2004 ISUZU TF SERIES Check ball

3C-20 FRONT SUSPENSION
5. Remove nut (8).
6. Remove upper ball joint by using remover 5-8840-
2017-0.
CAUTION: Be careful not to damage the ball joint
boot.

P1010005
7. Remove nut (3).
8. Remove bolt(1).
9. Remove bolt (10) and nut (9).
10. Remove upper ball joint.
11. Remove upper control arm assembly.
12. Remove bushing.
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
Installation
1. Install bushing by using installer 5-8840-0257-0
and 5-8840-2327-0.


P1010062
2. Install upper ball joint and tighten it to the specified
torque (9).
Torque: 31 N






m (3.2kg






m/23 lb ft)
3. Install nut (6) and cotter pin then tighten the nut to the specified torque, with just enough additional
torque to align cotter pin holes. Install new cotte
r
pin.
Torque: 98 N






m (10.0kg







m/72 lb ft)
4. Install upper control arm assembly.
5. Install bolt (1) and nut (3).
NOTE: Apply oil to the thread.
NOTE: Tighten the bolt (1) with the parts in the position
shown in the illustration below.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137 N






m (14.0kg






m/101 lb ft)





RTW340SH001301-X
6. Install nut (12).
7. Install nut (11).

3C-22 FRONT SUSPENSION
4. Support lower control arm with a jack.
5. Remove the nut (10).
6. Remove the nut (8).
7. Remove the shock absorber lower end from the
lower control arm.
8. Remove the lower ball joint from the lower control arm.
9. Remove nut (4) and cam plate.
10. Remove cam bolt.
11. Remove lower control arm.
12. Remove bushing.
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:


Lower control arm


Bushing
Installation
1. Install rear bushing by using installer 5-8840-
0257-0 and 5-8840-2327-0.


P1010063
2. Install lower control arm.
3. Install cam bolt.
4. Install lower ball joint and tighten it to the specified
torque (9).
Torque: 127 N






m (12.9kg






m/94 lb ft)
5. Install shock absorber and tighten it to the specified torque (5).

NOTE: Apply oil to the thread.
NOTE: Tighten the nut (4) with the parts in the position
shown in the illustration below.
Torque: 137 N






m (14.0kg






m/101 lb ft)




RTW340SH001301-X
6. Install stabilizer link and tighten it to the specified
torque (10).
Torque: 50 N






m (5.1kg






m/37 lb ft)
7. Install nut (4) and cam plate and tighten lower link nut finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut (4) with the parts in the position
shown in the illustration below.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 186 N






m (19.0kg






m/137 lb ft)





RTW340SH001301-X
8. Install nut (8) and cotter pin then tighten the nut to
the specified torque, with just enough additional
torque to align cotter pin holes. Install new cotte
r

3C-32 FRONT SUSPENSION

Stabilizer Bar
Stabilizer Bar and Associated Parts


RTW340MF000401
Legend

(1)
Rubber Bushing

(2)
Bracket and Bolt
(3) Link



(4)
Nut
(5) Stabilizer Bar
(6) Nut

Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove the stone guard.
3. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.
4. Remove nut (4) and (6).
CAUTION: Be careful not to break the ball joint
boot.
5. Remove link.
6. Remove bracket.
7. Remove stabilizer bar.
8. Remove rubber bushing.

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 :


Stabilizer bar


Rubber bushing


Link ball joint

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.

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

3C-46 FRONT SUSPENSION

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:


Lower control arm


Bushing
Installation
1. Install rear bushing by using installer 5-8840-2124-
0.



Front
901RW053
2. Install front bushing by using installer 5-8840-
2123-0.



Front
901RW156



3. Install lower ball joint bolt.
4. Install torsion bar arm bolt.
5. Install lower control arm.
6. Install rear bolt.
7. Install cam bolt the hole and projection are
upward.
8. Install lower ball joint and tighten it to the specified
torque (12).
Torque: 127 N




m (12.9kg




m/94 lb ft)
9. Install shock absorber and tighten it to the
specified torque (13).
Torque: 93 N




m (9.5kg




m/69 lb ft)
10. Install stabilizer link and tighten it to the specified
torque (14).
Torque: 50 N




m (5.1kg




m/37 lb ft)
11. Install torsion bar arm bracket and tighten it to the
specified torque.
Torque: 116 N





m (11.8kg





m/85 lb ft)
12. Install Torsion bar, refer to Torsion Bar in this
section.
13. Install rear nut and tighten lower link nut finger-
tight (4).
NOTE: Apply oil to the thread.
NOTE: Tighten the nut or bolt with the parts in the
position shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 235 N




m (24.0kg




m/174 lb ft)



450R100002

3C-54 FRONT SUSPENSION
TROUBLESHOOTING
1. VIBRATION, SHOCK, AND SHIMMY OF STEERING WHEEL

Checkpoint Trouble Cause Countermeasure



Check front axle


Check wheel alignment


Check suspension ball joint


Check shock absorber or
attaching nut and bolt


Replace


Adjust


Replace


Replace or retighten


Check steering unit and
linkage


Faulty


Worn


Malfunction or loose


Check upper and lower link
bushings
Replace


Adjust


Worn


Incorrect

OK OK OK
NG NG NG NG NG NG
OK OK
Check vehicle trim height





Improperly adjusted or worn front
wheel bearing.


Worn or incorrectl
y adjusted wheel
bearing.
Replace; refer to Section 4C "Front
Wheel Drive"


Insufficientl
y tightened steeringgear housing.


Wear of steering linkage.


Excessive backlash due to
improper ad
justment of the steeringgear box.

Worn column bearing weakened
column bearing spring, or loose
clamp.
Replace; refer to Section 3B
"Steering"


Improper tire pressure.

Imbalance and deformation of frond
wheel.


Unevenl
y worn tire or insufficient
tightening of wheel nuts.
Replace; refer to Section 3E "Wheel
and Tires"

3C-58 FRONT SUSPENSION
4. STIFF STEERING WHEEL

Checkpoint Trouble Cause Countermeasure



Steering gear box or steering
linkage


Steering linkage


Steering gear


Wheel alignment


Replace the part


Replace


Replace


Adjust

Insufficient lubricants or
impurities present; or
excessively worn

Deformed


Worn or damaged


Incorrect


Replace

Stiff or damaged or lack of
grease

OK OK OK OK OK
NG NG NG NG NG
OK
Upper and ball joint


Steering column with turn
signal switch

Replace

Interference abrasion
NG

Tire pressure

Adjust

Improper
NG