2004 ISUZU TF SERIES Workshop Manual

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Page 3521 of 4264

ISUZU TF SERIES 2004 Workshop Manual FRONT SUSPENSION 3C-29

Special Tools (4

2 Except High Ride Suspension)

ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION
PART NO.
PART NAME

5-8840-0595-0
Support; fixture 5-8840-2327

Page 3522 of 4264

ISUZU TF SERIES 2004 Workshop Manual 3C-30 FRONT SUSPENSION

FRONT SUSPENSION
(4

2 High Ride Suspension, 4

4)
CONTENTS

Service Precaution............................................. 3C - 29
Shock Absorber ........

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.

Page 3523 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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

Page 3524 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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

Page 3525 of 4264

ISUZU TF SERIES 2004 Workshop Manual FRONT SUSPENSION 3C-33

Installation
1. Install rubber bushing.
2. Install stabilizer bar.
3. Install bracket and bolt (2), then tighten it to the
specified torque.
Torque: 25 N
m (2.5kg

Page 3526 of 4264

ISUZU TF SERIES 2004 Workshop Manual 3C-34 FRONT SUSPENSION
Torsion Bar
Torsion Bar and Associated Parts

RTW340MF000501
Legend
(1)
Adjust Bolt, End Piece and Seat
(2)
Height Control Arm

(3) Tors

Page 3527 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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

Page 3528 of 4264

ISUZU TF SERIES 2004 Workshop Manual 3C-36 FRONT SUSPENSION

Rubber seat

2.
Apply grease to the portion that fits into the bracket
then install height control arm and align the setting
marks (2).

410RS005
3. Apply

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