2002 ISUZU AXIOM Service Repair Manual

3C±8FRONT SUSPENSION
3. Apply the setting marks(2) to the height control arm
and torsion bar, then remove height control arm.
410RS005
4. Apply the setting marks(3) to the torsion bar and
lower control arm, then remove torsion bar.
410RS006
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:

Torsion bar

Height control arm

Adjust bolt

Rubber seat
Installation
1. Apply grease to the serrated portions, then install
torsion bar. Make sure the bars are on their correct
respective sides and align the setting marks(3).
410RS007
410RS006

FRONT SUSPENSION3C±9
2. Apply grease to the portion that fits into the bracket
then install height control arm and align the setting
marks(2).
410RS005
3. Apply grease to the bolt portion of the end piece(4).
Apply grease to the portion of the seat(5) that fits into
the bracket.
410RS008
4. Apply grease to the serrated portions.
5. Install adjust bolt and seat, then turn the adjust bolt to
the setting mark(1) applied during disassembly.
NOTE: A d j u s t t h e t r i m h e ight. Refer to
Front End
Alignment Inspection and Adjustment in Steering section.
410RS004

3C±10FRONT SUSPENSION
Knuckle
Knuckle and Associated Parts
410RW006
Legend
(1) Torsion Bar
(2) Lower Ball Joint, Nut and Cotter Pin
(3) Back Plate
(4) Knuckle Assembly
(5) Knuckle(6) Needle Bearing (4WD MODEL)
(7) Thrust Washer (4WD MODEL)
(8) Oil Seal (4WD MODEL)
(9) Upper Ball Joint, Nut and Cotter Pin
(10) Wheel Speed Sensor
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove wheel and tire assembly. Refer to
Wheel in
this section.
3. Remove the brake caliper. Refer to Disc Brakes in
Brake section.
4. Remove the hub assembly. Refer to Front Hub and
Disk in this section.
5. Remove tie±rod end from the knuckle. Refer to Power
Steering Unit in Steering section.
6. Remove the speed sensor from the knuckle.
7. Loosen torsion bar by height control arm adjust bolt,
then remove torsion bar. Refer to
Torsion Bar in this
section.
8. Remove wheel speed sensor.

FRONT SUSPENSION3C±11
9. Remove back plate.
10. Remove lower ball joint by using remover J±29107.
CAUTION: Be careful not to damage the ball joint
boot.
901RW163
11. Remove upper ball joint by using remover J±36831.
CAUTION: Be careful not to damage the ball joint
boot.
901RW162
12. Remove knuckle assembly.
13. Remove oil seal (Except 2WD model).
14. Remove washer (Except 2WD model).15. Remove needle bearing by using remover J±23907
(Except 2WD model).
901RW044
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:

Knuckle

Knuckle arm

Needle bearing

Thrust washer
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g) and install
needle bearing by using installer J±36838 and
J±8092 (Except 2WD model).
901RW045

3C±12FRONT SUSPENSION
2. Apply multipurpose type grease to the thrust washer,
and install washer with chamfered side facing knuckle
(Except 2WD model).
3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2 g).
Then use installer J±36837 and J±8092 to install oil
seal. 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 (Except
2WD model).
901RW167
4. Install knuckle assembly.
5. Install upper ball joint and tighten the nut to the
specified torque, with just enough additional torque to
align cotter pin holes. Install new cotter pin.
Torque: 98 N´m (72 lb ft)
6. Install lower ball joint and tighten the nut to the
specified torque, with just enough additional torque to
align cotter pin holes. Install new cotter pin.
Torque: 147 N´m (108 lb ft)
7. Install back plate.
8. Install wheel speed sensor.
9. Install torsion bar, refer to
Torsion Bar in this section.
NOTE: A d j u s t t h e t r i m h e ight. Refer to Front End
Alignment Inspection and Adjustment in Steering.

FRONT SUSPENSION3C±13
Upper Control Arm
Upper Control Arm and Associated Parts
450R200004
Legend
(1) Bolt and Plate
(2) Camber Shims
(3) Caster Shims
(4) Nut Assembly
(5) Upper Control Arm Assembly
(6) Fulcrum Pin(7) Bushing
(8) Plate
(9) Nut
(10) Speed Sensor Cable
(11) Nut and Cotter Pin
(12) Upper Ball Joint
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove wheel and tire assembly. Refer to
Wheel in
this section.
3. Remove the brake caliper and disconnect brake pipe.
Refer to
Disc Brakes in Brake section.
4. Support lower control arm with a jack.
5. Remove speed sensor cable.
6. Remove nut and cotter pin then use remover
J±36831.

3C±14FRONT SUSPENSION
CAUTION: Be careful not to damage the ball joint
boot.
901RW162
7. Remove upper ball joint.
8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and
number of shims.
11. Remove caster shims and note the positions and
number of shims.
12. Remove upper control arm assembly.
13. Remove nut.
14. Remove plate.
15. Remove bushing by using remover J±29755.
901RW161
901RW160
16. Remove fulcrum pin.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

Upper control arm

Bushing

Fulcrum pin
Installation
1. Install fulcrum pin.
2. Install bushing by using installer J±29755 and
J±39376.
901RW164

FRONT SUSPENSION3C±15
901RW159
3. Install plate.
4. Install nut and tighten fulcrum pin nut finger±tight.
NOTE: Torque fulcrum pin nut after adjusting buffer
clearance.
Buffer clearance: 15 mm (0.59 in)
Torque: 108 N´m (80 lb ft)
450R200002
5. Install upper control arm assembly with the fulcrum
pin projections turned inward.
450RS013
Legend
(1) Projection
(2) Outward
6. Install the caster shims(2) between the chassis frame
and fulcrum pin.
7. Install the camber shims(1) between the chassis
frame and fulcrum pin.
450RS014
8. Install nut assembly.
9. Install bolt and plate, then tighten the bolt to the
specified torque.
Torque: 152 N´m (112 lb ft)
10. Install upper ball joint and tighten it to the specified
torque.
Torque: 57 N´m (42 lb ft)
11. Install nut and cotter pin then tighten the nut to the
specified torque, with just enough additional torque to
align cotter pin holes. Install new cotter pin.
Torque: 98 N´m (72 lb ft)
12. Install speed sensor cable.