wheel torque ISUZU TROOPER 1995 Owner's Manual

WHEELS AND TIRES 3E-9
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Wheels
Size
16 x7JJ
Offset mm (in) 38.0 (1.50)
P.C.D.,
wheel studs mm (in) 139.7 (5.50)
Standard tire
Size P245/70R16
Pressure
Front
kPa (psi) 210 (30)
Rear kPa (psi) 240 (35)
TORQUE SPECIFICATIONS
Fig. 3E-14
N·m (lb·ft)

SUPPLEMENTAL RESTRAINT SYSTEM (SRSl STEERING WHEEL & COLUMN 3F4-1
SECTION 3F4
SUPPLEMENTAL RESTRAINT SYSTEM
STEERING
WHEEL & COLUMN
W 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.
CONTENTS
General Description .......................................... 3F4-1
Lock Cylinder Replacement ......................... 3F4-10
On-Vehicle Service
............................................ 3F4-2 Steering Column Replacement .................... 3F4-13
Special Service Precaution ........................... 3F4-2 Main Data and Specifications .......................... 3F4-17
Inflator Module Replacement ...................... 3F4-3 Torque
Specifications ................................... 3F4-17
Steering Wheel Replacement ...................... 3F4-4 Special Tools ..................................................... 3F4-17
Combination
Switch Replacement ............. 3F4-7
GENERAL DESCRIPTION
W WARNING
TO AVOID DEPLOYMENT WHEN TROUBLE­
SHOOTING
THE SRS SYSTEM, DO NOT USE
ELECTRICAL TEST EQUIPMENT, SUCH AS
BATTERY-POWERED OR A/C-POWERED VOLT­
METER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN SPE­
CIFIED IN THIS MANUAL. DO NOT USE A NON­
POWERED
PROBE-TYPE TESTER.
INSTRUCTION IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PER­
SONAL INJURY MAY RESULT.
This steering
wheel and column repair section covers
the Supplemental Restraint System (SRS) steering
column. The following repair procedures are specific
to SRS Components. When servicing a vehicle
equipped with Supplemental Restraint System, pay
close attention to all WARNINGS and CAUTIONS.
For detailed explanation about SRS, refer to Section
9J "SUPPLEMENTAL
RESTRAINT SYSTEM (SRS)" of
this manual.
The steering column has three important features in
addition to the steering function:
1. The column is energy absorbing, designed to
compress in a front-end collision to minimize the
possibility of injury to the driver of the vehicle.
2. The ignition switch and lock are mounted con­
veniently on the column.
3. With the column mounted lock, the ignition and
steering operation can be
locked to prevent theft
of the vehicle.
The column may be disassembled and reassembled.
To insure the energy absorbing action, it is important
that the specified screws, bolts and nuts be used only
as designated and that they are tightened to the
specified torque.
When the column is removed from the vehicle, a
sharp
blow on the end of steering shaft or shift lever,
leaning
on the column assembly, or dropping the
assembly could shear or loosen the fasteners that
maintain column rigidity.

