wheel alignment ISUZU TROOPER 1995 Owner's Manual

3F4 -12 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN
Alignment mark
Fig. 3F4-28
\fCAUTION:
When turning the SRS coil clockwise to full, stop
turning if resistance is felt. Forced further turning
may damage to the cable in the SRS coil.
5. Steering column cover
• When installing the steering column cover, be
sure
to wire (through each harness) as
illustrated so that the harnesses starter
switch,
combination switch and SRS coil may
not catch wiring (Fig. 3F4-29).
Starter switch
harness
Combination
switch harness
Inflator module
harness
4. Steering wheel
Fig. 3F4-29
• Align the setting marks made when re­
moving.
\fCAUTION:
Never apply force to the steering wheel in
direction
of the shaft by using a hammer or other
impacttools in an attemptto remove the steering
wheel. The steering shaft is designed as an
energy absorbing unit.
• Tighten the steering wheel fixing nut to the
specified torque.
~~~ Torque N·m (lb-ft) 34 (25)
3. Inflator module
• Support the module and carefully connect the
module connector.
NOTE:
Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead
wire from being pinched.
• Secure the module with one bolt to relieve
weight on the connector wire.
• Tighten fixing bolts to specified sequence as
figure (Fig. 3F4-30).
1~1 Torque N·m (lb-in) 8 (69)
Fig.
3F4-30
2. Steering lower cover
• Install the engine hood opening lever.
1. Front console assembly
• Connect the wiring harness connectors.
• Install the transmission (for Mff) and transfer
control lever knob.
• Connect the yellow 3way SRS connector located
under the steering column.
• Connect the battery"-" terminal cable.
SYSTEM INSPECTION
• Set ignition to "ON" while watching warning
light.
•
Light should flash 7 times and then go off. If
lamp does not operate correctly, refer to
Section 9J.

3F4-16 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN
Alignment mark
Fig. 3F4-38
\fCAUTION:
When turning the SRS coil clockwise to full, stop
turning if resistance is felt. Forced furtherturning
may damage to the cable in the SRS coil.
6. Steering column cover
• When installing the steering column cover, be
sure
to wire (through each harness) as
illustrated so that the harnesses starter
switch,
combination switch and SRS coil may
not catch wiring (Fig. 3F4-39).
Starter switch
harness
Combination switch harness
Inflator module harness
5. Steering wheel
Fig. 3F4-39
• Align the setting marks made when re­
moving.
WCAUTION:
Never apply force to the steering wheel in
direction
ofthe shaft by using a hammer or other
impacttools in an attempt to remove the steering
wheel. The steering
shaft is designed as an
energy absorbing unit.
• Tighten the steering wheel fixing nut to the
specified torque. Torque
N·m (lb·ftl 34
(25)
4. Inflator module
• Support the module and carefully connect the
module connector.
NOTE:
Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead
wire from being pinched.
• Secure the module with one bolt to relieve
weight on the connector wire.
• Tighten bolts to specified sequence as figure
(Fig. 3F4-40).
Torque
N·m (lb-in) 8 (69)
Fig. 3F4-40
3. Driver knee bolster (reinforcement)
2. Steering lower cover
• Install the engine hood opening lever.
1. Front console assembly
• Connect the wiring harness connectors.
• Install the transmission (for M/T) and transfer
control lever knob.
• Connect the yellow 3way SRS connector located
under the steering column.
• Connect the battery "-"terminal cable.
SYSTEM INSPECTION
• Set ignition to "ON" while watching warning
light.
• Light should flash 7 times and then go off. If
lamp does not operate correctly, refer to
Section 9J.
•

4C-2 FRONT DRIVING AXLE
DIAGNOSIS OF FRONT DRIVING AXLE
PROBLEM POSSIBLE CAUSE CORRECTION
Oil
Leak At Front 1. Worn or defective oil seal. 1. Replace the oil seal.
Axle 2. Front axle housing cracked. 2. Repair or replace.
Oil Leak At Pinion 1. Too much gear oil. 1. Correct the oil level.
Shaft 2. Oil seal worn or defective. 2. Replace the oil seal.
3. Pinion flange loose or damaged. 3. Tighten or replace.
Noises In Front Axle Broken or worn drive shaft joints and Replace
the drive shaft joints and
Drive Shaft Joint bellows (BJ and DOJ) bellows.
