2004 ISUZU TF SERIES sensor

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-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-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.

3C-48 FRONT SUSPENSION

Upper Ball Joint
Upper Ball Joint and Associated Parts


RTW440LF001401
Legend

(1)
Bolt and Nut

(2)
Upper Ball Joint


(3) Nut and Cotter Pin


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove the speed sensor from the knuckle.
3. Remove upper ball joint nut and cotter pin, then
use remover 5-8840-2121-0 to remove the uppe
r
ball joint from the knuckle.

TRANSFER CASE 7D-7

Removal
NOTE: Before removing transmission and transfer
assembly from vehicle, change the transfer mode to
2WD using the 4WD push button switch on dash panel.
1.
Disconnect battery ground cable.
2.
Raise and support vehicle with suitable stands. Drain
transfer case fluid.
3. Remove the center exhaust pipe(5). (6VE1 only)
4.
Remove rear propeller shaft (1) and front propelle
r
shaft (2)(3).
NOTE: Apply alignment marks on the flange at both
front and rear sides.
5.
Disconnect harness connectors and clip.

Connector: transfer switch, 2WD-4WD actuator,
speed sensor.
NOTE: Avoid turning the vehicle ignition switch to the
ON position when the 2WD-4WD connector is removed
(battery connected).
If the ignition switch must be turned to the ON position,
the controller must first be removed (memory must be
cleared because the CHECK 4WD INDICATOR will
light).
6.
Remove transfer case (4) from the vehicle.
Installation
1.
Apply a thin coat of molybdenum disulfide grease to
the input shaft spline as shown in the figure.

260R300001

TRANSFER CASE 7D-9

For A/T
261R300002

3.
Connect harness connectors and clip.

Connector: transfer switch, 2WD-4WD actuator,
speed sensor.
4. Install center exhaust pipe(5). (6VE1 only)
5.
Install rear propeller shaft (1) and front propelle
r
shaft (2)(3).
Torque: 63 N




m (6.4 kg




m/46 lb ft)

TRANSFER CONTROL SYSTEM 7D1-5
System Components
Parts Location




Speed sensor
Revolutions of the rear output shaft are decreased and taken
out by the speed/drive/driven gears installed in the transfer
case and the number of revolutions is detected with a speed
sensor.
About 4/3 pulses per revolution of the shaft is output.

4WD switch
The 4WD switch detects the movement of the shift rod driving
the 4

2 - 4

4 sleeve.
PUSH open is achieved with the PUSH open switch when the
shift rod is at the 4
2 position.

4




2 - 4




4 sleeve & Arm
The 4
2 - 4
4 sleeve moves directly in the 4
4 direction with
the 4

2 - 4

4 shift rod, but, when moving in 4

2 direction, a

TRANSFER CONTROL SYSTEM 7D1-11
Function of Switch and indicator Lamp
Transfer-related indicator lamp and switch function

Item 4WD
lamp 4L lampNeutral
lamp Check
4WD
warning
light 4WD
switch Actuator
detection
(limit)
switches
LS1, LS2,
LS3. and
LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral
switch SOF
actuator
switch
Or
Axle
dummyRemarks
2H Off Off Off Off No
operation 1,0,1,0 Open Open Open -----
4H start
of
operation Off Off Off Off 4H position
for 0.1
second 1,0,1,0 Open Open Open Switch
operation
sensor
Start of
operation Blinking
(2HZ) Off Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
while
driving
During
operation
(Synchro) Blinking
(2HZ) Off Off Off No
operation 1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
using
synchro
and
retrial
During
operation
(Axle
drive) Blinking
(2HZ) Off Off Off No
operation 0,0,1,1 Closed Open Open Axle drive
Axle
waiting Blinking
(2HZ) Off Off Off No
operation 0,0,1,1 Closed Open Open Axle drive
4H On Off Off Off No
operation 0,0,1,1 Closed Open Closed -----
4L start
of
operation On Off Off Off 4L position
for 0.1
second 0,0,1,1 Closed Open Closed Switch
operation
sensor
Start of
operation On Blinking
(2HZ) Off Off No
operation 0,0,0,1
0,1,0,1 Closed Open Closed 4H to 4L
while
driving
During
operation
(N) Off Blinking
(2HZ) Off Off No
operation 0,0,0,1
0,1,0,1 Closed Closed Closed 4H to 4L
through
neutral
During
operation
(N) Off Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Closed Closed 4H to 4L
through
neutral
During
operation
(N) Off Blinking
(2HZ) Off Off No
operation 1,1,0,0 Closed Closed Closed 4H to 4L
through
neutral
4L
waiting On Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Closed Closed 4H to 4L
while
waiting
4L On On Off Off No
operation 1,1,0,1 Closed Open Closed -----
4H start
of
operation On Off Off Off 4H position
for 0.1
second 1,1,0,1 Closed Open Closed Switch
operation
sensor