ABS ISUZU TROOPER 1995 Owner's Guide

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) STEERING WHEEL & COLUMN 3F4-11
Fig. 3F4-25
WCAUTION:
Never apply force to the steering wheel in
direction
of the 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.
\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
LIKELY EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONALINJURY MAY RESULT
(FIG.3F4-26).
Fig. 3F4-26
5. Steering column cover
6. 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. 3F4-27).
Fig. 3F4-27
NOTE:
The
SRS coil is a part of the combination switch
assembly, which can not be
replaced separately.
Therefore, be sure not
to remove the SRS coil
from the combination switch assembly.
7. Snapring
8. Cushion rubber
9. Shift lock cable (for A/T)
10. Lock cylinder assembly
• Disconnect the starter switch harness
connector
located under the steering column.
E) INSTALLATION
10. Lock cylinder assembly
9. Shift lock cable (for A/T)
8. Cushion rubber
7. Snap ring
6. 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.3F4-28).

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.
•

REAR AXLE 48-3
DIAGNOSIS OF REAR AXLE NOISE
Many noises that seem to come from the rear axle
actually
originate from other sources such as tires,
road surface, wheel bearings, engine, transmission,
muffler,
or body drumming. Investigate to find the
source
ofthe noise before disassembling the rear axle.
Rear axles,
like any other mechanical device, are not
absolutely quiet but should be considered quiet unless
some abnormal noise is present.
To make a systematic check
for axle noise, observe the
following:
1. Select a level asphalt road to reduce tire noise and
body drumming.
2. Check rear axle lubricant level to assure correct
level, and then drive the vehicle far enough to
thoroughly warm up the rear axle lubricant.
3. Note the speed at which noise occurs. Stop the
vehicle and put the transmission in neutral. Run
the engine speed
slowly up and down to
determine if the noise is caused by exhaust,
muffler noise, or other engine conditions.
4. Tire noise changes with different road surfaces;
axle noises do not. Temporarily inflate all tires to
344
kPa (50 psi) (for test purposes only). This will
change noise caused by tires but will not affect
noise caused by the rear
axle.
Rear axle nose usually stops when coasting at
speeds under
48 km/h (30 mph); however, tire
noise continues
with a lower tone. Rear axle noise
usually changes when comparing pull and coast,
but tire noise stays about the same.
Distinguish between tire noise and rear
axle noise
by noting
if the noise changes with various
speeds
or sudden acceleration and deceleration.
Exhaust and
axle noise vary under these
conditions,
while tire noise remains constant and
is more pronounced at speeds
of 32 to 48 km/h
(20 to 30 mph). Further check for tire noise by
driving the vehicle
over smooth pavements or dirt
roads (not gravel) with the tires at normal
pressure.
If the noise is caused by tires, it will
change noticeably with changes in road surface.
5. Loose or rough front wheel bearings will cause
noise
which may be confused with rear axle
noise; however, front wheel bearing noise does
not change when comparing drive and coast.
Light application
of the brake while holding
vehicle speed steady
will often cause wheel
bearing noise to diminish. Front wheel bearings
may be checked for noise by jacking up the
wheels and spinning them
or by shaking the
wheels
to determine if bearings are loose.
6. Rear suspension rubber bushings and spring
insulators dampen
out rear axle noise when
correctly installed. Check to see that there is no
link or rod loosened or metal-to-metal contact.
7. Make sure that there is no metal-to-metal contact
between the
floor and the frame.
After the noise has been determined to be in the axle,
the type of axle noise should be determined, in order to
make any necessary repairs.
GEAR NOISE
Gear noise (whine) is audible from 32 to 89 km/h (20 to
55 mph) under four driving conditions.
1. In drive under acceleration or heavy pull.
2. Driving under load or under constant speed.
3. When using enough throttle to keep the vehicle
from driving the engine while the vehicle slows
down gradually (engine still pulls slightly).
4. When coasting with the vehicle in gear and the
throttle closed. The gear noise is
usually more
noticeable between 48 and 64
km/h (30 and 40
mph) and 80 and 89 km/h (50 and 55 mph).
BEARING NOISE
Bad bearings generally produce a rough growl or
grating sound, rather than the whine typical of gear
noise. Bearing noise frequently
"wow-wows" at
bearing rpm, indicating a bad pinion
or rear axle side
bearing. This noise can
be confused with rear wheel
bearing noise.
REAR WHEEL BEARING NOISE
Rear wheel bearing noise continues to be heard while
coasting at low speed with transmission in the neutral.
Noise may diminish by gentle braking. Jack up the rear
wheels, spin them by hand and
listen for noise at the
hubs. Replace any faulty
wheel bearings.
KNOCK AT LOW SPEEDS
Low speed knock can be caused by worn universal
joints or a side gear hub counter bore in the cage that is
worn oversize. Inspect and replace universal joints or
cage and side gears as required.
BACKLASH CLUNK
Excessive clunk on acceleration and deceleration can
be caused by a worn rear axle pinion shaft, a worn
cage, excessive clearance between the axle and the
side gear splines, excessive clearance between the
side gear hub and the counterbore in the cage,
worn
pinion and side gear teeth, worn thrust washers, or
excessive drive pinion and ring gear backlash.
Remove
worn parts and replace as required. Select
close-fitting parts when possible. Adjust pinion and
ring gear backlash.

