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For 1990-2009 cars only
Makes 🢒 Isuzu 🢒 1999 🢒 S/T Isuzu - 2WD 🢒 General Information 🢒 General Information 🢒 Relay Rod Replacement

Relay Rod Replacement RWD

Removal Procedure

Tools Required

    • J 6627-A Tie Rod Puller
    • J 24319-B Steering Linkage Puller
  1. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.

    2. Object Number: 291236 Size: SH
  2. Remove the inner tie rods ball stud nuts.

    3. Important: Use the proper tool in order to separate all ball joints.


    Object Number: 397350 Size: SH
  3. Disconnect the inner tie rods ball studs from the relay rod using J 6627-A .
  4. Remove the relay rod ball stud nut at the pitman arm.

    5. Object Number: 397356 Size: SH
  5. Disconnect the relay rod ball stud from the pitman arm using J 24319-B .
  6. Remove the relay rod ball stud nut at the idler arm.

    7. Object Number: 397352 Size: SH
  7. Disconnect the relay rod from the idler arm usingJ 24319-B .
  8. Remove the relay rod.
  9. Inspect the following components:
    10. • The threads on the tie rod for damage
    • The threads on the tie rod end for damage
    • The ball stud threads for damage
    • The ball stud seals for excessive wear
  10. Clean the threads on the ball stud.
  11. Clean the threads on the ball stud nut.

Installation Procedure

Tools Required

    • J 29193 Steering Linkage Installer (12 mm)
    • J 29194 Steering Linkage Installer (14 mm)

    Object Number: 291252 Size: SH
  1. Install the relay rod ball stud to the idler arm.

    2. Ensure that the seal is on the stud.


    Object Number: 240740 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Seat the taper using J 29193 or J 29194 .

    3. Tighten
    Tighten J 29193 or J 29194 to 54 N·m (40 lb ft)

  3. Remove J 29193 or J 29194 from relay rod ball stud.
  4. Install the new nut to the relay rod ball stud at the idler arm.

    5. Tighten
    Tighten the relay rod ball stud nut at the idler arm to 47 N·m (35 lb in).


    Object Number: 291242 Size: SH
  5. Install the relay rod ball stud to the pitman arm.

    6. Ensure that the seal is on the stud.


    Object Number: 240740 Size: SH
  6. Seat the taper using J 29193 or J 29194 .

    7. Tighten
    Tighten J 29193 or J 29194 to 54 N·m (40 lb ft).

  7. Remove J 29193 or J 29194 from relay rod ball stud.
  8. Install the new nut to the relay rod ball stud at the pitman arm.

    9. Tighten
    Tighten the relay rod ball stud nut at the pitman arm to 48 N·m (36 lb ft).


    Object Number: 291236 Size: SH
  9. Install the inner tie rod ball studs to the relay rod.

    10. Ensure that the seal is on the stud.

  10. Seat the taper using J 29193 or J 29194 .

    11. Tighten
    Tighten J 29193 or J 29194 to 54 N·m (40 lb ft).

  11. Remove J 29193 or J 29194 from relay rod ball stud.

    12. Repeat steps 10 and 11 for opposite inner tie rod to relay rod.

  12. Install the new nuts to the inner tie rod ball studs.

    13. Tighten
    Tighten the inner tie rod ball studs nuts to 47 N·m (35 lb ft).

  13. Lower the vehicle.
  14. Adjust the front toe. Refer to Front Toe Adjustment in Wheel Alignment.

Relay Rod Replacement 4WD

Removal Procedure

Tools Required

    • J 6627-A Tie Rod Puller
    • J 24319-B Steering Linkage Puller
  1. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the steering linkage shield. Refer to Steering Linkage Shield Replacement .

    3. Object Number: 141840 Size: SH
  3. Remove the differential carrier shield mounting bolts.
  4. Remove the differential carrier shield.

