2004 ISUZU TF SERIES wheel alignment

MAINTENANCE AND LUBRICATION 0B-3
SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading

1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
TRANSMISSION OR TRANSMISSION
WITH TRANSFER CASE


* AT Automatic transmission fluid - - - I - - - I - - - I - - - I - - - I * AT Transfer case oil - R - I - - - R - - - I - - - R - - - I * Manual transmission fluid - R - I - - - R - - - I - - - R - - - I * Transfer case oil - - - I - - - | - - - I - - - | - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Gear control mechani sm for
looseness - - - I - - - I - - - I - - - I - - - I
PROPELLER SHAFT Loose connections - I - I - I - I - I - I - I - I - I - I * Universal joints and splines for wear
- I - I - I - I - I - I - I - I - I - I
4WD Universal joints and splines - L - L - L - L - L - L - L - L - L - L FRONT AND REAR AXLE * Differential gear oil (Front and rear) - R - I - - - R - - - I - - - R - - - I Oi l l eakage I I I I I I I I I I I I I I I I I I I I Shift on the fly system gear oil I - - I - - - I - - - I - - - I - - - I Front axle shaft rubber boot for
damage - - - I - - - I - - - I - - - I - - - I
Axle shafts for distortion or damage - - - I - - - I - - - I - - - I - - - I Axle case for distortion or damage - - - I - - - I - - - I - - - I - - - I STEERING Power steering fl ui d I I I I I I R I I I I I I R I I I I I I Oil leakage I I I I I I I I I I I I I I I I I I I I * Steering system for looseness or
damage - I - I - I - I - I - I - I - I - I - I
Power steering hose - I - I - I - I - I - I - R - I - I - I Steering wheel play I I I I I I I I I I I I I I I I I I I I Steeri ng function I I I I I I I I I I I I I I I I I I I I Right and left turning radius - - - I - - - I - - - I - - - I - - - I Wheel alignment - - - I - - - I - - - I - - - I - - - I Joint ball for oil leakage or damage - I - I - I - I - I - I - I - I - I - I Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I

0B-6 MAINTENANCE AND LUBRICATION




I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading or
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60months whichever comes
fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
PROPELLER SHAFT Loose connections (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Loose connections (4JA1-TC) - - I - - I - - I - - I - - I - - I - - * Universal joints and splines for wear (4JH1-TC) - I - I - I - I - I - I - I - I - I - I * Universal joints and splines for wear (4JA1-TC) - - I - - I - - I - - I - - I - - I - - 4WD Universal joints and sliding
sleeve (4JH1-TC) - L - L - L - L - L - L - L - L - L - L FRONT AND REAR AXLE * Differential gear oil (Front and rear) (4JH1-TC) - R - I - - - R - - - I - - - R - - - I * Differential gear oil (Front and rear) (4JA1-TC) - - R - - I - - R - - I - - R - - I - - Oil leakage (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Oil leakage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Shift on the fly system Gear oil (4JH1-TC) I - - I - - - I - - - I - - - I - - - I Gear oil (4JA1-TC) - - - - - - - - I - - - - - - - - I - - Front axle shaft rubber boot for
damage (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Front axle shaft rubber boot for
damage (4JA1-TC) - - - - - - - - I - - - - - - - - I - - Axle case for distortion or damage (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Axle case for distortion or damage (4JA1-TC) - - - - - - - - I - - - - - - - - I - - Axle shafts for distortion or damage (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Axle shafts for distortion or damage (4JA1-TC) - - - - - - - - I - - - - - - - - I - - STEERING Power steering fluid (4JH1-TC) I I I I I I R I I I I I I R I I I I I I Power steering fluid (4JA1-TC) - - - - - - - - - - - I - - - - - - - - Oil leakage (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Oil leakage (4JA1-TC) - - I - - R - - I - - R - - I - - R - - * Steering system for looseness or
damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I * Steering system for looseness or
damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Power steering hose (4JH1-TC) - I - I - I - I - I - I - R - I - I - I Power steering hose (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Steering wheel play (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Steering wheel play (4JA1-TC) - - I - - I - - I - - R - - I - - I - - Steering function (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Steering function (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Right and left turning radius (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Right and left turning radius (4JA1-TC) - - - - - - - - I - - - - - - - - I - - Wheel alignment (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Wheel alignment (4JA1-TC) - - - - - - - - I - - - - - - - - I - - Joint ball for oil leakage or damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Joint ball for oil leakage or damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Joint ball rubber boot for damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Joint ball rubber boot for damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - -

7B1-54 MANUAL TRANSMISSION

TROUBLESHOOTING
1. ABNORMAL NOISE

1) NOISY IN NEUTRAL

Checkpoint Trouble Cause Countermeasure

Replenish or replace the gear
oilInsufficient or improper gear
oil NG
Mainshaft splines
Synchronizer clutch hub
splinesReplace the main shaft and
the synchronizer clutch hub
Replace the gear(s)
Replace the flywheel pilot
Worn splines
Worn or scuffed gear tooth
contact surfaces
Flywheel pilot bearingWorn flywheel pilot bearing
Bearings (Mainshaft,
countershaft, and transfer
shaft)
Gears (Mainshaft,
countershaft, reverse idler
gear and transfer gears)
Replace the bearing(s)Worn or broken bearing(s)
OK
NG NG NG NG OK
OK
OK
Gear oil
TransmissionRealign the transmissionTransmission misalignment OK
NG

