2004 ISUZU TF SERIES torque

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-28 FRONT SUSPENSION

Bump Rubber
Bump Rubber and Associated Parts
RTW340LF002601
Legend

(1)
Bolt



(2)
Bump Rubber


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove bolt.
3. Remove bump rubber.
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 :


Bump Rubber
Installation
1. Install bump rubber.
2. Install bolt (1), then tighten it to the specified
torque.
Torque: 42 N




m (4.3kg




m/31 lb ft)

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)

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




m/18 lb ft)
4. Install link.
5. Install nut (4), (6), then tighten it to the specified
torque.
Torque: 50 N





m (5.1kg





m/37 lb ft)

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.

3C-42 FRONT SUSPENSION

Installation
1. Install fulcrum pin.
2. Install bushing by using installer 5-8840-0256-0
and 5-8840-2307-0.


RTW340SH000701



RTW340SH000801
3. Install upper ball joint and tighten it to the specified
torque (12).
Torque: 57 N




m (5.8kg




m/42 lb ft)
4. 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 (11).
Torque: 98 N




m (10.0kg




m/72 lb ft)
5. Install plate (8).

6. Install nut (9) and tighten fulcrum pin nut finger-
tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut with the parts in the position
shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 108 N




m (11.0kg




m/80 lb ft)


450R100002
7. Install upper control arm assembly with the fulcrum
pin projections turned inward.


RTW340SH000901

Legend
(1) Projection
(2) Outward

8. Install the caster shims (2) between the chassis

FRONT SUSPENSION 3C-43

frame and fulcrum pin.
9. Install the camber shims (1) between the chassis
frame and fulcrum pin.





450R100004
10. Install nut assembly.
11. Install bolt and plate (1), then tighten the bolt to the
specified torque.
Torque: 152 N




m (15.5kg




m/112 lb ft)
NOTE: Apply oil to the thread.
12. Install speed sensor harness.