48-4 REAR AXLE
ON-VEHICLE SERVICE
AXLE HOUSING
; ~~:r~4 ,
L ___________ j
12 14
3a
1
• 3
~
~·
13 5
Removal steps
1. Parking brake cable 7. Nut 17.
Differential assembly
2. Breather hose 8.
Bolt and nut 9. Bolt and nut Installation steps
3. Anti lock brake system (ABS)
connector and bracket 10. Coil spring and insulator To install, follow the removal
steps in the reverse order.
3a. Rear wheel antilock (RWAL)
speed sensor, bracket and
harness connector 11.
Axle housing assembly
12. Brake caliper
13. Brake disc
4. Flare
nut 14. ABS speed sensor and harness
5. Nut 15.
Brake pipe
6. Nut 16.
Axle shaft assembly
Fig. 4B-2
1••1 REMOVAL
Preparations:
• Raise the vehicle and support it with suitable
safety stands.
The
hoist must remain under the rear axle
housing.
• Take out brake fluid. Refer to Section 5A2 "DISC
BRAKES".
•
Remove rear wheels and tires. Refer to Section
3E "WHEELS AND TIRES".
•
Remove propeller shaft. Refer to Section 4A
"PROPELLER SHAFT".
•
Drain the rear axle oil into a proper container.
1. Parking brake cable
•
Release the connection between the cable
fixing clip equalizer. Refer to Section 5C
"PARKING BRAKES".
2. Breather hose
• Move the clip aside and pull out the breather
hose.
3. ABS connector and bracket
• Disconnect the connectors and remove the
brackets attached to the frame and center link
(Fig. 4B-3).
3a. RWAL speed sensor,
bracket and harness
connector
• Disconnect the connector and remove the
brackets attached to the frame and center link.
4. Brake tube flare nut
• Loosen the flare nut, remove the clip and take
out the brake tube.
•

5.
6.
7.
8.
........,
9.
10.
11.
12.
B 0
g
Fig. 48-3
Nut
• Remove the shock absorber fixing nut from the
axle housing.
Nut
• Remove the stabilizer linkage mounting nut
from the axle housing.
Nut
• Remove the lateral rod fixing nut from the axle
housing.
Bolt and nut
• Remove the center link mounting bolt and nut
from the axle housing .
Bolt and nut
• Remove the trailing link fixing bolt and nut
from the axle housing.
Coil spring and insulator
• Jack down and remove the coil spring and
insulator.
Axle housing assembly
• Axle
housing assembly can be separated from
the vehicle on completion of steps 1 -10.
Brake caliper
•
Remove the brake caliper fixing bolt, loosen
the
flare nut, release the clip and take out the
brake caliper
together with the flexible hose
(Fig. 48-
4).
REAR AXLE 48 - 5
Bolt Clip
Fig. 48-4
13. Brake disc
14.
Antilock brake system speed sensor and
harness
• Remove the speed sensor fixing bolt and the
clip and bracket on the axle housing.
15. Brake
pipe
• Remove the clip and fixing bolt on the axle
housing and take out the brake pipe.
16.
Axle shaft assembly
• Remove the bearing holder fixing nut and
take
out the axle shaft assembly. Refer to
"AXLE SHAFT" in this section.
• Be sure not to damage the oil seal by the
spline of the shaft.
17. Differential
assembly
• Refer to "DIFFERENTIAL ASSEMBLY" in this
section.
OIL SEAL REPLACEMENT
• Remove the oil seal, carefully not to damage
the housing, and mount new oil seal using
special tools (Fig. 48-5).
1®.1 Oil seal installer: J-39210
Fig. 48-5