MANUAL TRANSMISSION 7B1-111

TROUBLESHOOTING
1. ABNORMAL NOISE

1) NOISY IN NEUTRAL

Checkpoint Trouble Cause Countermeasure

Replenish or replace the gear
oilInsufficient or improper gear
oil NG
Mainshaft splines
Synchronizer clutch hub
splinesReplace the main shaft and
the synchronizer clutch hub
Replace the gear(s)
Replace the flywheel pilot
Worn splines
Worn or scuffed gear tooth
contact surfaces
Flywheel pilot bearingWorn flywheel pilot bearing
Bearings (Mainshaft,
countershaft, and transfer
shaft)
Gears (Mainshaft,
countershaft, reverse idler
gear and transfer gears)
Replace the bearing(s)Worn or broken bearing(s)
OK
NG NG NG NG OK
OK
OK
Gear oil
TransmissionRealign the transmissionTransmission misalignment OK
NG

3A-2 FRONT ALIGNMENT

Front End Alignment Inspection and
Adjustment
General Description
“Front End Alignment” refers to the angular
relationshipbetween the front wheels, the front suspension
attachingparts and the ground.
Proper front end alignment must be maintained in order
toinsure efficient steering, good directional stability and
toprevent abnormal tire wear.
The most important factors of front end alignment arewheel
toe-in, wheel camber and axle caster.



Camber:
This illustration shows view from the front of the vehicle.
Camber is the vertical tilting inward or outward of the front
wheels. When the wheels tilt outward at the top, the camber is
positive (+). When the wheels tilt inward at the top, the camber
is negative (-). The amount of tilt measured in degrees from
the vertical is called the camber angle (1). If camber is extreme
or unequal between the wheels, improper steering and
excessive tire wear will result. Negative camber causes wear
on the inside of the tire, while positive camber causes wear to
the outside.

Caster:
This illustration shows view from the side of the vehicle.
Caster (1) is the vertical tilting of the wheel axis either
forward or backward (when viewed from the side of the
vehicle). A backward tilt is positive (+) and a forward tilt is
negative (-). On the short and long arm type suspension
you cannot see a caster angle without a special instrument, but
if you look straight down from the top of the upper control arm
to the ground, the ball joints do not line up (fore and aft) when
a caster angle other than 0 degree is present. With a positive
angle, the lower ball joint would be slightly ahead (toward the
front of the vehicle) of the upper ball joint center line.


Toe-in:
This illustration shows view from the top of the vehicle.
Toe-in is the measured amount the front wheels are turned in.
The actual amount of toe-in is normally a fraction of a degree.
Toe-in is measured from the center of the tire treads or from
the inside of the tires. The purpose of toe-in is to insure parallel
rolling of the front wheels and to offset any small deflections of
the wheel support system which occurs when the vehicle is
rolling forward. Incorrect toe-in results in excessive toe-in and
unstable steering. Toe-in is the last alignment to be set in
the front end alignment procedure.

FRONT ALIGNMENT 3A-3

Inspection
Before making any adjustments affecting caster, camber or
toe-in, the following front end inspection should be made.
1. Inspect the tires for proper inflation pressure. Refer to
Main Data and Specifications in Wheel and Tire System
section.
2. Make sure that the vehicle is unlade condition (Withno
passenger or loading).
3. Make sure that the spare tire is installed at the normal
position.
4. Inspect the front wheel bearings for proper adjustment.
Refer to Front Hub and Disc Overhaul in Suspension
section.
5. Inspect the ball joints and tie rod ends. If excessive
looseness is noted, correct before adjusting. Refer to
Steering Linkage in this section.
6. Inspect the wheel and tires for run-out. Refer to Wheel
Replacement in Wheel and Tire System section.
7. Inspect the trim height. If not within specifications, the
correction must be made before adjusting caster.
8. Inspect the steering unit for looseness at the frame.
9. Inspect shock absorbers for leaks or any noticeable noise.
Refer to Shock Absorber in Suspension section.
10. Inspect the control arms or stabilizer bar attachment fo
r
looseness. Refer to Suspension section.
11. Inspect the front end alignment using alignment equipment.
Follow the manufacturer’s instructions.
12. Park the vehicle on a level surface.

3A-8 FRONT ALIGNMENT




Toe-in Adjustment
Measurement should be taken with the vehicle on a surface
plate.
If a surface plate is not available, toe-in should be checked
with the vehicle parked on a level floor.
1. Set front wheels to straight ahead position.
2. Align the toe-in gauge with center height of each wheel a
t
front end.
3.
Apply center marks to each wheel, then take measurement
of distance A between the center marks on each wheel.
4. Slowly move the vehicle rearward until the center marks
reach the rear end position.
5. Take measurement of distance B between the cente
r
marks at rear end.
The toe-in can be calculated with next formula.
Toe-in = B - A
Toe-in mm (in)

4

2
(Except high ride suspension) 0
2 (0
0.08)





To adjust the toe-in angle, loosen the lock nuts (2) on the tie
rod (1) and turn the tie rod. Turn both rods the same amount,
to keep the steering wheel centered.
Lock Nut Torque N
m (kgf
m/lb
ft)
986.0 (10.00.6 / 72.34.3)

RTW330SH000101

Trim Height
Trim Height : at Curb Weight (Reference Data)
Trim height (Z) = A - B
Front mm (in)

Z
105(4.13)

FRONT ALIGNMENT 3A-9

RTW340SH001301-X

FRT Buffer clearance (Reference Data)

4
2 (Except high ride suspension)
25.9(1.02)


RTW340SH000101-X

RR Buffer clearance (Reference Data) mm(in)

4

2 (Except high ride suspension)
82.1 (3.23)



MAXIMUM STEERING ANGLE

4

2 (Except high ride suspension)
Outside wheel 33.5

Inside wheel 37.1