3F4-4 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN
(b!] INSPECTION AND REPAIR
\f' WARNING
THE INFLATOR MODULE SHOULD ALWAYS BE
CARRIED WITH THE URETHANE COVER AWAY
FROM YOUR BODY AND SHOULD ALWAYS BE
LAID ON A FLAT SURFACE WITH THE URE­
THANE SIDE UP. THIS IS NECESSARY BE­
CAUSE A FREE SPACE IS PROVIDED TO ALLOW
THE AIR CUSHION TO EXPAND IN THE UN­
LIKELYEVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY
MAY RESULT
(FIG. 3F4-5).
Fig. 3F4-5
The
Inflator module consists of a cover, air bag,
inflator, and retainer.
Inspect the Inflator module
mainly for the following:
1) Check for holes, cracks, severe blemishes and
deformation on the cover.
2) Check that the retainer is not deformed.
3) Check for defects such as damage and breakage in
the lead
wire ofthe squib.
If an abnormality is found as the result of the in­
spection, replace the
Inflator module with a new one.
l·u·IINSTALLATION
3. Inflator module
2. Module connector
• Support the module and carefully connectthe
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.
1. Fixing bolt
• Secure the module with one bolt to relieve
weight on the connector wire.
• Tighten bolts to specified sequence as figure
(Fig. 3F4-6).
Torque
N·m(lb·in.) 8 (69)
• Connect the yellow 3way SRS connector
located under the steering column.
• Connect the battery .. _. terminal cable.
• 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.
Fig. 3F4-6
STEERING WHEEL REPLACEMENT
\f' CAUTION:
Once the steering column is removed from the
vehicle, the
column is extremely susceptible to
damage. Dropping the column assembly on its
end
could collapse the steering shaft or loosen
the
slide block which maintains column rigidity.
Leaning on the column assembly could cause the
jacket
to bend or deform. Any of the above
damage could
impair the column's collapsible
design. If it is necessary to remove the steering
wheel, use
only the specified steering wheel
puller.
Under no conditions should the end of the
shaft be hammered upon,
as hammering could
loosen
slide block which maintains column
rigidity.
•

3F4-6 SUPPLEMENTAL RESTRAINT SYSTEM ISRSI STEERING WHEEL & COLUMN
2. Horn lead
3. Steering wheel fixing nut
4. Steering wheel
• Apply a setting mark across the steering
wheel and shaft so parts can be reassembled
in
their original position (Fig. 3F4-10)
•
Use special tool. Remove the steering wheel.
Move the tires to the straight ahead position
before removing
the steering wheel (Fig. 3F4-
11 ).
1®.1 Steering wheel remover: J-29752
Setting mark
Fig. 3F4-10
Fig. 3F4-11
"fCAUTION:
Never apply force to the steering wheel in
direction
ofthe 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.
B INSTALLATION
4. Steering wheel
• Align the setting marks made when re­
moving.
"f CAUTION:
3.
~
2.
1.
~
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.
Steering wheel fixing nut
• Tighten the steering wheel fixing nut to the
specified torque.
Torque
N-m (lb·ft) 34 (25)
Horn
lead
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 pinches.
• Secure the module with one bolt to relieve
weight on the connector wire.
• Tighten bolts to specified sequence as figure
(Fig. 3F4-12).
Torque
N·m (lb-in) 8 (69)
• Connect the yellow 3way SRS connector located
under the steering column.
• Connect the battery"-" terminal cable.
• 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.
Fig. 3F4-12
~
•

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN 3F4-9
B INSTALLATION
6. Combination switch and SRS coil assembly
•
After installation of combination switch as­
sembly, connect the combination switch
wiring harness connector and the SRS 3way
connector located under the steering column.
•
Turn the SRS coil clockwise to full, return
about 3
turns and align the neutral mark
(Fig.3F4-20).
Alignment mark
Fig. 3F4-20
WcAUTION:
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. 3F4-21 ).
Starter switch
harness
Combination switch harness
Inflator module harness
Fig. 3F4-21
4. Steering wheel
• Align the setting marks made when re­
moving.
W CAUTION:
Never apply force to the steering wheel in
direction
of the shaft by using a hammer or other
impact tools 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-ft) 34 (25)
3. SRS 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. 3F4-22).
Torque
N·m (lb·in) 8 (69)
2. Steering lower cover
• Install the engine hood opening lever.
1. Front console assembly
• Install
the transmission (for MfT) and transfer
control lever knob.
• Install the wiring harness connectors.
• Connect the battery "-"terminal cable.
• 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.
Fig. 3F4-22

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.

