Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1970

NOTICE

Before using this Workshop Manual to assist you in performing vehicle

service and maintenance operations, it is recommended that you

carefully read and thoroughly understand the information contained in

Section 0A under the headings "GENERAL REPAIR INSTRUCTIONS"

and "HOW TO USE THIS MANUAL".

All material contained in this Manual is based on the latest product

information available at the time of publication.

All rights are reserved to make changes at any time without prior

notice.

Applicable Model : TFS

This manual is applicable to 2000 year model vehicle.

SERVICE INFORMATION  4C2-1

SECTION 4C2

SERVICE INFORMATION

CONTENTS

PAGE

Troubleshooting ............................................................................................................. 4C2- 2

Shift on The Fly System ................................................................................................. 4C2- 3

Service Standard ............................................................................................................ 4C2- 5

Servicing ......................................................................................................................... 4C2- 6

Fixing Torque ............................................................................................................. 4C2- 9

Special Tools .................................................................................................................. 4C2-10

Unit Repair ...................................................................................................................... 4C2-11

Front Drive Axle Assembly........................................................................................ 4C2-11

Shift on The Fly System ............................................................................................ 4C2-15

Front Hub and Disc (4WD Model Normal Hub)........................................................ 4C2-23

Shift on The Fly System Electric Equipment................................................................ 4C2-28

INDEX

4C2-2  SERVICE INFORMATION

TROUBLESHOOTING

FRONT DRIVING AXLE

PROBLEM

POSSIBLE CAUSEC

ORRECTION

Oil Leak At Front
Axle

1. Worn or defective oil seal.

2. Front axle housing cracked.

1. Replace the oil seal.

2. Repair or replace.

Oil Leak At Pinion
Shaft

1. Too much gear oil.

2. Oil seal worn or defective.

3. Pinion flange loose or demaged.

1. Correct the oil level.

2. Replace the oil seal.

3. Tighten or replace.

Noises In Front Axle
Drive Shaft Joint

Broken or worn drive shaft joins and
bellows (BJ and DOJ)

Replace the drive shaft joints and
bellows.

"Clank" When
Accelerating From
"Coast"

1. Loose drive shaft joint to output shaft

bolts.

2. Damaged inner drive shaft joint.

1. Tighten.

2. Replace.

Shudder or
Vibration During
Acceleration

1. Excessive drive shaft joint angle.

2. Worn or damaged drive shaft joints.

3. Sticking spider assembly (inner drive

shaft joint).

4. Sticking joint assembly (outer drive

shaft joint).

1. Repair.

2. Replace.

3. Lubricate or replace.

4. Lubricate or replace.

Vibration At
Highway Speeds

1. Out of balance or out of round tires.

2. Front end out of alignment.

1. Balance or replace.

2. Align.

Noises in Front Axle

1. Insufficient gear oil.

2. Wrong or poor grade gear oil.

3. Drive pinion to ring gear backlash

incorrect.

4. Worn or chipped ring gear, pinion

gear or side gear.

5. Pinion shaft bearing worn.

6. Wheel bearing worn.

7. Differential bearing loose worn.

1. Replenish the gear oil.

2. Replace the gear oil.

3. Adjust the backlash.

4. Replace the ring gear, pinion gear or

side gear.

5. Replace the pinion shaft bearing.

6. Replace the wheel bearing.

7. Tighten or replace.

Wanders and Pulls

1. Wheel bearing preload too tight.

2. Incorrect front alignment.

3. Steering linkage loose or worn.

4. Steering gear out of adjustment gear.

5. Tire worn or improperly inflated.

6. Front or rear suspension parts loose

or broken.

1. Adjust the wheel bearing preload.

2. Adjust the front alignment.

3. Tighten or replace.

4. Adjust or replace the steering gear.

5. Adjust the inflation or replace.

6. Tighten or replace.

Front Wheel
Shimmy

1. Wheel bearing worn or improperly

adjusted.

2. Incorrect front alignment.

3. Worn ball joint or bush.

4. Steering linkage loose or worn.

5. Steering gear out of adjustment.

6. Tire worn or improperly inflated.

7. Shock absorber worn.

1. Adjust or replace.

2. Adjust the front alignment.

3. Replace the ball joint or bush.

4. Tighten or replace.

5. Tighten or replace.

6. Replace or adjust the inflation.

7. Replace the shock absorber.

SERVICE INFORMATION  4C2-3

SHIFT ON THE FLY SYSTEM

• When transfer lever is shifted from 4H to 2H, indicator light does not go out.

Trace this chart from the start
after repair or replace.

Trace this chart from the start
after repair or replace.

Trace this chart from the start after
repair.

Disassemble axle ASM for check.

Does actuator work all right?
Is the circuit to actuator all right?

⋅ Is controller all right?

⋅ Is the circuit to controller all right?

Yes

No

Yes

Yes

No

Yes

No

No

All right.

Trace this chart from the start after
repair.

Disassemble axle ASM for check.

⋅ Is actuator switch all right?

⋅ Is the circuit to indicator all right?

When the left side of front wheel is
rotated, the right side also rotates.

Jack up from tires.

Drive show 100 - 200m after a few
minutes’ idling. As a result, indicator light
has gone out.