torque ISUZU TROOPER 1995 Repair Manual

STEERING LINKAGE 383-7
J-22912·01
Fig. 383-15
E1 INSTALLATION
6. Bracket
5. Relay lever
4. Nut and washer
~ Torque N·m (lb·ft) 118 (87)
3. Relay lever and bracket
2. Bolt and nut
~ Torque N·m (lb·ft) I 44 (33)
.._.,. 1 . Nut and cotter pin
• 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·ft) I 59 (43)

383-8 STEERING LINKAGE
MAIN DATA AND SPECIFICATIONS
TORQUE SPECIFICATIONS N·m (lb·ft)
Fig. 383-16
SPECIAL TOOLS
ILLUSTRATION TOOL NO.
TOOL NAME
TOOL NO.
TOOL NAME ILLUSTRATION
~
J-36831
Tie rod end remover
J-22912-01
Relay lever remover
..

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.

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)
..

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.

3C-12 FRONT SUSPENSION
NOTE:
Torque fulcrum pin nut after adjusting buffer clearance
(Fig. 3C-25)
I~EI Buffer clearance (T) mm (in) I 20 (0.79)
~~~ Torque N·m (lb·ft) I 108 (80)
Fig. 3C-25
8. Upper control arm assembly (Fig. 3C-26)
• Install with the fulcrum pin projections turned
inward.
7. Caster shims (Fig. 3C-27)
• Install the caster shims between the chassis
frame and
fulcrum pin.
6. Camber shims (Fig. 3C-27)
• Install the camber shims between the chassis
frame and
fulcrum pin.
Projection
J Outward
Fig. 3C-26
Camber shim
Fig. 3C-27
5. Nut assembly
4. Bolt and plate
1~1 Torque N·m (lb·ft)
3. Upper ball joint
~~~ Torque N·m (lb·ft)
2. Nut and cotter pin
152 (112)
57 (42)
• Tighten the nut to the specified torque, with just
enough
additional torque to align cotter pin
holes. Install new cotter pin.
1~1 Torque N·m (lb·ft) I 98 (72)
1. Speed sensor cable (If equipped with ABS)
•

I••IINSTALLATION
14. Bushing, rear (Fig. 3C-33)
l®.llnstaller: J-36834
Fig. 3C-33
13.
Bushing, front (Fig. 3C-34)
l®llnstaller: J-36833
___ ..,._. Rear
Fig. 3C-34
12.
Bolt, lower ball joint
11. Bolt, torsion bar arm
10. Lower control arm
9. Bolt, rear
8. Bolt, front
7. Lower ball joint
~~~ Torque N-m (lb·ft) I
6. Shock absorber
~~~ Torque N-m (lb·ft) I
Rear side
Front side
103 (76)
82 (61)
FRONT SUSPENSION 3C-15
5. Stabilizer link
~~~ Torque N·m (lb·ft) I
4. Torsion bar arm bracket
~~~ Torque N-m (lb.ft) I
3. Torsion bar
50 (37)
116 (85)
• Refer to "Torsion bar" in this section.
2. Nut and washer, rear
• Tighten lower link nut finger-tight.
NOTE:
Torque lower control arm nut after adjusting buffer
clearance (Fig. 3C-35).
UFI Buffer clearance (T) mm (in) I 20 (0.79)
~~~ Torque N-m(lb·ft)l 196(145)
1. Nut and washer, front
• Tighten lower link nut finger-tight.
NOTE:
Torque lower control arm nut after adjusting buffer
clearance (Fig. 3C-35).
UFI Buffer clearance (T) mm (in) I 20 (0.79)
~~~ Torque N-m (lb·ft) I 157 (116)
Fig. 3C-35
NOTE:
Adjustthetrim height. Refer to "Front End Alignment"
in section 3A.

[L!) INSPECTION AND REPAIR
Make necessary parts replacement if wear, damage,
corrosion
or any other abnormal conditions are found
through inspection.
• Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement (Fig. 3C-38).
Inspect screw/taper area of ball for flaws.
If
any defects are found by the above inspections,
replace the ball joint assembly with new one.
Fig. 3C-38
• After moving the ball joint 4 or 5 times, attach nut
then measure the preload (Fig. 3C-39).
Starting torque
N·m (lb·ft) I 0.5 -3.2 (0.4 - 2.4)
lfthe above limits specified are exceeded, replace
the ball joint assembly.
Fig. 3C-39
FRONT SUSPENSION 3C-17
1••1 INSTALLATION
3. Upper ball joint
2. Bolt and nut
~~~--T~o_rq~u_e __ N_·m~(l_b_·ft~)_L _____ 5_7_(4_2_) ____ _
1. Nut and cotter pin
• Tighten the nut to the specified torque with just
enough
additional torque to align cotter pin
holes. Install new cotter pin.
1-"i"' I Torque N·m (lb·ft) j 98 (72) ~---~--~~--------

I L•IINSPECTION AND REPAIR
Make necessary parts replacement if wear, damage,
corrosion
or any other abnormal condition are found
through inspection.
• Inspect the lower end boot for damage or grease
leak.
Move the ball joint as shown in the figure to
confirm its normal movement (Fig. 3C-42).
Inspect screw/taper area of ball for flaws.
If
any defects are found by the above inspections,
replace the ball
joint assembly with new one.
,--~:_,.--,',\ ,-...
~ .. :::: , \~-,
Fig. 3C-42
• After moving the ball joint 4 or Stimes, attach nut
the measure the preload (Fig. 3C-43).
Starting torque N.m (lb.ft) I 0.5-6.4 (0.4-4.7)
If the above limits specified are exceeded,
replace
the ball joint assembly.
Fig.
3C-43
FRONT SUSPENSION 3C-19
I••! INSTALLATION
4.
3.
2.
Bolt
Lower ball joint
Nut
I~I_To_r_:_q_ue __ N_·m_O_b_·ft_) Ll ___ 10_3_(7_6_) __ _
1. Nut and cotter pin
• 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·ft) I 147 (108) --~----~-----------