warning ISUZU TROOPER 1998 Service User Guide

SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN 2A Ð 63
5. Steering Wheel
Align the setting marks made when removing.
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.
Steering Wheel Nut Torque Nám (kgám/lbáft)
34 (3.5 / 25)
4. Inflator Module
1) Support the module and carefully connect the
module connector.
CAUTION:
·Never use the air bag assembly from another vehicle.
Use only the air bag assembly for "UBS".
·When replace the inflator module, use only same parts
number assembly. If different parts number assembly is
installed, the air bag system can not function correctly
because it has different characteristic.
NOTE:
Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire
from being pinched.
2) Secure the module with one bolt to relieve
weight on the connector wire.
3) Tighten bolts to specified sequence as figure.
Inflator Module Bolt Torque Nám (kgám/lbáin)
8 (0.8 / 69)
3. Steering Lower Cover
Install the engine hood opening lever.
2. Lower Cluster Assembly
1. Front Console Assembly
1) Install the transmission (for M/T) and transfer
control lever knob.
2) Install the wiring harness connectors.
Connect the battery ground cable.
Turn the 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.
3
41
2
827RS017

SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN 2A – 65
CAUTION:
The wheels of the vehicle must be straight ahead and the
steering column in the "LOCK" position before
disconnecting the steering wheel. Failure to do so will
cause the coil assembly to become uncentered which will
cause damage to the coil assembly.
1. Front Console Assembly
1) Remove the transmission (for M/T) and transfer
control lever knob.
2) Disconnect the wiring harness connectors.
2. Lower Cluster Assembly
3. Steering Lower Cover
Remove the engine hood opening lever.
4. Inflator Module
1) Loosen the inflator module fixing bolt from
behind the steering wheel assembly using a
TORX
driver or equivalent until the inflator
module can be released from steering assembly.
2) Disconnect the yellow 2way SRS connector
located behind the inflator module.
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 URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE
AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF A
ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL
INJURY MAY RESULT.
827RS014
827RS015
827RS016
Up

2A Ð 68 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN
3
41
2
4. Inflator Module
1) Support the module and carefully connect the
module connector.
CAUTION:
·Never use the air bag assembly from another vehicle.
Use only the air bag assembly for "UBS".
·When replace the inflator module, use only same parts
number assembly. If different parts number assembly is
installed, the air bag system can not function correctly
because it has different characteristic.
NOTE:
Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire
from being pinched.
2) Secure the module with one bolt to relieve
weight on the connector wire.
3) Tighten bolts to specified sequence as figure.
Inflator Module Bolt Torque Nám (kgám/lbáin)
8 (0.8 / 69)
3. Steering Lower Cover
Install the engine hood opening lever.
2. Lower Cluster Assembly
1. Front Console Assembly
Connect the wiring harness connectors.
Install the transmission (for M/T) and transfer control
lever knob.
Connect the yellow 2way SRS connector located
under the steering column.
Connect the battery ground cable.
827RS017
SYSTEM INSPECTION
¥Turn the 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 STEERING WHEEL & COLUMN 2A – 71
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 URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE
AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF A
ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL
INJURY MAY RESULT.
6. Steering Wheel
Apply a setting mark across the steering wheel and
shaft so parts can be reassembled in their original
position.
Use special tool. Remove the steering wheel.
Move the tires to the straight ahead position before
removing the steering wheel.
Steering wheel remover: 5-8840-0016-0 (J-29752)
7. Steering Column Cover
8. Combination Switch and SRS Coil Assembly
1) Disconnect the wiring harness connectors
located under the steering column.
2) Remove the combination switch assembly with
SRS coil.
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.
9. Snap Ring
10. Cushion Rubber
11. Shift Lock Cable (for A/T)
12. Lock Cylinder Assembly
Disconnect the starter switch harness connector
located under the steering column.
827RS016
825RS046
Up
430RS004
Setting mark

2A – 74 SUPPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL & COLUMN
SYSTEM INSPECTION
Turn the 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.

