suspension ISUZU TROOPER 1995 User Guide

POWER STEERING SYSTEM TEST
TEST PROCEDURE
Test of fluid pressure in the power steering system is
performed to determine whether
or not the oil pump
and
power steering unit are functioning normally.
The power steering system test is method used to
identify and
isolate hydraulic circuit difficulties. Prior
to performing this test, the following inspections and
corrections,
if necessary, must be made.
[!) INSPECT
• Pump reservoir for proper fluid level.
•
Pump belt for proper tension.
• Pump driver pulley condition.
1. Place a container under the pump to catch the
fluid when disconnecting or connecting the
hoses.
2. With the engine NOT running, disconnect the
pressure hose
at the power steering pump and
install Power Steering tester (Fig. 3B1-3).
The gage
must be between the shutoff valve and
pump.
Open the shutoff valve.
li5\l Tester: J-29877-A
~ Adapter: J-39213
3. Check the fluid level. Fill the reservoir with power
steering fluid, to the "Full" mark. Start the engine
and,
momentarily holding steering wheel against
stop, check the connections at tester
for leakage.
4. Bleed the system. Refer to "Bleeding the Power
Steering
System".
POWER STEERING GEAR AND PUMP 381-3
5. Start the engine and check the pump fluid level.
And power steering fluid if required. When the
engine is at
normal operating temperature,
increase engine speed to 1500 rpm.
U7 CAUTION:
VI Do not leave shutoff valve fully closed for more
than 5 seconds,
as the pump could become
damaged
internally.
6. Fully close the shutoff valve. Record the highest
pressures.
• If the pressure recorded is within 9300-9800
kPa (1350-1420 psi), the pump is functioning
within its specifications.
• If the pressure recorded is higher than 9800 kPa
(1420 psi), the valve in the pump is defective.
• If the pressure recorded is lower than 9300 kPa
(1350 psi), the valve or the rotating group in the
pump is defective.
7. If the pump checks 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 (or one) side
ofthe gear, the gear is leaking internally and must
be disassembled and repaired.
8. Shut the engine off, remove the testing gage,
reconnect the pressure hose, check the
fluid level
and make the needed repairs.
9. If the problem still exists, the steering and front
suspension must be thoroughly examined.
Shut off Valve
J-29877-A
Oil Pressure Gauge
J-29877-A
Fig. 3B1-3

FRONT SUSPENSION 3C-1
SECTION 3C
FRONT SUSPENSION
'\f CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct
part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Fasteners
that are not reused, and those requiring thread locking compound, will be called out. The correct
torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.
Refer to section 3A in this manual for the wheel alignment procedure.
CONTENTS
General Description .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 3C- 1
On-Vehicle Service .............................. 3C-3
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-3
Stabilizer Bar . .. .. . .. .. ..

.. . .. .. . .. .. .. . .. .. .. . 3C- 4
Torsion Bar
.................................... 3C-5
Knuckle . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-7
Upper
Control Arm ........................... 3C-10
Lower Control Arm ........................... 3C-13
Upper Ball Joint ............................... 3C- 16
Lower
Ball Joint ............................... 3C-18
Main Data and Specifications.................. 3C-20
General
Specifications . .

. . . . . . . . . . . . . . . . . . . . . 3C-
20
Torque Specifications ........................ 3C-21
Special Tools ..................................... 3C-22
GENERAL DESCRIPTION
The front suspension is designed to allow each wheel
to compensate for changes in the road surface level
without greatly affecting the opposite wheel. Each
wheel is independently connected to the frame by a
steering
knuckle, ball joint assemblies, and upper and
lower control arms. The front wheels are held in
proper relationship to each other by two outer track
rods
which are connected to steering arms on the
knuckles and to a center track rod.
All models have a front suspension system consisting
of control arms, stabilizer bar, shock absorber and a
torsion bar. The front end of the torsion bar is
attached
to the lower control arm. The rear of the
torsion bar is mounted into a height control arm at the
crossmember. Vehicle trim height is controlled by
adjusting this arm.
Shock absorbers are
mounted between the brackets
on the
frame and the lower control arms. The lower
portion of each shock absorber is attached to the
lower control arm by a bolt and nut. The upper portion
of each shock absorber extends through a frame
bracket and is secured with two rubber bushings,
three retainers and a nut.
Ball joint assemblies are bolted to the outer end of the
upper and lower control arm and are attached to the
steering
knuckle by nuts and cotter pins.
The
inner ends of the upper control arm have pressed
in bushings.
Bolts, passing through the bushing,
attach the control arm to the frame. The inner ends of
the lower control arm are attached to the frame by
bolts passing through the bushings, which are
pressed in the frame.
Side
roll of the front suspension is controlled by a
spring steel stabilizer bar. It is mounted in rubber
bushings, which are held to the crossmember by
brackets. The ends of the stabilizer bar are connected
to the lower control arms by links.

