clutch ISUZU TF SERIES 2004 Workshop 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 277 of 4264
FRONT WHEEL DRIVE 4C1-57
FRONT HUB AND DISC
(4
4 Manual Locking Hub Model)
DISASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure
RTW440LF000301
Disassembly Steps
1. Bolt
2. Cover assembly
3. Snap ring and shim
4. Body assembly
5. Lock washer
6. Hub nut
7. Hub and disc assembly
8. Outer bearing
9. Oil seal
10. Inner bearing
11. ABS sensor rotor
12. Bolt
13. Wheel pin
14. Clutch assembly
15. Snap ring
16. Knob
17. Compression spring
18. Follower
19. Retaining spring
20. X-ring
21. Snap ring
22. Inner assembly
23. Snap ring
24. Ring
25. Spacer
Page 278 of 4264
4C1-58 FRONT WHEEL DRIVE
Important Operations
1. Bolt
Before removal, shift transfer lever into “2H” position and set
free wheeling hub knob into “FREE” position.
6. Hub nut
Wrench : 5-8840-2117-0
(J-36827)
7. Hub and disc assembly
Before disassembly, remove the disc brake caliper assembly
and hang it on the frame with wires.
Refer to Section “Brake” for disc brake caliper removal
procedure.
14. Clutch Assembly
While pushing follower knob, turn clutch assembly clockwise
and then remove clutch assembly from knob.
19. Retaining Spring
Remove retaining spring from clutch assembly by turning it
counterclockwise.
Page 280 of 4264
4C1-60 FRONT WHEEL DRIVE
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found
through inspection.
For inspection and servicing of disc caliper, and relative parts, and ABS parts, refer to Section Brakes.
Hub
Hub bearing, oil seal
Knuckle spindle
Disc
Caliper
ABS sensor rotor
Cap, Hub flange, Shim, Snap ring
Free wheeling hub parts (Option)
Clutch, Knob, follower, inner, ring and
spring
Visual Check
Check the following parts for wear, damage or other abnormal
conditions.
Page 281 of 4264
FRONT WHEEL DRIVE 4C1-61
REASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure.
RTW440LF000401
Reassembly Steps
1. Spacer
2. Ring
3. Snap ring
4. Inner assembly
5. Snap ring
6. X-ring
7. Knob
8. Snap ring
9. Retaining spring
10. Follower
11. Compression spring
12. Clutch assembly
13. Wheel pin
14. Bolt
15. ABS sensor rotor
16. Inner bearing
17. Oil seal
18. Outer bearing
19. Hub and disc assembly
20. Hub nut
21. Lock washer
22. Body assembly
23. Snap ring and shim
24. Cover assembly
25. Bolt
Page 282 of 4264
4C1-62 FRONT WHEEL DRIVE
Important Operations
1. Spacer
Apply grease to both faces of spacer.
4. Inner Assembly
Apply grease wheel bearing to inside face of ring.
g(oz)
Amount of grease 6 (0.21)
7. Knob
(1) Apply grease Wheel bearing to outer circumference of knob
and inner circumference of cover.
(2) Align detent ball to either groove of cover.
8. Snap Ring
Turn the smoother face to knob side.
9. Retaining Spring
Align the end of spring to the end of cut portion of clutch spring
groove.
10. Follower
Install follower to clutch so that follower nail will come closer to
the bent portion of retaining spring by aligning follower stopper
nail to outer teeth of clutch. Then, hook retaining spring onto
upper portion of hanger nails of follower.
11. Compression Spring
Turn the smaller diameter side to follower.
12. Clutch Assembly
Align follower nail to handle groove, and then assemble clutch
with knob by pushing and turning clutch counterclockwise to
knob.
Page 302 of 4264
4C2-4 SHIFT ON THE FLY SYSTEM
Shift On The Fly System and Association Parts
RTW440LF000701
Disassembly steps
1. Filler plug
2. Bolt
3. Front axle drive shaft (LH side)
4. Bolt
5. Actuator assembly
6. Bolt
7. Housing
8. Sleeve
9. Clutch gear
10. Snap ring
11. Inner shaft
12. Snap ring
13. Inner shaft bearing
14. Needing bearing
15. Oil seal
Reassembly steps
To reassemble, follow the disassembly steps in
the reverse order.
Page 303 of 4264
SHIFT ON THE FLY SYSTEM 4C2-5
DISASSEMBLY
1. Filler Plug
Remove filler plug and packing and drain oil.
2. Bolt
Loosen mounting bracket fitting bolts and remove front axle
drive shaft from front axle case.
3. Front Axle Drive Shaft (LH side)
4. Bolt
Loosen actuator ASM fitting bolts.
5. Actuator Assembly
Draw out actuator ASM.
6. Bolt
Remove hosing fitting bolts.
7. Housing
8. Sleeve
9. Clutch Gear
412RW017
10. Snap Ring
Remove snap ring from front axle case by using a snap ring
pliers.
11.Inner Shaft
Take out inner shaft from front axle case.
412RW016
12.Snap Ring
Remove snap ring from inner shaft by using a snap ring
pliers.
412RW015
13.Inner Shaft Bearing
Remove inner shaft bearing by using a special tool and
press.
Remove : 5-8840-2197-0 (J-37452)
NOTE:
Be careful not to damage the shaft.
Page 305 of 4264
SHIFT ON THE FLY SYSTEM 4C2-7
RTW440SH000101
Inner Shaft Bearing
Inspect the state of inner shaft bearing. If any abnormality
such as smoothlessness is found, replace with a new inner
shaft bearing.
Insert a clutch gear and check the state of needle bearing.
If there is an abnormality such as smoothlessness, replace
the needle bearing.
Sleeve
Visual Check
Check and see that there is not wear, damage, or crecking
in the sleeve.
NOTE:
Close inspection of the groove and inner gear are required
because those are important parts.
412RW011
Functional Check
Operate the sleeve with the inner shaft combined with the
clutch gear.
If smoothlessness is felt, replace the sleeve.
NOTE:
Gear oil should be applied to the contact surface of gear.
412RW022
Dimensional Check
Check the width of sleeve center groove.
Sleeve Center Groove (Limit) mm (in)
7.1 (0.28)
Page 306 of 4264
4C2-8 SHIFT ON THE FLY SYSTEM
RTW440SH000201
Clutch Gear
Visual Check
Check and see the there is not wear, damage, crack, or
any other abnormality in the clutch gear.
Functional Check
If there is an abnormality such as soothlessness when
operated in combination with sleeve, replace the clutch
gear.
NOTE:
When inspection, gear oil should be applied to the contact
surface of gear.
RTW440SH000301
Dimensional Check
Make sure of the size illustrated.
Clutch Gear Out Side Diameter (Limit) mm (in)
36.98 (1.46)
RTW440SH000501
RTW440SH000401
Actuator
Visual Check
Check and see that there is no damage, cracking, or other
abnormality.
Functional Check
Make sure of function with voltage (12V) applied to
terminal
3, 4 and set the tester to terminal 1, 2 in
accordance with the table below.
State Port 3Port 4Port 1, 2
Conducting Function
A
C
B
D
If there is an abnormality, replace the actuator as an
assembly.
NOTE:
Be careful not to permit the entry of water or dust into the ports
of the actuator.
Do not open the actuator cover, if the actuator will be reused.
Page 308 of 4264
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)