length ISUZU TROOPER 1998 Service Repair Manual

FRONT END ALIGNMENT 2A – 5
Position of shim
Camber angle Caster angle
Front side Rear side
When added When removed Decreases Decreases
When removed When added Increases Increases
Caster shim
When removed Unchanged Decreases
When added Unchanged Increases
When added Decreases Unchanged
Camber shim
When removed Increases Unchanged
TOE-IN ADJUSTMENT
1. To adjust the toe-in angle, loosen the lock nuts on the
outer track rods and turn the outer track rods. Turn
both rods the same amount, to keep the steering
wheel centered.
Toe-in mm(in)
0 ± 2 (0 ± 0.08)
2. Tighten the lock nut to the specified torque.
Lock Nut Torque N·m (kg·m/lb·ft)
118 (12.0 / 87)
MAXIMUM STEERING ANGLE
ADJUSTMENT
The maximum steering angle of the front wheels can be
adjusted with the stopper bolts under the frame side
members.
1. Position each front wheel on the turning radius gauge
in a straight-ahead position.
2. Set the parking brake firmly.
3. Adjust the inside wheel angle of each side with the
stopper bolts.
NOTE:
The maximum protruding length (L) of stopper bolt from
the lock nut should be 10 mm (0.4 in) or less.

2A – 48 STEERING LINKAGE
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear,
damage, corrosion, bending, deteriorations or any other
abnormal condition are found through inspection.
Check the following parts.
•Rod end assembly
•Ball joint (Boot, screws and tapered surfaces)
INSTALLATION
6. Rod End, Inner
Align the setting marks applied during desassembly.
5. Lock Nut, Inner
Lock Nut Torque N·m (kg·m/lb·ft)
118 (12.0 / 87)
NOTE:
In either outer rod, the screw on the right side of the
vehicle is threaded counterclockwise.
4. Rod End Assembly, Outer
Align the setting marks applied during disassembly.
3 Lock Nut, Outer
Lock Nut Torque N·m (kg·m/lb·ft)
118 (12.0 / 87)
2. Nut and Cotter pin, Knuckle Arm
Tighten the nut to the specified torque, with just
enough additional torque to align cotter pin holes.
Install new cotter pin.
Knuckle Arm Nut Torque N·m (kg·m/lb·ft)
98 (10.0 / 72)
1. Nut and Cotter Pin, Center Track Rod
Tighten the nut to the specified torque, with just
enough additional torque to align cotter pin holes.
Install new cotter pin.
Track Rod Nut Torque N·m (kg·m/lb·ft)
98 (10.0 / 72)
NOTE:
If replacing the track rod, adjust the new track rod
length.
Rod Length (L) mm (in)
328.3 (12.93) : Wide Tread
299 (11.77) : Narrow Tread
NOTE:
Adjust the toe-in. Refer to “Front End Alignment” in
section 3A.

3D – 4 REAR SUSPENSION; COIL SPRING
INSTALLATION
5. Coil Spring
Make sure that the coil spring is installed in the proper
position.
REMOVAL
Preparation:
1) Raise the vehicle and support the frame with suitable
safety stands.
2) Support the rear axle case with a jack.
1. Parking Brake Cable Bracket
Remove the parking brake cable from the trailing link.
2. Stabilizer Bar
Disconnect the stabilizer bar at the stabilizer link.
3. Shock Absorber
Remove the shock absorber from the axle case.
4. Insulator
5. Coil Spring
Remove the insulator and coil spring while lowering
the rear axle case.
CAUTION:
Be sure not to let the brake hose, parking brake cable,
and breather hose extend to their full length.
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
•Coil spring
•Insulator
Fit the end of the coil spring to the coil spring seat and
mount the coil spring on the rear axle case.

4A2A±28
DIFFERENTIAL (REAR 220mm)
Legend
(7) Fitting section with the case.
(8) Face contacting the inner surface of the
differential case.
Repair burrs and nicks using an oil stone.
(9) Sliding surface with the side gear or case.
(11) Contact surface with spring disc.
Measure the Deformation of the friction disc & plate.
Limit: 0.08 mm (0.003 in)
425RS061
Measure the wear of the friction plate & disc
Limit(A±B): 0.1 mm (0.004 in)
Remarks:
A=Inner or outer projections
B=Sliding surface subjected to abrasion
425RS062
Measure the wear of the thrust washer
Limit: 1.3 mm (0.05 in)
425RS063
Reassembly
Adjust the clearance between the friction disc and plate.
1. Measuring the depth of the differential cage.
Standard (A±B): 80.58 mm (3.17 in)
(C): 10.58 mm (0.41 in)
425RS064
2. Measuring the overall length of the pressurering,
friction disc and friction plate.

Mount the pinion shaft in the pressurering and then
install the friction disc & plate.

DIFFERENTIAL (REAR 220mm)
4A2A±29

Measure the length between the plates over the
V±groove. (D)
425RS065
3. After measuring dimensions A,B,C and D, make
adjustment in the following manner:

Measure the thickness (E) of the spring disc.
1.75mm (0.069in)y4 discs
4. Select the friction disc & plate so as to satisfy the
following equation:
{(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in)
Also, the total size difference of the friction disc &
plate and spring disc should be 0.05mm (0.02in) or
less.
Thickness :1.75±1.85mm(0.069±0.073 in)
Backlash adjustment of the side gear in
the direction of the shaft
1. Measuring the depth of the differential cage.
(F±B): 82.03 mm (3.23 in)
(G): 12.03 mm (0.47 in)
425RS066
2. Measuring the dimension between the thrust washers
at both ends.