3C-2 FRONT SUSPENSION
Hight control arm
Upper
control
Link
Lower control arm
Fig. 3C-1

FRONT SUSPENSION 3C-3
ON-VEHICLE SERVICE
SHOCK ABSORBER
Fig. 3C-2
1••1 REMOVAL
Preparation: • Raise the vehicle and support it with
suitable safety stands.
'W' • Remove wheel and tire assembly.
Refer to "Wheels and Tires" in
section
3E.
1. Bolt, nut and washer
2. Nut
3. Rubber bushing and washer
4. Shock absorber
5. Rubber bushing and washer
IL'it'l INSPECTION AND REPAIR
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
• Shock absorber
• Rubber bushing
EJ
5.
4.
3.
2.
~
1.
~
Removal steps
1.
Bolt, nut and washer 2. Nut
3. Rubber bushing and washer
4.
Shock absober 5. Rubber bushing and washer
Installation steps To install, follow the removal steps in the reverse order.
INSTALLATION
Rubber bushing and washer
Shock absorber
Rubber bushing and washer
Nut
Torque N-m (lb·ft) 20 (14)
Bolt, nut and washer
Torque N-m (lb·ft) 82 (61)

3C-4 FRONT SUSPENSION
STABILIZER BAR
5
l
3
Removal steps
1. Nut and washer
2. Link 3. Bracket
4. Stabilizer bar 5. Rubber bushing
Installation steps To install, follow the removal steps in the reverse order.
Fig. 3C-3
1••1 REMOVAL
Preparation: • Raise the vehicle and support the
frame
with suitable safety stands.
• Remove the stone guard.
• Remove wheel and tire assembly.
Refer to "Wheels and Tires" in
section
3E.
1. Nut and washer
W CAUTION:
VI Be careful not to break the ball joint boot.
2. Link
3. Bracket
4. Stabilizer bar
5. Rubber bushing
~ INSPECTION AND REPAIR
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
• Stabilizer bar
• Rubber bushing
• Link ball joint
1••1 INSTALLATION
5. Rubber bushing
4. Stabilizer bar
3. Bracket
~ Torque N·m (lb·ft) 22 (16)
2. Link
1. Nut and washer
~ Torque N-m (lb·ft) 50 (37)
..

TORSION BAR
Fig. 3C-4
E) REMOVAL
Preparation: • Raise the vehicle and support the
frame
with suitable safety stands.
1. Adjust bolt, end piece and seat (fig. 3C-5)
• Apply the setting marks to the adjust bolt and
end piece.
Setting mark
Fig. 3C-5
2. Height control arm (Fig. 3C-6)
• Apply the setting marks to the height control
arm and torsion bar.
3. Torsion bar (Fig. 3C-7)
• Apply the setting marks to the torsion bar and
lower control arm.
FRONT SUSPENSION 3C-5
Removal steps 1. Adjust bolt, end piece and seat
2. Height control arm
3. Torsion bar
Installation steps To install, follow the removal
steps in the reverse order.
Fig. 3C-6
Fig. 3C-7

