2004 ISUZU TF SERIES ECU

REAR AXLE 4B-35

Reassembly
1. Install side gear with thrust washer in differential
cage.
2. Install the pinion gear by engaging it with the side
gears while turning both pinion gears
simultaneously in the same direction.


425RS048

3. Install cross pin.


Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the
differential cage.




425RS049

4. Check the amount of backlash.
Backlash between the side gear and the pinion
gear. mm (in)

0.13-0.18 (0.005-0.007)
If the backlash is beyond the limits, adjust with a thrust
washer of selected thickness.
Thicknesses of thrust washers available.
Backlash mm (in
)

0.80
(0.031)0.90
(0.035)1.00
(0.039) 1.10
(0.043) 1.20
(0.047)1.30
(0.051)





425RY00008

5. Install lock pin.
After lock pin installation, stake the case to
secure the lock pin.
6. Install ring gear.
Refer to “Ring gear replacement” on this section.

4C1-16 FRONT WHEEL DRIVE
17. Support the differential case by the jack.
18. Remove the front axle mounting bolts and nuts, lower the
jack slowly. Remove the left side drive shaft end from the
knuckle, then lower the axle assembly from the vehicle.
CAUTION :
1. During the work, be sure that the axle assembly is
supported securly.
2. Be careful not to damage the bellows of the power
steering unit by interference.
3. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.


Installation
1. Support the differential case by the jack.
2. Jack up the front drive axle assembly, install the left side
drive shaft to the knuckle, then install the mount bolts and
nuts.
CAUTION :
1. Be careful not to damage the bellows of the power
steering unit by interference.
2. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.
3. When installing the drive shaft to the knuckle, be
careful not to damage the oil seal inside of the knuckle.

RTW34CSH000101
3. Tighten the mounting bolts and nuts to the specified torque.
Torque : 169 N·m (17.2kg·m/124 lb ft)



4. Install the right side knuckle with lower control arm to the
upper control arm.
Refer to Knuckle in Suspension section.
CAUTION :
When insert the drive shaft to the knuckle, be careful not
to damage the oil seal inside of the knuckle.

5. Align the bolt hole of the lower control arm, install the bolts
and nuts.

4C1-22 FRONT WHEEL DRIVE

Legend
1. UJ Case
2. Bellows



8. Install band. Note the setting direction. After installation,
check Standard Caulk Measure.
Discard the used band and install a new one.
Use the special tool pliers 5-8840-2745-0 to caulk the band
to the specified value.
For both sides on UJ bellows.





Standard Caulk Measure

1.2mm (0.05in) <= (1), (2) <= 4.0mm (0.16in)

(1) - (2) or (2) - (1) <= 0.4mm (0.016in)
9. Install another bellows and fix band.
Discard the used band and install a new one.
10. Install the ball guide with the smaller diameter side ahead
onto the shaft.
11. Install ball retainer.

12. Using snap ring pliers, install the snap ring (1) securing the
ball retainer to the shaft.
Discard the used snap ring and install a new one.

