Transmission ISUZU TF SERIES 2004 Workshop Manual

9A-30 SUPPLEMENTAL RESTRAINT SYSTEM

SRS Control Unit
5. Remove the three SRS control unit fixing bolts and
remove SRS control unit.


RTW49JSH000101
Legent
(1) SRS control unit
(2) SRS Harness
(3) Connector Position Assurance

Service Precautions
WARNING: DURING SERVICE PROCEDURES, BE
VERY CAREFUL WHEN HANDLING SRS control
unit. NEVER STRIKE OR JAR SRS control unit.
UNDER SOME CIRCUMSTANCES, IT COULD
CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY OR IMPROPER OPERATION
OF THE SUPPLEMENTAL RESTRAINT SYSTEM
(SRS) . SRS control unit MOUNTING BRACKET
BOLTS MUST BE CAREFULLY TORQUED TO
ASSURE PROPER OPERATION. NEVER POWE
R
UP THE SRS WHEN SRS control unit IS NOT
RIGIDLY ATTACHED TO THE VEHICLE. THE SRS
control unit COULD BE ACTIVATED WHEN
POWERED WHILE NOT RIGIDLY ATTACHED TO
THE VEHICLE WHICH COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL
INJURY.
WARNING: PROPER OPERATION OF THE SRS
CONTROL UNIT REQUIRES THE SRS CONTROL
UNIT TO BE RIGIDLY ATTACHED TO THE
VEHICLE STRUCTURE AND THAT THE ARROW
ON THE SENSOR BE POINTING TOWARD THE
FRONT OF THE VEHICLE.
SRS control unit is specifically calibrated and is keyed
to the SRS control unit location SRS wiring harness.
Caution should be used to ensure proper location of
the SRS control unit. The keying of the SRS control
unit to its location and wiring harness connectors
should never be modified in the field.

Removal
1. Disable the SRS (Refer to “Disabling the SRS” in
this section).
2. Remove the transmission knob (for M/T) and
transfer lever knob.
3. Remove the front console assembly and
disconnect wiring harness connector.
4. Pull CPA (Connector Position Assurance) out and
push connector lock down to disconnect the SRS
control unit harness connector.

Installation
1. Install the SRS control unit on bracket and fixing
bolts and tighten the fixing bolts to the specified
torque.
Torque: 7




2 N
 m (0.7




0.2 kg
 m/61 lb in)
2. Connect the SRS control unit harness connecto
r
and after that, put CPA into connector.
3. Install the front console.
4. Install the transmission knob (for M/T) and transfe
r
lever knob.

PROPELLER SHAFT 4A-3
MAIN DATA AND SPECIFICATIONS
REAR PROPELLER SHAFT

mm(in)
4

2 Model
Engine Model 4JA1-T(L) 4JA1-TC 4JH1-TC
Transmission Type 5 M/T (MUA) 5M/T (MUA) 4A/T
Wheel Base Long Long Extra Long Long
Front Suspension
High Ride
SuspensionExcept High
Ride
Suspension


Rear Axle 
220mm 



Type 
OBS 



Outside Diameter mm 75 68.9 68.9 68.9 63.5
(in) (2.95) (2.71) (2.71) (2.71) (2.50)
Inside Diameter mm 71.8 64.9 64.9 64.9 60.3
(in) (2.89) (2.63) (2.63) (2.63) (2.44)
Length 1st(L1) mm 799.5 798.5 801.5 946.5 720.5
(in) (31.48) (31.44) (31.56) (37.26) (28.37)
2nd(L2) mm 796 801 796 801 801
(in) (31.34) (31.54) (31.34) (31.54) (31.54)
Spline Major mm 29.89 29.89 29.89 29.89 29.89
Diameter (in) (1.18) (1.18) (1.18) (1.18) (1.18)
Fix Bolt Size M10 M10 M10 M10 M10
* OBS - Outboard Slip (Spline Engagement To T/M)



mm(in)
4

2 Model
Engine Model C24SE
6VE1
Transmission Type 5M/T (MUA)
5M/T (MUA) 4A/T
Wheel Base Long Extra Long Long Extra Long Long Extra Long
Front Suspension High Ride
Suspension Except High
Ride
Suspension










Rear Axle 


220mm 



Type 


OBS 



Outside Diameter mm 75 75 75 68.9 68.9 75 75
(in) (2.95) (2.95) (2.95) (2.71) (2.71) (2.95) (2.95)
Inside Diameter mm 71.8 71.8 71.8 64.9 64.9 71.8 71.8
(in) (2.89) (2.89) (2.89) (2.63) (2.63) (2.89) (2.89)
Length 1st(L1) mm 823.5 820.5 970.5 823.5 971.5 778.5 928.5
(in) (32.42) (32.30) (38.21) (32.42) (38.25) (30.65) (36.56)
2nd(L2) mm 801 796 796 801 801 801 801
(in) (31.54) (31.34) (31.34) (31.54) (31.54) (31.54) (31.54)
Spline Major mm 29.89 29.89 29.89 29.89 29.89 30.48 30.48
Diameter (in) (1.18) (1.18) (1.18) (1.18) (1.18) (1.20) (1.20)
Fix Bolt Size M10 M10 M10 M10 M10 M10 M10
* OBS - Outboard Slip (Spline Engagement To T/M)