48-6 REAR AXLE
1••1 INSTALLATION
17. Differential assembly
• Refer to "DIFFERENTIAL ASSEMBLY" in this
section.
16.
Axle shaft assembly
• Tighten the bearing holder mounting nut to the
specified torque.
~~~ Torque N·m (lb·ft) 74 (54)
• Be sure not to damage the oil seal by the spline
of the shaft.
15. Brake
pipe
14. Antilock brake system (ABS) speed sensor and
harness
• Refer to Section 5A4 "4-WHEEL ANTI-LOCK
BRAKE SYSTEM (ABS)".
13. Brake disc
12. Brake
caliper
• Refer to Section 5A2 "DISC BRAKES".
11.
Axle housing assembly
10. Coil spring and insulator
9. Bolt and nut
• For the procedures in Items 9-5, refer to Section
3D "REAR SUSPENSION".
8. Bolt and nut
7. Nut
6. Nut
5. Nut
4. Brake tube flare nut
• Refer to Section 5A2 "DISC BRAKES".
3a. Rear Wheel Antilock (RWAL) speed sensor,
bracket and harness connector
• Tighten the speed sensor bolt to the specified
torque.
1~1 Torque N-m (lb·ft) j 24 (18)
3. ABS connector and bracket
2. Breather hose
1. Parking brake cable
• Refer to Section 5C "PARKING BRAKES".

AXLE SHAFT
1
I
1••1 REMOVAL
Preparation:
• Raise the vehicle.
12 11
2
Fig. 4B-6
• Remove tires and wheels. Refer to Section 3E
"WHEELS & TIRES".
1. Brake caliper
• Use a wire to attach the brake caliper to the
frame. Refer to
Section 5A2 "DISC BRAKES".
2. Brake disc
3. ABS sensor (If equipped with ABS)
4. Parking brake assembly
• Refer to Section 5C "PARKING BRAKES".
5. Bolt (Behind the back plate)
• Remove the parking brake cable mounting
bolts (Fig. 4B-7).
REAR AXLE 48-7
Removal steps
1. Brake caliper
2. Brake disc
3. Antilock brake system (ABS)
speed sensor
4. Parking brake assembly
5. Bolt
6. Nut 7. Axle shaft assembly 8. Snap ring
9. Retainer
10. Bearing
11. Bearing holder
12. Back plate
13. Wheel pin
Installation steps To install, follow the removal
steps
in the reverse order.
Bolt
Fig. 4B-7

E) INSTALLATION
5. Collapsible spacer
• Discard the used collapsible spacer and install
a new one.
4. Outer bearing
NOTE:
• Do not drive in, but just temporarily set in the
outer bearing
by hand, which should be
indirectly pressed in finally by tightening the
flange nut.
3. Oil seal
1"?.:\1 • Use the seal installer to install a new oil seal that
l.::::'i:il has been soaked in axle lubricant.
Installer:
J-37263
DIFFERENTIAL ASSEMBL V
~ 1
REAR AXLE 48-11
J-37263
Pinion oil seal
Fig. 4B-17
2. Flange
1. Flange nut
• Refer to "DIFFERENTIAL ASSEMBLY (UNIT
REPAIR)" for flange nut reassembly in this
section.
NOTE:
• Discard the used nut and install a new one.
3
/
Removal steps
1. Parking brake cable
2. Nut 3. Axle shaft assembly 4. Bolt and nut 5. Differential assembly
Installation
steps
To install, follow the removal steps in the reverse order.
Fig. 4B-18
E) REMOVAL
Preparations:
• Jack up and .support the frame with stands.
• Remove the wheel and tire. Refer to Section 3E
"WHEELS & TIRES".
•
Drain the differential oil. •
Remove
the propeller shaft. Refer to Section 4A
"PROPELLER SHAFT".
•
Remove the RWAL speed sensor. Refer to Section
5A3
"REAR WHEEL ANTILOCK BRAKE SYSTEM
(RWAL)".
•
Remove the ABS speed sensor. Refer to Section
5A4
"4-WHEEL ANTI-LOCK BRAKE SYSTEM
(ABS)".

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.
..