3E – 4 WHEELS AND TIRES
TIRES
REPLACEMENT
When replacement is necessary, the original metric size
should be used. Most metric tire sizes do not have exact
corresponding alphanumeric tire sizes. It is recommended
that new tires be installed in pairs on the same axle. If
necessary to replace only one tire, it should be paired with
tire having the most tread, to equalize braking traction.
CAUTION:
Do not mix different types of tires such as radial, bias and
bias-belted tires except in emergencies, because vehicle
handling may be seriously affected and may result in loss
of control.
TIRE MOUNTING
Remove valve cap on valve stem and deflate the tire.
Then use a tire changing machine to mount or dismount
tires.
Follow the equipment manufacturer’s instruction. Do not
use hand tools or tire lever alone to change tires as they
may damage the tire beads or wheel rim.
TIRE DISMOUNTING
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, and light rust.
Before mounting a tire, the bead area should be well
lubricated with an approved tire lubricant.
After mounting, inflate the tire to 196 kPa (28 psi) so that
beads are completely seated. Inflate the air to specified
pressure and install valve cap to the stem
WARNING:
NEVER STAND OVER TIRE WHEN INFLATING. BEAD MAY
BREAK WHEN BEAD SNAPS OVER RIM’S SAFETY HUMP
AND CAUSE SERIOUS PERSONAL INJURY.
NEVER EXCEED 240 kPa (35 psi) PRESSURE WHEN
INFLATING. IF 240 kPa (35 psi) PRESSURE WILL NOT
SEAT BEADS, DEFLATE, RE-LUBRICATE AND RE-INFLATE.
OVER INFLATION MAY CAUSE THE BEAD TO BREAK AND
CAUSE SERIOUS PERSONAL INJURY.
TIRE REPAIR
There are many different materials on the market used to
repair tires.
Manufacturers have published detailed instructions on
how and when to repair tires. These instructions can be
obtained from the tire manufacturer if they are not
included with the repair kit.
UNIT REPAIR

WHEELS AND TIRES 3E – 5
WHEELS
REPLACEMENT
Damaged wheels and wheels with excessive runout must
be replaced.
Wheel Runout at Rim (Based on Hub bore.)
GENERAL BALANCE PROCEDURE
Deposits of mud, etc. must be cleaned from the inside of
the rim.
The tire should be inspected for the following: match
mount paint marks, bent rims, bulges, irregular tire wear,
proper wheel size and inflation pressure. Then balance
according to the equipment manufacturer’s
recommendations.
There are two types of wheel and tire balance.
Static balance is the equal distribution of weight around
the wheel.
Assemblies that are statically unbalanced cause a
bouncing action called tramp. This condition will
eventually cause uneven tire wear.
Dynamic balance is the equal distribution of weight on
each side of the wheel center-line so that when the tire
spins there is not tendency for the assembly to move from
side to side. Assemblies that are dynamically unbalanced
may cause shimmy.
WARNING:
STONES SHOULD BE REMOVED FROM THE TREAD TO
AVOID OPERATOR INJURY DURING SPIN BALANCING
AND TO OBTAIN A GOOD BALANCE.
Steel Aluminum
AVertical play:
Less than mm(in)1.5 (0.059) 0.7 (0.028)
BHorizontal play:
Less than mm(in)1.5 (0.059) 0.7 (0.028)

