2004 ISUZU TF SERIES lock

3B-60 POWER-ASSISTED STEERING SYSTEM

9. Turn the SRS coil counter clockwise to full, return
about 3 turns and align the neutral mark. (with SRS
air bag)
CAUTION: When turning the SRS coil counte
r
clockwise to full, stop turning if resistance is felt.
Forced further turning may damage to the cable in
the SRS coil.
826RW014
10. When installing the steering column cover, be sure to
route each wire harness as illustrated so that the
harnesses do not catch any moving parts.
825RW017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness

11. Install steering wheel and align the setting marks
made when removing.
Refer to the adjustment method in case a mark is
not attached in this section.
NOTE: Confirm SRS and Horn harness connector is
fixed by the steering wheel.
RTW33BSH000601

CAUTION: Never apply force to the steering wheel in
direction of the shaft by using a hammer or othe
r
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
12. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 31 - 39 N




m (3.2 – 4.0 kg




m/23 - 29 lb ft)
13. Support the module and carefully connect the
module connector and horn lead, then install inflato
r
module.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of inflator to prevent lead
wire from being pinched.
14. Tighten bolts to specified torque.
Torque: 2 - 4 N




m (0.2 – 0.4 kg




m/17 - 35 lb in)
15. Install driver knee bolster (reinforcement).
16. Install instrument panel lower cover.
17. Install the engine hood opening lever.
18. Connect the yellow 2-way SRS connector and horn
lead located under the steering column.
19. Connect the battery "-" terminal cable. (with SRS ai
r
bag)

3C-8 FRONT SUSPENSION


FRONT SUSPENSION
(4




2 Except High Ride Suspension)
CONTENTS

Service Precaution............................................. 3C-8
Shock Absorber ................................................. 3C-9
Shock Absorber and Associated Parts ........... 3C-9
Removal ......................................................... 3C-9
Installation....................................................... 3C-10
Shock Absorber with Coil Spring .................... 3C-12
Stabilizer Bar ..................................................... 3C-15
Stabilizer Bar and Associated Parts ............... 3C-15
Removal ......................................................... 3C-15
Inspection and Repair..................................... 3C-15
Installation....................................................... 3C-16
Knuckle .............................................................. 3C-17
Knuckle and Associated Parts........................ 3C-17
Removal ......................................................... 3C-17
Inspection and Repair..................................... 3C-18
Installation....................................................... 3C-18
Upper Control Arm ............................................. 3C-19
Upper Control Arm and Associated Parts ...... 3C-19
Removal ......................................................... 3C-19
Inspection and Repair..................................... 3C-20
Installation....................................................... 3C-20

Lower Control Arm ............................................. 3C-21
Lower Control Arm and Associated Parts ...... 3C-21
Removal ......................................................... 3C-21
Inspection and Repair..................................... 3C-22
Installation ...................................................... 3C-22
Upper Ball Joint ................................................. 3C-23
Upper Ball Joint and Associated Parts ........... 3C-23
Removal ......................................................... 3C-23
Inspection and Repair..................................... 3C-24
Installation ...................................................... 3C-24
Lower Ball Joint ................................................. 3C-25
Lower Ball Joint and Associated Parts ........... 3C-25
Removal ......................................................... 3C-25
Inspection and Repair..................................... 3C-26
Installation ...................................................... 3C-26
Bump Rubber .................................................... 3C-27
Bump Rubber Joint and Associated Parts...... 3C-27
Removal ......................................................... 3C-27
Inspection and Repair..................................... 3C-27
Installation ...................................................... 3C-27
Special Tools .................................................. 3C-28

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 or
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.

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.

7D-2 TRANSFER CASE

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, REFER
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, or
other corrosion inhibitors) on threaded fasteners or
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.

7D-14 TRANSFER CASE

10.
Remove the transfer chain and the front output shaft
from the main shaft.
11.
Remove the main shaft snap ring.
12.
Remove the speedometer drive gear, the ball
bearings, the retaining ring, and the oil pump
assembly.
13.
Remove the sprocket snap ring.
14.
Remove the thrust washer, the drive sprocket, the
inside ring, the outside ring, the block ring, and the
rear synchronizer spring.