3C-6 FRONT SUSPENSION
(L!] INSPECTION AND REPAIR
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the following parts:
• Torsion bar
• Height control arm
• Adjust bolt
• Rubber seat
1•+1 INSTALLATION
3. Torsion bar
8 • Make sure the bars are on their correct
respective sides (Fig.
3C-8).
1-ool • Apply grease to the serrated portions.
• Align the setting marks (Fig. 3C-9).
Fig. 3C-8
Fig. 3C-9
2. Height control arm
§]•
u:
Apply grease to the portion that fits into the
bracket.
Align the setting marks (Fig. 3C-1 0).
Apply grease to the bolt portion of the end
piece.
r::=;] • Apply grease to the portion of the seat that fits
D into the bracket (Fig. 3C-11 ).
1-ool • Apply grease to the serrated portions.
Fig.
3C-10
Fig. 3C-11
1. Adjust bolt and seat (Fig. 3C-12)
• Turn the adjust bolt to the setting mark applied
during disassembly.
NOTE:
Adjust the trim height. Refer to "Front End Alignment"
in section 3A.
Setting mark
Fig. 3C-12
IIIII

FRONT SUSPENSION 3C-7
KNUCKLE
2
~,
Removal steps 1. Torsion bar 6. Oil seal Installation steps 2.
Back plate 7. Thrust washer To install, follow the removal steps in the reverse order. 3. Lower ball joint 8. Needle bearing
4. Upper
ball joint 9. Knuckle
5. Knuckle assembly
Fig. 3C-13
1••1 REMOVAL
Preparation: • Raise the vehicle and support the
frame
with suitable safety stands.
• Remove wheel and tire assembly.
Refer to
"Wheels and Tires" in
section
3E.
• Remove the brake caliper. Refer
to"Brakes" in section 5.
• Remove the hub assembly. Refer to
"Hub and Disk" in section 4C.
• Remove outer track rod from the
knuckle. Refer to
"Steering
Linkage" in section 3B3.
• Remove the speed sensor (If
equipped with antilock brake
system)
from the knuckle. 1.
Torsion bar
• Loosen
torsion bar by height control arm adjust
bolt.
• Refer to "Torsion bar" in this section.
2. Back plate
3. Lower ball joint (Fig. 3C-14)
1®.1 Remover: J-291 07
'\f7 CAUTION:
'(! Be careful not to break the ball joint boot.
4. Upper ball joint (Fig. 3C-15)
1®.1 Remover: J-36831
'\f7 CAUTION:
'(! Be careful not to break the ball joint boot.
5. Knuckle assembly

3C-8 FRONT SUSPENSION
6. Oil seal
7. Washer
8. Needle bearing (Fig. 3C-16)
1®.1 Remover: J-23907
9. Knuckle
Fig. 3C-14
Fig. 3C-15
Fig. 3C-16
J-29107
11!) INSPECTION AND REPAIR
Make necessary correction or parts replacement if ~
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the
following parts:
• Knuckle
• Knuckle arm
• Needle bearing
• Thrust washer
•

I••IINSTALLATION
9. Knuckle
8. Needle bearing (Fig. 3C-17)
• Before installation, apply appropriate amount
of multipurpose type grease to the new
bearing (Approx. 5 g).
1®.1 Installer: J-36838 and J-8092
Fig. 3C-17
7. Washer
• Apply multipurpose type grease to the thrust
washer, and install it with chamfered side
facing
knuckle.
6. Oil seal
• Use a new oil seal, and apply multipurpose
type grease to the area surrounded by the lip
(approx. 2 g).
• After fitting the oil seal to the installer, drive it
to the knuckle using a hammer or bench press
until the tool front face contacts with the thrust
washer (Fig. 3C-18).
Installer:
J-36837 and J-8092
Fig. 3C-18
FRONT SUSPENSION 3C-9
5. Knuckle assembly
4. Upper ball joint
• Tighten the nut to the specified torque, with
just enough additional torque to align cotter
pin holes. Install new cotter pin.
~~~ Torque N·m (lb·ftl I 98 (72)
3. Lower ball joint
• Tighten the nut to the specified torque, with
just enough additional torque to align cotter
pin holes. Install new cotter pin.
~~~ Torque N·m (lb·ftl I 147 (108)
2. Back plate
1. Torsion bar
• Refer to "Torsion bar" in this section.
NOTE:
Adjust the trim height. Refer to "Front End Alignment"
in section 3A.