"Clank" When Ac-1. Loose drive shaft joint to output shaft 1. Tighten.
celerating From bolts.
"Coast" 2. Damaged inner drive shaft joint. 2. Replace.
Shudder or Vibration 1. Excessive drive shaft joint angle. 1. Repair.
During Acceleration 2. Worn or damaged drive shaft joints. 2. Replace.
3. Sticking spider assembly (inner drive 3. Lubricate or replace.
shaft joint).
4. Sticking joint assembly (outer drive 4. Lubricate or replace.
shaft joint).
Vibration At 1. Out of balance or out of round tires. 1. Balance or replace.
Highway Speeds 2. Front end out of alignment. 2. Align.
Noises in Front Axle 1. Insufficient gear oil. 1. Replenish the gear oil.
2. Wrong or poor grade gear oil. 2. Replace the gear oil.
3. Drive pinion to ring gear backlash 3. Adjust the backlash.
incorrect.
4. Worn or chipped ring gear, pinion 4. Replace the ring gear, pinion gear
gear
or side gear. or side gear.
5. Pinion shaft bearing worn. 5. Replace the pinion shaft bearing.
6. Wheel bearing worn. 6. Replace the wheel bearing.
7. Differential bearing loose or worn. 7. Tighten or replace.
Wanders and Pulls 1. Wheel bearing preload too tight. 1. Adjust the wheel bearing preload.
2. Incorrect front alignment. 2. Adjust the front alignment.
3. Steering linkage loose or worn. 3. Tighten or replace.
4. Steering gear out of adjustment. 4. Adjust or replace the steering
gear.
5. Tire worn or improperly inflated. 5. Adjust the inflation or replace.
6. Front or rear suspension parts loose 6. Tighten or replace.
or broken.
Front Wheel Shimmy 1. Wheel bearing worn or improperly 1. Adjust or replace.
adjusted.
2. Incorrect front alignment. 2. Adjust the front alignment.
3. Worn ball joint or bush. 3. Replace the ball joint or bush.
4. Steering linkage loose or worn. 4. Tighten or replace.
5. Steering gear out of adjustment. 5. Tighten or replace.
6. Tire worn or improperly inflated. 6. Replace or adjust the inflation.
7. Shock absorber worn. 7. Replace the shock absorber.
..

SA-2 HYDRAULIC BRAKES
BRAKE SYSTEM DIAGNOSIS
ROAD TESTING THE BRAKES
Brake Test
Brakes should be tested on a dry, clean, reasonably
smooth and
level roadway. A true test of brake
performance cannot be made
if the roadway is
wet, greasy
or covered with loose dirt so that all
tires do not grip the road equally. Testing will also
be adversely affected if the roadway is crowned so
as to throw the weight of the vehicle toward
wheels on one side or if the roadway is so rough
that wheels tend to bounce. Test the brakes at dif­
ferent vehicle speeds with both light and heavy
pedal pressure; however, avoid locking the wheels
and sliding the tires. Locked wheels and sliding
tires do not indicate brake efficiency, since heavily
braked but turning wheels will stop the vehicle in
less distance than locked wheels. More tire-to-road
friction is present
with a heavily braked turning tire
then
with a sliding tire.
The standard brake system is designed and
balanced
to avoid locking the wheels except at very high
deceleration
levels.
It
is designed this way because the shortest stopping
distance and best
control is achieved without brake
lock-up.
Because of high deceleration capability, a firmer pedal
may be felt at higher deceleration levels.
External Conditions That Affect Brake
Performance
1.
2.
3.
Tires: Tires having unequal contact and grip on
the road
will cause unequal braking. Tires must
be equally inflated, identical in size, and the tread
pattern
of right and left tires must be approxi­
mately equal.
Vehicle loading:
A heavily loaded vehicle requires
more braking effort.
Wheel Alignment: Misalignment of the wheels,
particularly
in regard to excessive camber and
caster,
will cause the brakes to pull to one side.
BRAKE FLUID LEAKS
With engine running at idle and the transmission in
"Neutral", depress the brake pedal and hold a constant
foot pressure on the pedal. If pedal gradually falls
away with the constant pressure, the hydraulic system
may be leaking.