4A-4 PROPELLER SHAFT

mm(in)
4

4 Model
Engine Model 4JA1-T(L) 4JA1-TC 4JH1-TC
Transmission Type 5M/T (MUA) 5M/T (MUA) 4A/T
Wheel Base Long Long Extra Long Long
Front Suspension








Rear Axle 220mm 220mm 


Type OBS OBS 


Outside Diameter mm 75 68.9 68.9 63.5
(in) (2.95) (2.71) (2.71) (2.50)
Inside Diameter mm 71.8 64.9 64.9 60.3
(in) (2.89) (2.63) (2.63) (2.44)
Length 1st(L1) mm 469.5 468.5 616.5 402.5
(in) (18.48) (18.44) (24.27) (15.85)
2nd(L2) mm 801 801 801 801
(in) (31.54) (31.54) (31.54) (31.65)
Spline Major mm 29.89 29.89 29.89 29.89
Diameter (in) (1.18) (1.18) (1.18) (1.18)
Fix Bolt Size M10 M10 M10 M10
* OBS - Outboard Slip (Spline Engagement To T/M)


mm(in)
4

4 Model
Engine Model C24SE 6VE1
Transmission Type 5M/T
(MUA) 5M/T (MUA) 4A/T
Wheel Base Long Long Extra Long Long
Front Suspension




Rear Axle    
Type    
Outside Diameter mm 63.5 68.9 68.9 75
(in) (2.50) (2.71) (2.71) (2.95)
Inside Diameter mm 60.3 64.9 64.9 71.8
(in) (2.44) (2.63) (2.63) (2.89)
Length 1st(L1) mm 495.5 492.5 641.5 484.5
(in) (19.51) (19.39) (25.26) (19.07)
2nd(L2) mm 801 801 801 801
(in) (31.54) (31.54) (31.54) (31.54)
Spline Major mm 29.89 29.89 29.89 29.89
Diameter (in) (1.18) (1.18) (1.18) (1.18)
Fix Bolt Size M10 M10 M10 M10
* OBS - Outboard Slip (Spline Engagement To T/M)

4A-6 PROPELLER SHAFT
Front Propeller Shaft

mm(in)
4

4 Model
Engine Model 4JA1-T(L) 4JA1-TC 4JH1-TC C24SE 6VE1
Transmission Type 5M/T (MUA) 5M/T
(MUA) 4A/T 5M/T
(MUA) 5M/T
(MUA) 4A/T
Wheel Base Long Long Long Long Long Long
Outside Diameter mm 40 40 40 40 40 40
(in) (1.57) (1.57) (1.57) (1.57) (1.57) (1.57)
Inside Diameter mm 32 32 32 32 32 32
(in) (1.26) (1.26) (1.26) (1.26) (1.26) (1.26)
Length (L) mm 607 607 676 586 586 607
(in) (25.90) (25.90) (26.61) (23.07) (23.07) (23.90)
Fix Bolt Size T/F M10 M10 M10 M10 M10 M10
Axle M10 M10 M10 M10 M10 M10


RTW34ASF000101

4A-8 PROPELLER SHAFT
Rear Propeller Shaft
General Description
4




2 (Except High Ride Suspension) Model
F04R300001

4





2 (High Ride Suspension), 4





4 Model
401R300007

Torque is transmitted from the transmission to the
axle through propeller shaft and universal joint
assembles. All propeller shafts are the balanced
tubular type. A splined slip joint is provided in some
drivelines.

Since the propeller shaft is total balanced carefully,
welding or any other modification are not permitted. 
Alignment marks should be applied to each
propeller shaft before removal.

Be sure vehicle is stopped, engine is not running,
brake is secured and vehicle is secured to prevent
injury.

Be careful not to grip the propeller shaft tube too
tightly in the bise as this will be cause deformation.