    5. Object Number: 291250 Size: SH

    Important: Use the proper tool in order to separate all ball joints.

  5. Remove inner tie rods ball stud nuts.

    6. Object Number: 397360 Size: SH
  6. Remove the inner tie rods ball studs from the relay rod using J 6627-A .

    7. Object Number: 291256 Size: SH
  7. Remove the steering shock absorber ball stud nut at the relay rod.

    8. Object Number: 397364 Size: SH
  8. Disconnect the steering shock absorber from the relay rod usingJ 24319-B .

    9. Object Number: 291250 Size: SH
  9. Remove the pitman arm ball stud nut at the relay rod.

    10. Object Number: 397366 Size: SH
  10. Disconnect the pitman arm ball stud from the relay rod using J 24319-B .

    11. Object Number: 291252 Size: SH
  11. Remove the idler arm ball stud nut at the relay rod.

    12. Object Number: 397363 Size: SH
  12. Disconnect the idler arm ball stud from the relay rod using J 24319-B .
  13. Remove the relay rod.
  14. Inspect the following components:
    15. • The threads on the tie rod for damage
    • The threads on the tie rod end for damage
    • The ball stud threads for damage
    • The ball stud seals for excessive wear
  15. Clean the threads on the ball stud.
  16. Clean the threads on the ball stud nut.

Installation Procedure

Tools Required

    • J 29193 Steering Linkage Installer (12 mm).
    • J 29194 Steering Linkage Installer (14 mm).

    Object Number: 291252 Size: SH
  1. Install the idler arm ball stud to the relay rod.

    2. Ensure that the seal is on the stud.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Seat the taper using J 29193 or J 29194 .

    3. Tighten
    Tighten J 29193 or J 29194 to 54 N·m (40 lb ft).

  3. Remove J 29193 or J 29194 from the idler arm ball stud.
  4. Install the new nut to the idler arm ball stud at the relay rod.

    5. Tighten
    Tighten the idler arm ball stud nut to 82 N·m (60 lb ft).


    Object Number: 291254 Size: SH
  5. Install the relay rod ball stud to the pitman arm.

    6. Ensure that the seal is on the stud.

  6. Seat the taper using J 29193 or J 29194 .

    7. Tighten
    Tighten J 29193 or J 29194 to 54 N·m (40 lb ft).

  7. Remove J 29193 or J 29194 from the pitman arm ball stud.
  8. Install the new nut to the pitman arm ball stud at the relay rod.

    9. Tighten
    Tighten the pitman arm ball stud nut to 83 N·m (61 lb ft).


    Object Number: 291256 Size: SH
  9. Connect the steering shock absorber to the relay rod.
  10. Install the steering shock absorber ball stud nut at the relay rod.

    11. Tighten
    Tighten the steering shock absorber ball stud nut to 63 N·m (46 lb ft).


    Object Number: 291250 Size: SH
  11. Install the inner tie rod ball studs to the relay rod.

    12. Ensure the seal is on the stud.


    Object Number: 240740 Size: SH
  12. Seat the tapers using J 29193 or J 29194 .

    13. Tighten
    Tighten J 29193 or J 29194 to 54 N·m (40 lb ft).

  13. Remove J 29193 or J 29194 from inner tie rod ball stud.
  14. Repeat steps 12 and 13 for the opposite side.
  15. Install the new nuts to the inner tie rod ball studs at the relay rod.

    16. Tighten
    Tighten the inner tie rod ball stud nuts to 47 N·m (35 lb ft).


    Object Number: 141840 Size: SH
  16. Install the differential carrier shield.
  17. Install the differential carrier shield mounting bolts.

    18. Tighten
    Tighten the differential carrier shield mounting bolts to 25 N·m (19 lb ft).

  18. Install the steering linkage shield. Refer to Steering Linkage Shield Replacement .
  19. Lower the vehicle.
  20. Adjust the front toe. Refer to Front Toe Adjustment in Wheel Alignment.