. Remove switch (4).
5. Disconnect parking brake cable T-end (2) from
parking brake lever assembly (5).
6. Take out parking brake lever assembly (5).

Installation
1. Apply grease (multipurpose type grease) to the
connecting portion of parking brake rear cable T-
end (2) and parking brake lever equalizer (7).
(arrow mark)
2. Connect parking brake rear cable T-end (2) to
equalizer (7).
3. Install switch (4).

4. Tighten the parking brake lever fixing bolt (6) to
the specified torque.
Torque: 15 N




m (1.5 kg




m/11 lb ft)
5. Drive adjust nut (3) on parking brake assembly so
that parking brake cable T-end fits into equalize
r
(7).
6. Install rear floor console (1).
Refer to section 10.
7. Pull parking brake lever with a force equivalent to
operating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
8.
Adjust nut (3) so that parking brake lever goes
through 6

8 notches, when pulled with a operation
force of 294 N (30 kg/66 lb).
9. Check brake for no drag.

WORKSHOP MANUAL
TF SERIES
CAB

SECTION 10

CAB 10-1
SECTION 10
CAB
TABLE OF CONTENTS
PAGE
Windshield.......................................................................................................................... 10- 2
Rear Window Assembly .................................................................................................... 10- 7
Front Door Assembly ........................................................................................................ 10- 10
Rear Door Assembly (Crew Cab) ...................................................................................... 10- 20
Instrument Panel................................................................................................................ 10- 28
Floor Console..................................................................................................................... 10- 34
Console Box (Without Floor Console) ............................................................................. 10- 38
Headlining .......................................................................................................................... 10- 39
Interior Trim Panels ...........................................................................................................10- 44
Fuel Filler Lid Opener Lever/Cable................................................................................... 10- 55
Quarter Glass (Extend Cab) .............................................................................................. 10- 70
Font Seat ............................................................................................................................ 10- 71
Rear Seat (Crew Cab) ........................................................................................................ 10- 74
Jump Seat (Extend Cab) ................................................................................................... 10- 75
Front Seat Belt ................................................................................................................... 10- 76
Rear Seat Belt (Crew Cab) ................................................................................................ 10- 80
Rear Seat Belt (Extend Cab) ............................................................................................. 10- 84
Front Wheel Extension ...................................................................................................... 10- 87
Rear Wheel Extension ....................................................................................................... 10- 88
Tail Gate Assembly ............................................................................................................ 10- 89

CAB 10-29

Important Operations
1. Front Console Assembly


Refer to Floor Consol in this section.



2. Glove Box


Remove 2 fixing screws and pulling the handle.



3. Instrument Panel Driver Lower Cover Assembly
1) Remove the engine hood opener 2 fixing screws.
2) Remove the lower cover one fixing screw.
3) Pull out the cover (Stick type parking brake only).
4) Pull out the lower cover assembly.




4. Driver Knee Bolster Assembly


Remove 4 fixing bolts.
Caution:
For precaution on installation or removal of SRS-air bag
system, refer to section 9 “Supplemental Restraint System
(SRS) - AIR BAG”

5. Driver Air Bag
6. Steering Wheel/Steering Cowl


Refer to Section 3B “STEERING COLUMN” for steering
lock assembly removal steps.




7. Meter Cluster Assembly


Pull out the 4 clip positions.

CAB 10-31



13.Ashtray Case

Pull out the ashtray case.
14. Center Cluster Assembly
1) Pull out the cluster at the 6 clip positions.
2) Disconnect the cigarette lighter, accessory socket,
hazard switch and clock connectors.
15. Control Lever Assembly


Remove the 2 fixing screws.
17.Ashtray Bracket


Remove the 3 fixing screws and illumination connector.


Caution:
For precautions on installation or removal of SRS-air bag
system, refer to section 9 "Supplemental Restraint System
(SRS) - AIR BAG".
21. Passenger Air Bag



Remove 2 fixing bolts, 2 fixing nuts and connector.
22. Side Ventilation Grille.

Pull out the grilles and disconnect switch connecto
r
(Driver’s side).
23. Vent Duct Assembly/Defroster Nozzle Assembly


Refer to section 1 “HVAC” for defroster nozzle and
ventilation duct removal steps.




25. Instrument Panel


Remove the clip and 6 fixing bolts.
26. Cross Beam

10-42 CAB
Important Operations - Removal
1. Interior Trim Panels


Refer to Interior Trim Panels in this section.



2. Sunvisor/Sunvisor Holder
1) Remove the 2 screws fixing the sunvisor.
2) Remove the screw fixing the sunvisor holder.


3. Spot Light


Pull out the spot light and disconnect the connector.


4. Assist Grip


Remove the 2 fixing screw.


6. Coat Hook

Open the cover and remove the fixing screw.



7. Dome Light
1) Remove the dome light lens and the fixing screws.
2) Disconnect the dome light connector.

10-70 CAB
QUARTER GLASS (EXTEND CAB)
REMOVAL AND INSTALLATION



RTW4A0MF000101

Removal Steps

1. Body side rear trim covers
2. Hinge/Faster
3. Quarter glass
4. Weather strip

Installation Steps


4. Weather strip
3. Quarter glass
2. Hinge/Faster
1. Body side rear trim covers







Important Operation - Removal
1. Body Side Rear Trim Covers
Refer to Interior Trim Panels in this section.

Important Operation – Installation
4. Weather Strip
Install the weather strip by aligning to corners with white
mark to the upper coners on the body panel.

CAB 10-79


Important Operations - Removal
1. Front Seat Assembly


Refer to Front Seat in this section.




2. Side Seat Belt Buckle/Pretensioner Seat Belt/Center
Seat Belt

Remove the seat belt fixing screw and the warning
harness connector clip (Bucket seat model).



RTW4A0SH000101-X



Remove the pretensioner seat belt fixing screw and the
warning harness connector (With pretensioner seat bel
t
model).
24.jpg


Remove the seat belt fixing screws and the warning
harness connector clip (Bench seat model).







Important Operations - Installation
2. Side Seat Belt Buckle/Pretensioner Seat Belt /Center
Seat Belt


Tighten the seat belt fixing screws to the specified
torque.
Torque N
m (kgf
m/lb
ft)
40 (4.1 / 30)
1. Front Seat Assembly


Tighten the seat assembly fixing bolts to the specified
torque.
Torque Nm (kgfm/lbft)
40 (4.1 / 30)