4A1±1 DIFFERENTIAL (FRONT)
DRIVELINE/AXLE
CONTENTS
Differential (Front) 4A1. . . . . . . . . . . . . . . . . . . . . . .
Differential (Rear/220mm) 4A2A. . . . . . . . . . . . . . . .
Differential (Rear/244mm) 4A2B. . . . . . . . . . . . . . . .
Driveline Control System (Shift on the Fly) 4B1. . Driveline Control System (TOD) 4B2. . . . . . . . . . .
Driveshaft System 4C. . . . . . . . . . . . . . . . . . . . . . .
Transfer Case (Standard Type) 4D1. . . . . . . . . . .
Transfer Case (TOD) 4D2. . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL (FRONT)
CONTENTS
Service Precaution 4A1±1. . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 4A1±2. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal 4A1±3. . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal and Associated Parts 4A1±3
Removal 4A1±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1±4. . . . . . . . . . . . . . . . . .
Installation 4A1±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle Assembly 4A1±5. . . . . . . . . . . . . . .
Front Drive Axle Assembly and
Associated Parts 4A1±5. . . . . . . . . . . . . . . . . . . . . .
Removal 4A1±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A1±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A1±9. . . . . . . . . . . . . . . . . . . .
Disassembled View 4A1±9. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1±9. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A1±12. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A1±21. . . . . . . . . . . . . . .
Disassembled View 4A1±21. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1±22. . . . . . . . . . . . . . . . . .
Reassembly 4A1±23. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A1±25. . . . . . . . . . .
Special Tools 4A1±28. . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: I F S O E Q U IPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE REFORMING SERVICE ON
OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally,such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specification. Following these
instructions can help you avoid damage to parts and
systems.

DIFFERENTIAL (REAR 220mm)
4A2A±1
DRIVELINE/AXLE
DIFFERENTIAL (Rear 220mm)
CONTENTS
Service Precaution 4A2A±1. . . . . . . . . . . . . . . . . . . . . .
General Description 4A2A±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A2A±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing 4A2A±4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts 4A2A±4. . . . . .
Removal 4A2A±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4A2A±5. . . . . . . . . . . . . . . . . .
Installation 4A2A±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal 4A2A±6. . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts 4A2A±6. . . . .
Removal 4A2A±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2A±7. . . . . . . . . . . . . . . . . .
Installation 4A2A±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A2A±8. . . . . . . . . . . . . . . . . . . .
Differential Assembly and Associated Parts 4A2A±8
Removal 4A2A±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A2A±9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4A2A±10. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2A±11. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A2A±13. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A2A±21. . . . . . . . . . . . . . .
Disassembled View 4A2A±21. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2A±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2A±22. . . . . . . . . . . . . . . . . .
Reassembly 4A2A±23. . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Slip Differential 4A2A±25. . . . . . . . . . . . . . . . . . .
Disassembled View 4A2A±25. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2A±26. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2A±26. . . . . . . . . . . . . . . . . .
Reassembly 4A2A±28. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A2A±32. . . . . . . . . . .
Special Tools 4A2A±34. . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: I F S O E Q U IPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE REFORMING SERVICE ON
OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally,such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specification. Following these
instructions can help you avoid damage to parts and
systems.

DIFFERENTIAL (REAR 244mm)
4A2B±1
DRIVELINE/AXLE
DIFFERENTIAL (REAR 244mm)
CONTENTS
Service Precaution 4A2B±1. . . . . . . . . . . . . . . . . . . . . .
General Description 4A2B±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A2B±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing 4A2B±4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts 4A2B±4. . . . . .
Removal 4A2B±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4A2B±5. . . . . . . . . . . . . . . . . .
Installation 4A2B±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal 4A2B±6. . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts 4A2B±6. . . . .
Removal 4A2B±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B±7. . . . . . . . . . . . . . . . . .
Installation 4A2B±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A2B±8. . . . . . . . . . . . . . . . . . . .
Differential Assembly and Associated Parts 4A2B±8
Removal 4A2B±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A2B±9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4A2B±10. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B±11. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A2B±13. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A2B±20. . . . . . . . . . . . . . .
Disassembled View 4A2B±20. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B±21. . . . . . . . . . . . . . . . . .
Reassembly 4A2B±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Locking Differential Assembly 4A2B±23. . . . . . . . . . . . .
Disassembled View 4A2B±23. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B±23. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B±25. . . . . . . . . . . . . . . . . .
Reassembly 4A2B±25. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A2B±27. . . . . . . . . . . . .
Special Tools 4A2B±29. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: I F S O E Q U IPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE REFORMING SERVICE ON
OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally,such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specification. Following these
instructions can help you avoid damage to parts and
systems.