Assemble the side gear, pinion, pinion shaft,
pressure ring and thrust washer, and pressing the
pressure ring to±the pinion shaft in the direction of
the shaft to make the clearance 0.

Have the side gear contact to the pinion to make the
backlash 0.

Measure the dimension (H) between thrust
washers at both ends.
425RS067

4C±47 DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
Engine6VE1 (3.5L)6VD1 (3.2L)4JX1 (3.0L)4JG2 (3.1L)
Transmission
M/TA/T
A/T
with
TOD
M/TA/T
A/T
with
TOD
M/TA/TM/TA/T
Construction
Hollow steel tube
with yoke and
spider type
universal joint
Hollow
steel
tube
with
consta
nt
velocity
joints
Hollow steel tube
with yoke and
spider type
universal joint
Hollow
steel
tube
with
consta
nt
velocity
joints
Hollow steel tube with yoke and
spider type universal joint
Outside
diameter40.0mm (1.57 in)
Length559mm
(22.01in)559mm
(22.01in)577mm
(22.72in)393mm
(15.47in)559mm
(22.01in)577mm
(22.72in)627mm
(24.69in)627mm
(24.69in)421mm
(16.57in)627mm
(24.69in)
Torque Specifications
E04RW021

4C±55 DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
Engine6VE1 (3.5L)6VD1 (3.2L)4JX1 (3.0L)4JG2 (3.1L)
Transmission
M/TA/T
A/T
with
TOD
M/TA/T
A/T
with
TOD
M/TA/TM/TA/T
ConstructionHollow steel tube with yoke and spider type universal joint
LengthS
W
B
668mm (26.30in)Ð846mm
(33.31in)678mm
(26.69in)Ð604mm (23.78in)810mm
(31.89in)Ð
L
W
B
1093mm (43.03in)1075mm
(42.32in)1271mm
(50.04in)1103mm
(43.43in)1083mm
(42.64in)1029mm (40.51in)1236mm
(48.66in)1037mm
(40.83in)
Outside
diamterS
W
B
68.9mm (2.71in)Ð68.9mm (2.71in)Ð68.9mm (2.71in)Ð
LW
B68.9mm (2.71in)82.6mm
(3.25in)68.9mm (2.71in)82.6mm
(3.25in)68.9mm
(2.71in)
Torque Specifications
E04RW023

TRANSFER CASE (STANDARD TYPE)
4D1±35
Limit : 3.0 mm (0.118 in)
226RS037
2WD±4WD 3±Cone Synchronizer (Shift On
The Fly model)
1. Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
2. If the measured value exceeds the specified limit, the
2WD±4WD synchronizer assembly must be
replaced.
Block ring and insert clearance
Standard : 1.5 mm (0.059 in)
Limit : 0.8 mm (0.031 in)
226RW142
Clutch Hub and Insert Clearance
1. Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
2. If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard : 0.01±0.19 mm (0.0004±0.0075 in)
Limit : 0.3 mm (0.012 in)
226RS038
Detent Springs
1. Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.
Detent Spring Free Length
1. Use a vernier caliper to measure the detent spring
free length.

4D1±36
TRANSFER CASE (STANDARD TYPE)
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Standard : 23.4 mm (0.921 in)
Limit : 22.8 mm (0.898 in)
Interlock pin
Standard : 1.59 mm (0.063 in)
Limit : 1.53 mm (0.060 in)
220RW035
Detent Spring Tension
1. Use a spring tester to measure the detent spring
tension.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Compressed height : 18.7 mm (0.736 in)
Standard : 68.6±88.2 N (7.0±9.0kg/15.4±19.8 lb)
Interlock pin
Compressed height : 11.5 mm (0.453 in)
Standard : 9.8 N (1.0kg/2.2 lb)
220RS013
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring.
Replace if these conditions are present.
Shift Arm Thickness
1. Use a micrometer to measure the shift arm thickness.
2. If the measured value is less than the specified limit,
the shift arm must be replaced.
Shift arm thickness
Standard : 9.60±9.85 mm (0.378±0.388 in)
Limit : 9.0 mm (0.354 in)
230RS006

4D1±38
TRANSFER CASE (STANDARD TYPE)
3. Install the sub±gear (23) to the counter gear (22).
4. Install the belleville spring (24).
5. Install the spacer (25) and put the snap ring (29) on
the sub±gear (23).
6. Install the ball bearing (26), using a bench press.
7. Select a snap ring that will allow the minimum axial
play.
Clearance : 0±0.1 mm (0±0.004 in)
Snap ring availability:
ThicknessColor±coding
1.50 mm (0.059 in)White
1.55 mm (0.061 in)Yellow
1.60 mm (0.063 in)Blue
8. Use a pair of snap ring pliers to install the snap ring
(27) to the counter gear (22).
226RS170
226RS021
Sub±Gear (anti±lash plate) Preload
1. Hook a length of piano wire (4) over one of the
sub±gear (5) teeth.
2. Attach the other end of the piano wire (4) to a
spring balancer.
3. Measure the sub±gear preload.
Preload : 59±98 N (6.0±10kg/13±22 lb)
226RS075
9. Install ball bearing (21), using a bench press.
10. Install snap ring (20).
11. Install the counter gear assembly (28) to the transfer
case (1).
12. Use a pair of snap ring pliers to install the snap ring
(29) to the transfer case (1).
NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.
13. Use a bench press to install the ball bearing (4) to the
front output shaft (5).
262RS012