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN 3F4-15
Fig. 3F4-35
6. Steering column cover
7. Combination switch and SRS coil assembly
•
Disconnect the wiring harness connectors
located under the steering column.
• Remove the combination switch assembly
with SRS coil (Fig. 3F4-36).
Fig. 3F4-36
NOTE:
SRS coil is a part of combination switch
assembly, which can not be replaced singly.
Therefore, be sure not to remove the SRS coil
from the combination switch assembly.
8. Snap ring
9. Cushion rubber
10. Shift lock cable (For A/T)
11. Lock
cylinder assembly
• Disconnect the starter switch harness
connector located under the steering column.
12. Steering column assembly
•
Apply a setting mark across the universal joint
and steering shaft to reassemble the parts in
their original position (Fig. 3F4-37). Fig.
3F4-37
NOTE:
A setting mark can be easily made if the shaft is
withdrawn a little by loosening the steering shaft
universal joint.
B INSTALLATION
12. Steering column assembly
• Align the setting marks on the universal joint
and steering shaft made during removal.
•
Tighten the steering column fixing bolt (dash
panel) to the specified torque.
Torque
N-mOb·ft) 19 (14)
• Tighten the steering column fixing bolt (pedal
bracket) to the specified torque.
Torque N·m(lb·ft) 17 (13)
• Tighten the universal joint to the specified
torque.
Torque
N-m(lb·ft)
11. Lock cylinder assembly
10.
Shift lock cable (For A/T)
9. Cushion rubber
8. Snap ring
25 (18)
7. Combination switch and SRS coil assembly
• After installation of combination switch
assembly, connect the combination switch
wiring harness connector and the SRS 3way
connector located under the steering column.
•
Turn the SRS coil clockwise to full, return
about 3 turns and align the neutral mark
(Fig. 3F4-38).

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.
•

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN 3F4-17
MAIN DATA AND SPECIFICATIONS
TORQUE SPECIFICATIONS
Fig. 3F4-41
SPECIAL TOOLS
TOOL NO.
ILLUSTRATION TOOL
NAME
~~
J-29752
Steering wheel remover
N-m (lb.ft)

REAR AXLE 48-1
SECTION 48
REAR AXLE
\V 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 values must be used when installing fasteners that require torque. If the above conditions
are not followed, parts or system damage could result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . 48-1
Diagnosis of Rear
Axle Noise . .

. . . . . . . . . . 48-3
On-Vehicle Service ..................... 48-4
Axle Housing . .

. . . . . . . . . . . . . . . . . . . . . 48-4
Axle Shaft . .

. . . . . . . . . . . . . . . . . . . . . . . . 48-7
Pinion
Oil Seal . .

. . . . . . . . . . . . . . . . . . . .
48-10
Differential Assembly
. .

. . . . . . . . . . . . . . 48-11 Unit
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-13
Differential Assembly . .
. . . . . . . . . . . . . .
48-13 Differential Cage Assembly . . . . . . . . . . . . 48-23
Limited
Slip Differential . .

. . . . . . . . . . . . 48-27
Main Data and Specifications . . . . . . . . . . . . 48-33
General Specifications . .

. . . . . . . . . . . . . . 48-33
Torque Specifications
................ 48-34
Special Tools ......................... 48-35
GENERAL DESCRIPTION
The rear axle assembly is of the semi-floating type in
which the vehicle weight is carried on the axle
housing (Fig. 48-1).
The center
line of the pinion gear is below the center
line of the ring gear (hypoid drive).
All parts necessary to transmit power from the
propeller shaft to the rear wheels are enclosed in a
banjo type axle housing.
The 8.7 inch ring gear rear axle uses a conventional
ring and
pinion gear set to transmit the driving force
of the engine to the rear wheels. This gear set transfers
this driving force at a 90 degree angle from the
propeller shaft to the drive shafts. The
axle shafts
are supported at the wheel end of the
shaft by a roller bearing.
The
pinion gear is supported by two tapered roller
bearings. The pinion depth is set by a shim pack
located between the gear end of the pinion and the
roller bearing that is pressed onto the pinion. The
pinion bearing preload is set by crushing a collapsible
spacer between the bearings in the axle housing.