Check the master cylinder fluid level. While a slight
drop in reservoir level will result from normal lining
wear, an abnormally low level in reservoir indicates a
leak in the system. The hydraulic system may be
leaking internally as well as externally. Refer to
"Master Cylinder Inspection". Also, the system may
appear
to pass this test but still have slight leakage. If
fluid level
is normal, check the vacuum booster
push rod
length. If an incorrect length push rod is
found, adjust
or replace the push rod. Check the
brake
pedal travel and the parking brake adjust­
ment.
When checking the
fluid level, the master cylinder fluid
level
may be low from the "MAX" mark if the front and
rear
linings are worn. This is not abnormal.
WARNING LIGHT OPERATION
When the ignition switch is in the START position,
the
"BRAKE" warning light should glow and go off
when the ignition switch returns to the ON position.
The
following conditions will activate the "BRAKE"
light:
1. Parking brake applied. The light should be on
whenever the parking brake is applied and the
ignition switch is on.
2. Low fluid level. A low fluid level in the master
cylinder will turn the "BRAKE" light on (Except
Rear
Wheel Antilock Brake System (RWAL)
model).
3. During engine cranking the "BRAKE" light
should
remain on. This notifies the driver that
the warning circuit is operating properly.
4. In the event of a front or rear system malfunc­
tion (RWAL model only).
5. In the event of RWAL malfunction (RWAL
model only. Refer to Section 5A3).
ANTILOCK BRAKE SYSTEM (RWAL or
ABS}
Refer to Section 5A3 or 5A4 for inspection and di­
agnosis procedure of the hydraulic unit.
..

HYDRAULIC BRAKES 5A-3
DIAGNOSIS OF BRAKE SYSTEM
Condition
Possible Cause Correction
Brake
Pull 1. Tire inflation pressures unequal. 1. Adjust
2. Front wheel alignment incorrect. 2. Adjust
3. Unmatched tires on same axle. 3. Tires with approx. the same amount of
tread should be used on the same axle.
4. Restricted brake pipes or hoses. 4. Check for soft hoses and damaged
lines. Replace with new hoses and new
double-walled steel brake piping.
5. Water or oil on brake pads. 5. Clean or replace.
6. Brake pads hardened. 6. Replace.
7. Brake pads worn excessively. 7. Replace.
8. Brake rotor worn or scored. 8. Grind or replace.
9. Disc brake caliper malfunctioning. 9. Clean or replace.
10. Front hub bearing preload incorrect. 10. Adjust or replace.
11. Loose suspension parts. 11. Check all suspension mountings.
12. Loose
calipers. 12. Check and tighten bolts to specifi-
cations.
Brake 1. Excessive lateral runout. 1. Check per instructions.
Roughness-or If not within specifications, replace or
Chatter machine the rotor.
(Pulsates) 2. Parallelism not within specifications. 2. Check per instructions.
If not within specifications, replace or
machine the rotor.
3. Wheel bearings not adjusted. 3. Adjust wheel bearings to correct
specifications.
4. Pad reversed (steel against iron). 4. Replace brake pad and machine rotor
to within specifications.
Excessive Pedal 1. Malfunctioning vacuum booster. 1. Check vacuum booster operation and
Effort repair, if necessary.
2. Partial system failure. 2. Check front and rear brake system for
failure and repair. Also, check brake
warning
light. If a failed system
is
found, the
light should indicate a
failure.
3. Excessively worn pad. 3. Check and replace pads in sets.
4. Piston in caliper stuck or sluggish. 4. Remove caliper and rebuild.
5. Fading brakes due to incorrect pad. 5. Remove and replace with original
equipment pad or equivalent.
6. Vacuum leak to vacuum booster. 4. Check for ruptured or loose hose.
7. Check direction of check valve within 5. Correct vacuum hose direction.
vacuum hose.
8. Grease on the brake pads. 6. Replace or clean.
Excessive Brake 1. Air in hydraulic circuit. 1. Bleed hydraulic circuit.
Pedal Travel 2. Level of brake fluid in reservoir too low. 2. Replenish brake fluid reservoir to speci-
fied
level and bleed hydraulic circuit as
necessary.
3. Master cylinder push rod clearance ex-3. Adjust.
cessive.
