2004 ISUZU TF SERIES ABS

4B-12 REAR AXLE

Legend


1.
Offset Box Wrench

10.
Remove wheel cylinder.
11.
Remove bearing holder fixing nuts.
12.
Take out axle shaft assembly with back plate and
set it on a bench press as following illustration.
Put bolt head on thick steel plate.

When axle shaft is extracted, since axle case oil
seal is damaged, axle case oil seal.
13.
Remove snap ring. Use snap ring pliers to
remove. Snap ring is prohibition of reuse.
14.
Remove shim (If so equipped)
15.
Remove sensor rotor (or spacer), double tape
r
roller bearing, oil seal, bearing holder, and back
plate from axle shaft by means of a press.

Discard used oil seal, double taper roller
bearing, snap ring, ABS sensor rotor and
spacer.
A03R300002
Legend

1.
Bench Press Fitting

2. Steel Plate (25-30 mm thickness)
3. Axle Shaft

16. Remove differential assembly fixing bolts and
nuts and take out differential assembly.
17.
Remove wheel pin from axle shaft, using the
remover 5-8840-0079-0.
420L100009
18.
Remove axle case oil seal.

Discard used oil seal.

4B-16 REAR AXLE

8.
Certainly install new snap ring, use snap ring pliers.
When transform or damage, replace new one.



RTW34BMH000101
Legend


1.
Snap ring

2.
Crevice
3.
Sensor rotor (with ABS)

Spacer (without ABS)


9.
Insert a shim of sufficient thickness between snap
ring and end of sensor rotor (or spacer).


Standard
0 
0.2 mm (0 
0.008 in)


Crevice is measured using thickness gauge, and
when crevice exceeds 0.2 (mm), it adjusts so that
is may become 0.2 (mm) or less using shim.


Shim Pats No.
Thickness

1 9-41519110-
0.18 mm (0.0071 in)

2 8-97130387-

0.50 mm (0.0197 in)


Crevice
No. of shim
Total

Mm (in)
1 2
mm (in)

1.0(0.0394) 
2
1.00(0.0394)

0.9(0.0354)
2
1
0.86(0.0339)

0.8(0.0315)
1
1
0.68(0.0268)

0.7(0.0276)
1
1
0.68(0.0268)

0.6(0.0236)

1
0.50(0.0197)

0.5(0.0197)

1
0.50(0.0197)

0.4(0.0158)
2 
0.36(0.0142)
0.3(0.0118)
1 
0.18(0.0071)
0.2(0.0079)
1 
0.18(0.0071)

10. Install axle shaft assembly in rear axle case
assembly.
Note:
When inserting an axle shaft, it inserts so that an
oil seal may not be damaged.
11. Install and tighten bearing holder fixing nut to the
specified torque.

Torque : 84 N
m (8.6 kg
m/62 lb
ft)
12. Install wheel cylinder and tighten the bolt to the
specified torque.

Torque : 9 N
m (0.9 kg
m/78 lb
ft)
13. Install parking brake outer cable in back plate and
inner cable in parking brake lever.

4B-18 REAR AXLE

17.
Install brake pipe and ABS sensor and tighten it to
the specified torque.

Torque :

ABS Sensor
8 N
m (0.8 kg
m/69 lb
ft)

Brake Pipe
16 N
m (1.6 kg
m/12 lb
ft)
420R30003

18.
Bleed brake pipe at the wheel cylinder. (Refer to
the section “Power-assisted Brake System”)
19.
Install brake drum.


Install propeller shaft. (Refer to Section “Rear
Propeller Shaft”.)


Refill differential oil.


Install wheel and tire.


Lower vehicle.

4C1-6 FRONT WHEEL DRIVE
RECOMMENDED LIQUID GASKET

Type Brand Name Manufacture Remarks

RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
Water Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer

Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacture's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying
the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater
than 0.25 mm (0.01 in). Poor adhesion will result.

RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.

LOCTITE 262

Red 2. Apply LOCTITE to the bolts.


LOCTITE 270

Green

LOCTITE 271

Red
3. Tighten the bolts to the specified torque.
4. Wait at least on hour before continuing the installation procedure.

FRONT WHEEL DRIVE 4C1-15

Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
3. Remove the stone guard.
4. Remove the brake caliper fixing bolt and hang the caliper.
Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front Wheel Speed Sensor in Brake section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to Front Propeller Shaft in
this section.
8. Loosen the height control arm of the torsion bar, then
remove the torsion bar from lower control arm.
Refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock absorber.

12. Remove the tie-rod end from the knuckle.
Refer to Power Steering Unit in Steering Section.
13. Disconnect the breather hose of the front axle.
14. Disconnect the actuator connector. (With shift on the fly)
15. Remove the bolts and nuts of the lower control arm (Frame
side), then disconnect the lower control arm from frame.
16. Disconnect between the right side upper control arm and
the knuckle, then remove the knuckle with lower control
arm.
CAUTION :
When removing the knuckle, be careful not to damage the
oil seal inside of the knuckle.

FRONT WHEEL DRIVE 4C1-17
NOTE :
Adjust the buffer clearance before tighten the bolts and nuts of
the lower control arm.

6. Install the breather hose of the front axle.
7. Install the actuator connector of the shift on the fly. (With
shift on the fly)
8. Install the tie-rod end of the power steering unit to the
knuckle, tighten the nut to the specified torque.
Torque : 98 N·m (10.0kg·m/73 lb ft)

9. Install lower bolts and nuts of the shock absorber, tighten it
to the specified torque.
Torque : 93 N·m (9.5kg·m/69 lb ft)
10. Install lower nuts of the stabilizer link, tighten it to the
specified torque.
Torque : 50 N·m (5.1kg·m/37 lb ft)
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the bearing
preload.
Refer to Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake
system.
16. Install the brake caliper. Tighten the bolt of the caliper
bracket to the specified torque.
Torque : 155 N·m (15.8kg·m/115 lb ft)
17. Install the stone guard.
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Steering section.
20. Tighten the bolts and nuts of the lower control arm to the
specified torque.
Refer to Lower Control Arm in Suspension section.

4C1-42 FRONT WHEEL DRIVE
FRONT HUB AND DISC
(4




2 Except High Ride Suspension Model)
DISASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure.

RTW34CLF000801
Disassembly Steps
1. Bolt


2. Brake caliper


3. Hub cap
4. Split pin
5. Nut retainer
6. Hub nut
7. Lock washer


8. Outer bearing


9. Hub and disc assembly
10. Oil seal
11. Inner bearing and outer race
12. ABS sensor rotor


13. Bolt


14. Wheel pin

FRONT WHEEL DRIVE 4C1-43
Important Operations
Before removal, jack up the front of vehicle and support frame
with jack stands.



2. Brake Caliper
(1) Remove the two bolts from the rear side of the knuckle arm,
then remove the brake caliper, with the brake hose
attached.
(2) Use a wire etc., for attaching the brake caliper to the uppe
r
link.
Refer to the section Brake.



3. Hub Cap
When removing hub cap, exercise care so as not to scratch or
distort hub fitting face.



9. Hub and Disc Assembly
Using a brass bar to remove the outer bearing outer race (1),
oil seal, inner bearing and inner bearing outer race (2) from the
hug.



If necessary, replace the wheel pin in the following manner.

13. Bolt
14. Wheel Pin ; Front Hub
(1) Scribe mark on hub to disc before disassembly to insure
proper assembly.
(2) Drive out the ABS sensor rotor using a metal bar and
hammer through the two bolt holes.

Discard the used ABS sensor rotor
Refer to the section Brake.