2004 ISUZU TF SERIES section 8

3C-40 FRONT SUSPENSION

Upper Control Arm
Upper Control Arm and Associated Parts


RTW440LF001301
Legend
(1)Bolt and Plate
(2)Camber Shims
(3)Caster Shims
(4)Nut Assembly
(5)Upper Control Arm Assembly
(6)Fulcrum Pin


(7)Bushing
(8)Plate
(9)Nut
(10)Speed Sensor harness
(11)Nut and Cotter Pin
(12)Upper Ball Joint, Bolt and Nut


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
in this section.
3. Remove the brake caliper and disconnect brake
pipe. Refer to Disc Brakes in Brake section.

FRONT SUSPENSION 3C-45

Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
in this section.
3. Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle
driving shaft to release the shaft from hub. Refer to
Front Hub and Disc in Driveline/Axle section.
5. Support lower control arm with a jack.
6. Remove cam plate and nut.
7. Remove rear nut.
8. Remove torsion bar, refer to Torsion Bar in this
section.
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control
arm.
11. Remove the shock absorber lower end from the
lower control arm.
12. Remove the lower ball joint from the lower control
arm.
13. Remove cam bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover 5-8840-
2123-0.



Front
901RW154



Front
901RW155
19. Remove rear bushing by using remover 5-8840-
2124-0.


Front
901RW051




Front
901RW052

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-47

14. Install cam plate and nut then tighten lower link nut
finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut (3) or bolt with the parts in the
position shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 186 N




m (19.0kg




m/137 lb ft)
NOTE: Adjust the trim height. Refer to Front En
d
Alignment Inspection and Adjustment in Steering
section.



450R100002

3C-50 FRONT SUSPENSION

Lower Ball Joint
Lower Ball Joint and Associated Parts


RTW340LF001601
Legend

(1)
Bolt

(2)
Lower Ball Joint


(3) Nut

(4)
Nut and Cotter Pin


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
in this section.
3. Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle
driving shaft to release the shaft from hub. Refer to
Front Hub and Disc in Driveline/Axle section.
5. Support lower control arm with a jack.
6. Remove lower ball joint nut and cotter pin, then
use remover 5-8840-2005-0 to remove the lowe
r
ball joint from the knuckle.

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"

REAR SUSPENSION 3D-1
SECTION 3D
REAR SUSPENSION
TABLE OF CONTENTS
PAGE
Main Data and Specifications...........................................................................................3D- 2
Torque Specifications........................................................................................................ 3D- 3
Rear Suspension................................................................................................................3D- 4
General Description ...................................................................................................... 3D- 4
Leaf Spring and Shock Absorber ..................................................................................... 3D- 5
Leaf Spring and Associated Parts ............................................................................... 3D- 5
Removal .........................................................................................................................3D- 6
Inspection and Repair ................................................................................................... 3D- 7
Installation ..................................................................................................................... 3D- 8
Leaf Spring Assembly ....................................................................................................... 3D- 9
Disassembly .................................................................................................................. 3D- 9
Inspection and Repair ................................................................................................... 3D- 9
Reassembly ................................................................................................................... 3D- 10
Troubleshooting................................................................................................................. 3D- 11

WHEELS AND TIRES 3E-1

SECTION 3E
WHEELS AND TIRES
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 3E- 2
Torque Specifications ....................................................................................................... 3E- 3
Special Parts Fixing Nuts and Bolts ............................................................................ 3E- 3
Wheels and Tires ...............................................................................................................3E- 4
General Description ...................................................................................................... 3E- 4
Servicing ........................................................................................................................ 3E- 6
Disassembly and Reassembly ..................................................................................... 3E- 7
Inspection and Repair................................................................................................... 3E- 8
Troubleshooting ................................................................................................................3E- 10