4. Leakage in hydraulic system. 4. Correct or replace defective parts.

78-6 MANUAL TRANSMISSION
6. Engine rear mount nuts
• Support the transfer case with a jack.
• Remove two engine rear mount nuts (Fig.
78-8).
7. Third crossmember
• Remove eight third crossmember bolts.
8. Engine rear mount
• Remove two engine rear mount bolts.
•
Remove the rear mount from the transmission.
9. Front crossmember
• Remove four front crossmember bolts.
•
Remove the front crossmember from the
frame.
10. Front propeller shaft
• Remove the front propeller shaft (Fig. 78-9).
W NOTE:
Apply alignment marks on the flange at both the
front and rear sides.
I I I
II
Fig. 78-8
Fig. 78-9
11. Gear control lever (Fig. 78-1 0)
• Remove the gear control lever knob.
• Remove the front console assembly.
•
Remove the grommet assembly.
•
Remove the transmission control lever and
transfer
control lever. •
Support
the transmission with a transmission
jack
.and then remove jack from the transfer
case side (Fig. 78-11).
~
12. Flywheel under cover bolts
• Remove three flywheel under cover bolts.
Fig. 78-10
Fig. 78-11
13. Transmission assembly
li5\l • Use the remover for disconnect the clutch
~ release bearing from the clutch pressure plate
(Fig. '78-12).
Clutch release
bearing remover: J-39207
Fig. 78-12
•

Pilot aligner: J-24547
• Mark the flywheel, clutch cover and pressure
plate lug for alignment when installing.
4. Release bearing
• Remove the release bearing from the
transmission case (Fig. 7C-9).
5. Shift fork
• Remove the snap pin.
• Remove the shift fork pin and shift fork from the
fulcrum bridge (Fig. 7C-10).
!
Fig. 7C-9
Fig. 7C-10
6. Fulcrum bridge
• Remove the fulcrum bridge bolts.
•
Remove the fulcrum bridge from the
transmission case (Fig. 7C-11).
7. Flywheel assembly and crankshaft bearing
• Do not remove except for replacement.
~~~· Use the remover to remove the crankshaft
bearing (Fig. 7C-12).
Remover; J-5822
Sliding hammer; J-23907
Fig. 7C-11
Fig. 7C-12
[L!j INSPECTION AND REPAIR
CLUTCH 7C-7
Make necessary correction or parts replacement if
wear, damage, or any other
abnormal condition are
found through inspection.
Pressure plate assembly (Fig. 7C-13)
• Visually check the pressure plate friction
surface
for excessive wear and heat cracks.
If excessive wear or deep heat cracks are
present, the pressure
plate must be replaced.
e ·---------
Fig. 7C-13

I ..
8 -70 CHASSIS ELECTRICAL
When placing a live inflator module on a bench
or other surface, always face the bag and trim
cover up, away from the surface. This is neces­
sary so that a free space is provided to allow the
air bag to expand in the unlikely event of acci·
dental
deployment.
4. Steering wheel
• Refer to STEERING WHEEL REPLACEMENT in
Section 3F4.
5. Lighting switch (Combination switch)
• Disconnect the switch connector.
• Remove four screws.
• Remove the lighting switch together with SRS
coil assembly.
'\f CAUTION:
Do not remove SRS coil assembly from the com·
bination switch assembly.
E) INSTALLATION
To install, follow the removal steps in the reverse
order, noting the
following points.
1. Check to see if the vehicle is in the straight driving
condition and turn the rotary section of the SRS
coil assembly provided to the upper surface ofthe
lighting switch (combination switch) clockwise
fully until it stops. Then from where it stops, turn
it back about 3 rotations to set the alignment
marks together before installing the steering
wheel. (Fig. 8-83)
Alignment mark
Fig. 8-83
2. Tighten the steering shaft nut to the s ecified
torque.
Nut torque N·m (lb.ft)
3. When connect the double lock type of nflator
module connector, insert the connecto com­
pletely
and lock at outside. Imperfect locki g may
cause malfunction of SRS system circuit.
4. When installing the steering cowl, be sure o pass
the harnesses
through the route as show in the
illustration so that the starter switch, th com­
bination switch and the inflator module
will not get caught. (Fig. 8-84)
Starter switch
harness
Combination
switch harness
~~ ~
Fig. 8-84
cowl
•