2004 ISUZU TF SERIES suspension

3C-34 FRONT SUSPENSION
Torsion Bar
Torsion Bar and Associated Parts


RTW340MF000501
Legend
(1)
Adjust Bolt, End Piece and Seat
(2)
Height Control Arm


(3) Torsion Bar


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Apply the setting marks (1) to the adjust bolt and end piece, then remove adjust bolt, end piece and
seat.








410RS004

FRONT SUSPENSION 3C-35

3. Apply the setting marks(2) to the height control
arm and torsion bar, then remove height control
arm.
NOTE: “Besco chassis grease” shall be applied on
contact area of height control arm with frame.
(RH & LH Both side)





410RS005
4. Apply the setting marks (3) to the torsion bar and
lower control arm, then remove torsion bar.


RTW340SH000301
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
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



RTW340SH000301

3C-36 FRONT SUSPENSION


Rubber seat


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: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering
section.






410RS004

FRONT SUSPENSION 3C-37

Knuckle
Knuckle and Associated Parts


RTW340LF001301
Legend
(1) Torsion Bar
(2 )Lower Ball Joint, Nut and Cotter Pin
(3) Back Plate
(4) Knuckle Assembly
(5) Knuckle


(6) Needle Bearing (44 Model Only)
(7) Thrust Washer (44 Model Only)
(8) Oil Seal (4
4 Model Only)
(9) Upper Ball Joint, Nut and Cotter Pin
(10) Speed Sensor harness


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.

3C-38 FRONT SUSPENSION

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 Ba
r
in this section.
8. Remove speed sensor harness.
9. Remove back plate.
10. Remove lower ball joint by using remover 5-8840-
2005-0.
CAUTION: Be careful not to damage the ball joint
boot.



901RW271

11. Remove upper ball joint by using remover 5-8840-
2121-0.
CAUTION: Be careful not to damage the ball joint
boot.

901RW272
12. Remove knuckle assembly.
13. Remove oil seal. If replacement required.
(4
4 Model Only)
14. Remove washer. If replacement required.
(4
4 Model Only)
15. Remove needle bearing by using remover 5-8840-
2000-0 and sliding hammer 5-8840-0019-0.
If replacement required. (4
4 Model Only)





(4

4 Model Only)
RTW340SH00401

FRONT SUSPENSION 3C-39

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

Thrust washer (44 Model Only)
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g) and
install needle bearing by using installer 5-8840-
2128-0 and grip 5-8840-0007-0. (4
4 Model Only)





(4
4 Model Only)
901RW275
2. Apply multipurpose type grease to the thrust
washer, and install washer with chamfered side
facing knuckle. (44 Model Only)

3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2
g). Then use installer 5-8840-2127-0 and grip 5-
8840-0007-0 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. (4
4 Model Only)




(4
4 Model Only)
901RW274
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 (9).
Torque: 98 N




m (10.0kg




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 (2).
Torque: 147 N





m (15.0kg





m/108 lb ft)
7. Install back plate.
8. Install speed sensor harness.
9. Install torsion bar, refer to Torsion Bar in this
section.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering.

3C-40 FRONT SUSPENSION

Upper Control Arm
Upper Control Arm and Associated Parts


RTW440LF001301
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 harness
(11)Nut and Cotter Pin
(12)Upper Ball Joint, Bolt and Nut


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.

FRONT SUSPENSION 3C-41

4. Support lower control arm with a harness.
5. Remove speed sensor harness.
6. Remove nut and cotter pin then remove knuckle
using remover 5-8840-2121-0.
CAUTION: Be careful not to damage the ball joint
boot.

RTW340SH000401
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 (9).
14. Remove plate (8).

15. Remove bushing (7) by using remover 5-8840-
0256-0.

RTW340SH000501



RTW340SH000601
16. Remove fulcrum pin (6).
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