4A-10 PROPELLER SHAFT
Diagnosis of Propeller Shaft and
Universal Joint

Condition Possible cause Correction
Rough surface on splined yoke;
burred nicked or worn. Replace the seal. Minor burrs can
be Smoothed by careful use of
crocus cloth or fine stone honing.
Replace the yoke if badly burred. Leak at the Front Slip Yoke (An
Occasional Drop of Lubricant
Leaking from the Splined Yoke is
Normal)
Defective transmission rear oil seal. Replace the transmission rear oil
seal and replenish the transmission
oil.
Worn universal joint bearings. Replace.
Improper lubrication. Lubricate as directed.
Universal Joint Noise.
Loose flange bolts. Tighten to specifications.
Loose bushing bolts on the rear
springs or upper and lower control
arms. Tighten the bolts to specified
torque. Ping, Snap, or Click in Drive Line
(Usually Heard on Initial Load after
the Transmission is in Forward or
Reverse Gear)
Loose or out-of-phase end yoke. Remove end yoke, turn 180
degrees from its original position,
lubricate the splines and reinstall.
Tighten the bolts and pinion nut to
specified torque.
Squeak Lack of lubricant. Lubricate joints and splines. Also
check for worn or brinelled parts.
Loose or missing bolts at the
flanges. Replace or tighten bolts to specified
torque.
Incorrectly set front joint angle. Install shim under the transmission
support mount to change the front
joint angle.
Shudder on Acceleration (Low
Speed)
Worn universal joint. Replace.
Incorrect shaft runout. Replace.
Shaft out of balance. Adjust.
Transmission rear housing bushing,
transfer case housing bushing worn.Replace.
Vibration
Yoke spline jammed. Replace.

PROPELLER SHAFT 4A-11
Removal and Installation

401RS023
Removal
1. Raise the vehicle on a hoist.
NOTE:
Apply alignment marks on the flange at the rear
propeller shaft both front and rear side.


2. Remove center bearing fixing bolt.
3. Remove rear axle side bolt, nut and washer.
4. Remove rear propeller shaft.

NOTE:
Plug the hole of the transmission rear end to prevent oil
leakage.

401L100007
Installation
NOTE:
Cover the slip yoke with cloth to avoid damage to the oil seal
contact surface, when removing propeller shaft from
transmission. Do not damage the oil seal contact surface of
slip yoke with other parts at removal and installation.
Completely remove the dust or foreign matter from the
connecting surface of flange coupling on each end of the
propeller shaft.

1.
Align the mark which is applied at removal and insert the
propeller shaft in the transmission.
2. Install rear propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 N




m(6.4kg




m/46 lb




ft)
3. Install center bearing and tighten the bolts to the specified
torque.
Torque: 69 N





m(7.0kg





m/51 lb





ft)

FRONT WHEEL DRIVE 4C1-3
MAIN DATA AND SPECIFICATIONS
FRONT AXLE AND DIFFERENTIAL
Ring gear size mm (in) 194 (7.6)
Axle tube
Type It consists of the duce, a cast iron housing and the Axle tube.
Gear type Hypoid
Gear ratio (to 1) 4.100, 4.300, 4.555, 4.777, 5125
Differential type Two pinion
Specified gear oil (APL grade) GL-5
Oil capacity liter 1.4
(US/UK gal.) (0.4/0.33)
Axle shaft type Constant velocity joint (Birfield joint type and double offset joint).


FRONT PROPELLER SHAFT mm(in)
4

4 Model
Engine Model 4JA1-T(L) 4JA1-TC 4JH1-TC C24SE 6VE1
Transmission Type 5M/T (MUA) 5M/T
(MUA) 4A/T 5M/T
(MUA) 5M/T
(MUA) 4A/T
Front Axle 194 mm










Outside Diameter mm 40 40 40 40 40 40
(in) (1.57) (1.57) (1.57) (1.57) (1.57) (1.57)
Inside Diameter mm 32 32 32 32 32 32
(in) (1.26) (1.26) (1.26) (1.26) (1.26) (1.26)
Length (L) mm 607 607 676 586 586 607
(in) (23.90) (23.90) (26.61) (23.07) (23.07) (23.90)
Fix Bolt Size T/F M10 M10 M10 M10 M10 M10
Axle M10 M10 M10 M10 M10 M10

4C1-74 FRONT WHEEL DRIVE
PROPELLER SHAFT
1. NOISE

Checkpoint Trouble Cause Countermeasure

Spider bearingReplaceWorn or jammed
ReplaceDamaged or worn
NG NG
OKYoke spline



2. VIBRATION

Shaft balanceAdjustUnbalance
ReplaceIncorrect
NG NG
OKShaft runout
Transmission rear housing
bushing, transfer case
housing bushing
ReplaceWorn NG OK
Yoke splineReplaceJammed NG OK

PARKING BRAKE SYSTEM 5D-5

Front Parking Brake Cable
Front Parking Brake Cable and Associated Parts (Bench Seat)


750R300003

Legend

(1)
Shift Knob (manual transmission)

(2)
Front Floor Console

(3)
Rear Cover

(4)
Bolt


(5)
Seat Assembly

(6)
Buckle: side seat and Center Seat Belt

(7)
Seat Adjuster