RTW37DMF000101
Legend


(1) Rear synchronizer spring
(9) Sprocket Snap Ring
(2) Block Ring
(10) Oil Pump ASM
(3) Outside Ring
(11) Oil Pump Retaining Ring
(4) Inside Ring
(12) Retaining Ring
(5) Drive Sprocket
(13) Ball Bearing
(6) Transfer Chain
(14) Speedometer Drive Gear
(7) Front Output shaft
(15) Main Shaft Snap Ring
(8) Thrust Washer

TRANSFER CASE 7D-17

Internal Component Disassembly and Reassembly

226R300017


















H-L Shift Disassembly

1.
Remove the guide roller.
2.
Use a vise to compress the H-L shift spirng (inside
the assembly.







3.
Remove the uter snap ring.
4.
Remove the shift block assembly from the shift rod.








5.
Use a socket and a vise to compress the shift block
spring (inside the assembly.
6.
Remove the inner retaining ring.
7.
Remove the collar (rear.
8.
Remove the shift block spring.
9.
Remove the collar (rear.
10.
Removethe shift block assembly
11.
Remove the uter snap ring.
12.
Remove the shift arm.
13.
Remove the front and rear companion flange.
Legend

(1) ARM; SHIFT
(2) BLOCK ASM; SHIFT
(3) RING; RETAINING, INNER
(4) COLLER (FRONT)
(5) SPRING
(6) COLLER (REAR)
(7) ROD; SHIFT
(8) RING; SNAP, OUTER
(9) ROLLER; GUIDE
(10) PIN ASM; SPRING

7D-18 TRANSFER CASE

H-L shift reassembly

1.
Install the shift arm to the shift rod.
2.
Install the spring pin. The top of the pin must be
flush with the surrounding surface (no projection).
3.
Install the front collar, the spring, and the rear colla
r
to the shift block in that order.
4.
Use a socket and a vise to compress the shift block
spring.
5.
Install the inner retaining ring. Be sure that the arm
aperture width is within the specified limit.

226R300014






6.
Install the shift lock assembly to the shift rod.
7.
Use a socket and a vise to compress the H-L shift
spring.
8.
Install the outer snap ring.
9.
Install the guide roller.
2-4 shift ASM


226R300016











2-4 shift disassembly
1.
Remove the guide roller.
2.
Compress the spring and remove the snap ring.
3.
Remove the shift arm.
4.
Remove the spring.
5.
Remove the spring pin.
6.
Remove the shift block assembly.
7.
Remove the shift rod.

Legend

(1) 25.62

(2) 14.1mm Legend

(1) ROD; SHIFT
(2) ARM; SHIFT
(3) SPRING
(4) BLOCK ARM;SHIFT
(5) PIN ARM; SPRING
(6) ROLLER; GUIDE
(7) RING; SNAP

TRANSFER CASE 7D-19

2-4 shift reassembly

1.
Install the shift block assembly to the shift rod.
2.
Install the spring pin. The head of the pin must not
project beyond the surface (1) of the shift block.

226R300015
3.
Install the spring.
4.
Install the shift arm.
5.
Compress the spring and install the snap ring.
6.
Install the guide roller.

Oil pump disassembly
1.
Remove the clamps securing the screen.
2.
Remove the screen.
3.
Remove the clamps securing the hose.
4.
Remove the hose.
NOTE: To maintain and porotect oil pump function, the
pump is constructed so that it cannot be disassembled.
Under no conditions attempt to disassemble the pump.
Oil pump reassembly
1.
Tighten the clamps to secure the hose.
2.
Tighten the clamps to secure the screen.
NOTE: Be carefull in the direction of clamps.
RTW37DSH000101

Legend
(1) OIL PUMP ASM
(2) CLAMP
(3) HOSE
(4) SCREEN ASM