2004 ISUZU TF SERIES boot

FRONT SUSPENSION 3C-25

P1010005
5. Remove bolt (1) and nut (3).
6. 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.




450R300030


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 (1) and nut (3), then tighten them to the specified torque.
Torque: 31N






m (3.2kg






m/23 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 (4).
Torque: 98 N






m (10.0kg







m/72 lb ft)
4. Install nut (5), then tighten to the specified torque. Torque: 50 N






m (5.1kg






m/37 lb ft)

FRONT SUSPENSION 3C-27
CAUTION: Be careful not to damage the ball joint
boot.


P1010003
6. Remove nut (3).
7. Remove bolt (5).
8. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition 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.





450RS026

After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 2.5-6.4 N






m (0.26-0.65kg






m/1.9-
4.7 lb ft)






450RS024


If the above limits specified are exceeded, replace
the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install bolt (5).
3. Install nut (3) and tighten it to the specified torque. Torque: 127 N






m (12.9kg






m/94 lb ft)
4. Install ball joint nut, then tighten it 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)
5. Install nut (4), then tighten to the specified torque. Torque: 50 N






m (5.1kg






m/37 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

3C-38 FRONT SUSPENSION

4. Remove the hub assembly. Refer to Front Hub
and Disk in this section.
5. Remove tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
6. Remove the speed sensor from the knuckle.
7. Loosen torsion bar by height control arm adjust
bolt, then remove torsion bar. Refer to Torsion Ba
r
in this section.
8. Remove speed sensor harness.
9. Remove back plate.
10. Remove lower ball joint by using remover 5-8840-
2005-0.
CAUTION: Be careful not to damage the ball joint
boot.



901RW271

11. Remove upper ball joint by using remover 5-8840-
2121-0.
CAUTION: Be careful not to damage the ball joint
boot.

901RW272
12. Remove knuckle assembly.
13. Remove oil seal. If replacement required.
(4
4 Model Only)
14. Remove washer. If replacement required.
(4
4 Model Only)
15. Remove needle bearing by using remover 5-8840-
2000-0 and sliding hammer 5-8840-0019-0.
If replacement required. (4
4 Model Only)





(4

4 Model Only)
RTW340SH00401

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

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)

FRONT SUSPENSION 3C-51

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




901RW271
7. Remove nut.
8. Remove bolt.
9. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition 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.




450RS026


After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 2.5-6.4 N




m (0.25-0.65kg




m/1.8-
4.7 lb ft)






450RS024


If the above limits specified are exceeded, replace
the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install bolt.
3. Install nut (3) and tighten it to the specified torque.
Torque: 127 N




m (12.9kg




m/94 lb ft)
4. Install ball joint nut, then tighten it to the specified
torque with just enough additional torque to align
cotter pin holes. Install new cotter pin (4).
Torque: 147 N




m (15.0kg




m/108 lb ft)