BRAKE CONTROL SYSTEM 5A-3

DTC C0235 (Flash Code 35) Rear Left Wheel Speed Sensor Short Circuit or
Circuit Open .................................................................................................................... 5A-62
DTC C0236 (Flash Code 36) Rear Left Wheel Speed Sensor Incorrect Signal ............. 5A-64
DTC C0237 (Flash Code 37) Rear Left Wheel Speed Sensor Signal - Tooth
Chipping ........................................................................................................................... 5A-66
DTC C0238 (Flash Code 38) Tire Diameter Error ............................................................. 5A-68
DTC C0241 (Flash Code 41) Front Right Isolation Solenoid Circuit Open or
Shorted to Ground ........................................................................................................... 5A-69
DTC C0242 (Flash Code 42) Front Right Dump Solenoid Circuit Open or Shorted
to Ground.......................................................................................................................... 5A-69
DTC C0243 (Flash Code 43) Front Right Isolation Solenoid Circuit Shorted to
Battery............................................................................................................................... 5A-69
DTC C0244 (Flash Code 44) Front Right Dump Solenoid Circuit Shorted to
Battery............................................................................................................................... 5A-69
DTC C0245 (Flash Code 45) Front Left Isolation Solenoid Circuit Open or
Shorted to Ground ........................................................................................................... 5A-71
DTC C0246 (Flash Code 46) Front Left Dump Solenoid Circuit Open or Shorted
to Ground.......................................................................................................................... 5A-71
DTC C0247 (Flash Code 47) Front Left Isolation Solenoid Circuit Shorted to
Battery............................................................................................................................... 5A-71
DTC C0248 (Flash Code 48) Front Left Dump Solenoid Circuit Shorted to
Battery............................................................................................................................... 5A-71
DTC C0251 (Flash Code 51) Rear Isolation Solenoid Circuit Open or Shorted to
Ground .............................................................................................................................. 5A-73
DTC C0252 (Flash Code 52) Rear Dump Solenoid Circuit Open or Shorted to
Ground .............................................................................................................................. 5A-73
DTC C0253 (Flash Code 53) Rear Isolation Solenoid Circuit Shorted to Battery ......... 5A-73
DTC C0254 (Flash Code 54) Rear Dump Solenoid Circuit Shorted to Battery .............. 5A-73
DTC C0265 (Flash Code 65) Fail Safe Relay (FSR) Shorted to Ground ......................... 5A-75
DTC C0266 (Flash Code 66) Fail Safe Relay (FSR) Shorted to Battery.......................... 5A-75
DTC C0267 (Flash Code 67) ABS Motor Shorted to Ground .......................................... 5A-77
DTC C0268 (Flash Code 68) ABS Motor Shorted to Battery ........................................... 5A-77
DTC C0271 (Flash Code 71) ECU Failure or Valve +B Circuit Open .............................. 5A-79
DTC C0274 (Flash Code 74) ABS Operation Long Time ................................................. 5A-80
DTC C0276 (Flash Code 76) G-Sensor Malfunction ........................................................ 5A-82

5A-28 BRAKE CONTROL SYSTEM

Isolation Valve Test
Purpose: The purpose of this test is to detect brake
pipe and valve line harness wire for wrong connections
and valve trouble.
This test will help you confirm the result of your repair
service including the removal/reinstallation of brake
pipe, valve line harness and valve.
Test conditions: The ignition key is in the “ON” position
with the four wheels lifted up. The brake pedal is
stepped on, released and stepped on again with the
parking brake released.
Test procedure:
1. Connect Tech 2 with the vehicle, and select
Actuaor Test from the menus.
2. Select a Solenoid Valve Test Menu from the
Actuaor Test Menus.

060L300002
3. Select Isolation Valve from the Valve Select Menus.
4. Step on the brake pedal.
5. Release the brake pedal.
6. Make sure that the Isolation Valve “ON” aimed at by
Tech 2 and the wheel locked position are the same.
If different, check brake pipe, valve line harness
wiring and H/UNIT. Repair is needed if abnormality
is found.
7. Conduct Step 2 through Step 5 above on all the
four wheels.

060L300002
CAUTION: When conducting this test, please
observe the following cautions.

1. Do not start the engine.
2. Lift up the vehicle at a level floor.





Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
5. Do not load the vehicle.





When lifting up the vehicle, be sure to
observe the lifting up points. Refer to
vehicle lifting points in 0A section.

BRAKE CONTROL SYSTEM 5A-29

Dump Valve Test
Purpose: The purpose of this test is to detect brake
pipe and valve line harness wire for wrong connections
and valve trouble.
This test will help you confirm the result of your repai
r
service including the removal/reinstallation of brake
pipe, valve line harness and valve.
Test conditions: The ignition key is in the “ON” position
with the four wheels lifted up. The brake pedal is
stepped on, released and stepped on again with the
parking brake released.
Test procedure:
1. Connect Tech 2 with the vehicle, and select
Actuator Test Function from the menus.
2. Select a Solenoid Valve Test Menu from the
Actuator Test Menus.

