1997 ISUZU TFS SERIES lock

4C1-80 FRONT WHEEL DRIVE
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair front axle problems. Each troubleshooting chart has three
headings arranged from left to right.
(1) Checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into ten sub-sections:
42 Model
1. Wanders and pulls
2. Front wheel shimmy
44 Model
1. Oil leak at front axle
2. Oil leak at pinion shaft
3. Noises in front axle drive shaft joint
4. Noises in front axle
5. Wanders and pulls
6. Front wheel shimmy
7. Automatic locking free wheel hub
1) Does not lock or locks only on one side
2) Does not freewheel or freewheels only to one side
3) Noises in automatic locking free wheel hub
Propeller shaft
1. Noise
2. Vibration

FRONT WHEEL DRIVE 4C1-87
7. AUTOMATIC LOCKING FREE WHEEL HUB
(1) DOES NOT LOCK OR LOCKS ONLY ON ONE SIDE
Note :
1. Stop the vehicle
2. Shift the transfer lever to 4H or 4L
3. Now start driving the vehicle and the
hubs will lock automatically.
4. Once the hubs are locked, they will
remain locked, even if the transfer lever
is shifted from 4L or 4H into 2H, as long
as the vehicle travels in a same
direction.
Checkpoint Trouble Cause Countermeasure
ReplaceStill will not lock NGTry locking procedure once
more
(2) DOES NOT FREEWHEEL OR FREEWHEELS ONLY TO ONE SIDE
Note :
Freewheel operation
1. Stop the vehicle
2. Shift the transfer lever to 2H
3. Back up the vehicle for three or four feet;
this will disengage the front differential.
Checkpoint Trouble Cause Countermeasure
ReplaceStill will not freewheel
Driver the vehicle for five
minutes and then try the
freewheel procedure again
Still will not freewheel NGTry freewheel procedure once
more

4C1-88 FRONT WHEEL DRIVE
(3) NOISES IN AUTOMATIC LOCKING FREE WHEEL HUB
Note :
Some noise at the time of shifting from
“LOCK” to “FREE” or vice versa is normal.
It is not a sign of trouble.
Checkpoint Trouble Cause Countermeasure
Operating of automatic locking
free wheel hubReplace the driven clutchOne side operating
Connect the axial play or
replace the driven clutchExcessive axial play
NG NG
OKHoldout ring axial play
Front axle or jointReplace or tightenDamaged or loose NG OK

FRONT WHEEL DRIVE 4C1-93
ITEM NO. ILLUSTRATION PART NO. PART NAME
FAL-57
5-8522-0053-0
(J-29016)Outer bearing installer
(for 2WD)
FAL-58
5-8522-0054-0
(J-29015)Inner bearing installer
(for 2WD)
FAL-54
5-8522-0051-0
(J-33161)Hub oil seal installer
(for 2WD)
FAL-62
5-8840-2117-0
(J-36827) Hub nut wrench
FAL-17
5-8840-2119-0
(J-36829)Outer bearing inner race
installer (for 4WD)
FAL-19
5-8840-2120-0
(J-36830) Oil seal installer (for 4WD)
FAL-18
5-8840-0054-0
(J-29015)Outer bearing outer race
installer (for 4WD)
FAL-61
5-8840-2137-0
(J-38194) Inner cam installer
FAL-395-8840-2126-0Auto locking shim gauge
(for 4WD)

5-24 BRAKES
ADJUSTMENT PROCEDURE OF SERVICE AND PARKING BRAKE
Stem type
All brakes are self-adjusting.
Brake are adjusted by repeated stepping on the brake pedal.
The parking brake adjustment should be performed as follows:
1. Release the parking brake lever fully.
2. Loosen the lock nut (A).
3. Repeat stepping the brake pedal firmly and releasing it until
the rear brake auto-adjuster completes the function.
4. Rotate the adjust nut (B) until all slack disappears from the
cable.
5. Set the lock nut.
The parking brake lever travel is normal when the lever comes
out 9 to 11 notches when pulled with a force of 30 kg (66 lbs.).

BRAKES 5-25
Floor mount type
All brakes are self-adjusting.
Brakes are adjusted by repeated stepping on the brake pedal.
(After stepping on the pedal and releasing it, the rear auto-
adjuster, in the rear brake, produces a clicking sound.
the same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released position.
2. Parking cable must be loosened sufficiently.
(Loosen the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly, and releasing it
until the clicking sound can no longer be heard.
If the difference between the brake drum inside diameter of
the brake shoes is adjusted to be 0.5 mm, the number of
times for depressing the brake pedal can be reduced.
4. Remove the drum.
Measure the brake drum inside diameter and diameter and
diameter of the brake shoes.
Shoe Clearance mm(in)
0.25 - 0.40 (0.0098 - 0.0157)
If incorrect, check the brake auto-adjusting system.
5. Turn the equalizer nut so that the parking brake lever
travels 6 or 7 notches when pulled up with a force 30 kg (66
lbs.).
6. Make sure there is not brake dragging and tighten the cable
lock nut.
Torque N
m(kgfm/lbft)
8 - 18 (0.8 - 1.8 / 5.8 - 13)

5-26 BRAKES
ADJUSTMENT PROCEDURE OF BRAKE PEDAL
The push rod serves as the brake pedal stopper when the
pedal is fully released.
Brake pedal height adjustment should be performed as follows.
Brake Pedal - Height
Measure the brake pedal height after making sure the pedal is
fully returned by the pedal return spring.
Note:
Pedal height (L2) must be measured after starting the
engine and increasing the revolution several times by
stepping on the accelerator pedal.
mm(in)
Pedal free play (L1) 6-10 (0.23 - 0.39)
LHD 174-184 (6.85-7.24)
RHD 193-203 (7.60 7.99)Height (L2)
Note:
Pedal free play must be measured after turning off the
engine and stepping on the brake pedal firmly five times or
more.
If the measured value deviates from the above range, adjust
the brake pedal as follows:
a) Disconnect the stop lamp switch.
b) Loosen the lock nut on the push rod.
c) Adjust the brake pedal to the specified height by rotating the
push rod in the appropriate direction.

BRAKES 5-27
Lock Nut Torque Nm(kgfm/lbft)
15- 25 (1.5 - 2.5 / 11 - 18)
d) Install the stop lamp switch.
Note:
Pedal height (L
2) must be 95 mm (3.7 in.) or more when
applying about 50 kg (110.25 lbs.) of stepping force.
Clearance
Between the Switch Housing and the Brake Pedal (A).
mm(in)
0.5 - 1.0 (0.02 - 0.04)