2004 ISUZU TF SERIES air suspension

3C-30 FRONT SUSPENSION


FRONT SUSPENSION
(4





2 High Ride Suspension, 4





4)
CONTENTS

Service Precaution............................................. 3C - 29
Shock Absorber ................................................. 3C - 30
Shock Absorber and Associated Parts ........... 3C - 30
Removal ......................................................... 3C - 30
Inspection and Repair..................................... 3C - 30
Installation....................................................... 3C - 30
Stabilizer Bar ..................................................... 3C - 31
Stabilizer Bar and Associated Parts ............... 3C - 31
Removal ......................................................... 3C - 31
Inspection and Repair..................................... 3C - 31
Installation....................................................... 3C - 32
Torsion Bar ........................................................ 3C - 33
Torsion Bar and Associated Parts .................. 3C - 33
Removal ......................................................... 3C - 33
Inspection and Repair..................................... 3C - 34
Installation....................................................... 3C - 34
Knuckle .............................................................. 3C - 36
Knuckle and Associated Parts........................ 3C - 36
Removal ......................................................... 3C - 36
Inspection and Repair..................................... 3C - 38
Installation....................................................... 3C - 38
Upper Control Arm ............................................. 3C - 39
Upper Control Arm and Associated Parts ...... 3C - 39
Removal ......................................................... 3C - 39

Inspection and Repair..................................... 3C - 40
Installation ...................................................... 3C - 41
Lower Control Arm ............................................. 3C - 43
Lower Control Arm and Associated Parts ...... 3C - 43
Removal ......................................................... 3C - 44
Inspection and Repair..................................... 3C - 45
Installation ...................................................... 3C - 45
Upper Ball Joint ................................................. 3C - 47
Upper Ball Joint and Associated Parts ........... 3C - 47
Removal ......................................................... 3C - 47
Inspection and Repair..................................... 3C - 48
Installation ...................................................... 3C - 48
Lower Ball Joint ................................................. 3C - 49
Lower Ball Joint and Associated Parts ........... 3C - 49
Removal ......................................................... 3C - 49
Inspection and Repair..................................... 3C - 50
Installation ...................................................... 3C - 50
Bump Rubber .................................................... 3C - 51
Bump Rubber and Associated Parts .............. 3C - 51
Removal ......................................................... 3C - 51
Inspection and Repair..................................... 3C - 51
Installation ...................................................... 3C - 51
Special Tools .................................................... 3C - 52



Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.



CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners o
r
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

FRONT SUSPENSION 3C-31

Shock Absorber
Shock Absorber and Associated Parts
RTW340MF000901
Legend

(1)
Nut

(2)
Rubber Bushing and Washer

(3) Bolt and Nut

(4)
Shock Absorber
(5) Rubber Bushing and Washer


Removal
1. Raise the vehicle and support it with suitable
safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.
3. Remove bolt and nut.
4. Remove nut.
5. Remove rubber bushing and washer.
6. Remove shock absorber.
7. Remove rubber bushing and washer.
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 :


Shock absorber


Rubber bushing
Installation
1. Install rubber bushing and washer.
2. Install shock absorber.
3. Install rubber bushing and washer.
4. Install nut (1), then tighten it to the specified
torque.
Torque: 20 N




m (2.0kg




m/14 lb ft)
5. Install bolt and nut (3), then tighten to the specified
torque.
Torque: 93 N




m (9.5kg




m/69 lb ft)

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-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

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

FRONT SUSPENSION 3C-49

CAUTION: Be careful not to damage the ball joint
boot.


RTW340SH000401
4. Remove bolt and nut.
5. Remove upper ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.


Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.


Inspect screw/taper area of ball for damage.


If any defects are found by the above inspections,
replace the ball joint assembly with new one.





450RS023



After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 1.3–3.2 N




m (0.13-0.33kg




m/0.9-
2.4 lb ft)







450RS024
If the above limits specified are exceeded, replace the
ball joint assembly.
Installation
1. Install upper ball joint.
2. Install bolt and nut (1), then tighten them to the
specified torque.
Torque: 57 N




m (5.8kg




m/42 lb ft)
3. Install nut and cotter pin, then tighten the nut to the
specified torque with just enough additional torque
to align cotter pin holes. Install new cotter pin (3).
Torque: 98 N




m (10.0kg




m/72 lb ft)