060L300002
3. Select Dump Valve from the Valve Select Meuns.
4. Step on the brake pedal.
5. Make sure that the Dump Valve “ON” aimed at by
Tech 2 and the wheel released position are the
same. If different, check brake pipe, valve line
harness wiring and H/UNIT. Repair is needed if
abnormality is found.
6. Conduct Step 2 through Step 5 above on all the
four wheels.

060L300002
CAUTION: When conducting this test, please
observe the following cautions.

1. Do not start the engine.
2. Lift up the vehicle at a level floor.





Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
5. Do not load the vehicle.





When lifting up the vehicle, be sure to
observe the lifting up points. Refer to
vehicle lifting points in 0A section.

BRAKE CONTROL SYSTEM 5A-31

Warning Lamp System Control Main Items DTC
(Flash
Code) Description
ABS Brake
(EBD)ABS EBD
C0248
(48) Front Left Dump Solenoid Circuit
Shorted to Battery



Solenoid (EHCU)
C0251
(51) Rear Isolation Solenoid Circuit Open or
Shorted to Ground



Solenoid (EHCU)
C0252
(52) Rear Dump Solenoid Circuit Open or
Shorted to Ground



Solenoid (EHCU)
C0253
(53) Rear Isolation Solenoid Circuit Shorted
to Battery



Solenoid (EHCU)
C0254
(54) Rear Dump Solenoid Circuit Shorted to
Battery



Solenoid (EHCU)
C0265
(65) Fail Safe Relay (FSR) Shorted to
Ground



Motor (EHCU)
C0266
(66) Fail Safe Relay (FSR) Shorted to
Battery



Relay (EHCU)
C0267
(67) ABS Motor Shorted to Ground



Motor (EHCU)
C0268
(68) ABS Motor Shorted to Battery



Motor (EHCU)
C0271
(71) ECU Failure or Valve +B Circuit Open



EHCU
C0274
(74) ABS Operation Long Time



EHCU

C0276
(76) G-Sensor Malfunction



Sensor or Wiring




Battery, Wiring or EHCU
(less than 9V) C0277
(77) Power Supply Low Input




Battery or Wiring
(less than 10V)
C0278
(78) Power Supply High Input



Battery or Wiring EHCU
C0282
(82) 4 Wheel Drive State Input Signal Failure



Wiring
C0285
(85) Assembly Error (G-sensor)



Vehicle (Sensor or EHCU)

*A : When three or more failure are detected, or when
failure containing both front wheels and each rear
wheels are detected, EBD warning lamp is "ON"
and control is canceled.
*B : ABS lamp is “OFF” when the ABS lamp is “ON”
after a repair until vehicles speed becomes more
than 6km/h (4mph) in the following ignition cycle
and failure is not detected.

BRAKE CONTROL SYSTEM 5A-79

DTC C0271 (Flash Code 71) ECU Failure or Valve +B Circuit Open



RTW45AMF000201

Step Action
Value(s) Yes No
1 Was the “Basic Diagnostic Flow Chart” performed?
- Go to Step 2 Go to Basic
Diagnostic
Flow Chart
2 1. Ignition “OFF”.
2. Check the EHCU circuit for an open, short to
ground, or short to voltage. Also, check the EHCU
ignition feed circuit for an open or short to ground
and the EHCU ground circuit for an open or short to
voltage.
3. If a problem is found, repair as necessary.
Was a problem found?
- Verify repair Go to Step 3
3 1. Ignition “ON,” engine “OFF.”
2. Select “Display DTCs” with the Tech 2.
Note: Perform the various tests (actuator test, test
run, brake test, etc.) then observe the DTC with a
Tech2.
Are any DTCs stored? - Go to Step 4 Verify repair
4 Replace EHCU.
Note : Check the EHCU type for specification, when
the EHCU is replaced.
(Specification ; 2WD model or 4WD model)
Was the action complete? - Verify repair -