ISUZU TF SERIES 2004 Workshop Manual

REAR AXLE 4B-27

Note :





Do not overtighten or loosen and then
retighten the nut.





Pinion nut torque will be in the range of 245-
294 N
 m (25-30 kg
 m/181-217 lb
 ft).
425RW018
d. Using punch 5-8840-2293-0, stake the flange
nut at two points.
Note :
When staking, be sure to turn the nut to ensure
that there is no change in bearing preload. Make
sure NOTE: of preload again as instructed in c.

RTW34BSH000201

11. Adjust ring gear backlash.
a.
Attach the side bearing to the differential
assembly without shims by using installer 5-
8840-2162-0 and grip 5-8840-0007-0.

425L100010
b. Insert the differential cage assembly with
bearing outer races into the side bearing bores
of the carrier.

4B-28 REAR AXLE


425RS030

c. Using two sets of feeler gauges, insert a feele
r
stock of sufficient thickness between each
bearing outer race and the carrier to remove all
end play. Make certain the feeler stock is
pushed to the bottom of the bearing bores.
Mount the dial indicator 5-8840-0126-0 on the
carrier so that the indicator stem is at righ
t
angles to a tooth on the ring gear.
425RW049

d.
Adjust feeler gauge thickness from side to side
until ring gear backlash is in the specified range.
Backlash :
0.15–0.20 mm (0.006–0.008 in)


425RS032

With zero end play and correct backlash
established, remove the feeler gauge packs,
determine the thickness of the shims required
and add 0.05 mm (0.002 in) to each shim pack
to provide side bearing preload. Always use
new shims.
e. Remove side bearing by using remover 5-
8840-0013-0 and 5-8840-0014-0 and adapter
5-8840-2196-0.

415L100001

REAR AXLE 4B-29

12. Install the side bearings together with the selected
shims by using installer 5-8840-2162-0, drive
handle 5-8840-0007-0.

425L100010
13. Install side bearing outer race.
14. Install differential cage assembly.
15. Align the setting marks (1) applied at disassembly
then install the bearing cap.




425RS035



16. Tighten the bolt to the specified torque.
Torque :
108 N
m (11 kg
m/80 lb
ft)

4B-30 REAR AXLE

Gear Tooth Contact Pattern Check and Adjustment
1. Apply a thin coat of Prussian blue or equivalent to
the faces of the 7–8 teeth of the ring gear. Check
the impression of contact on the ring gear teeth
and make necessary adjustment as described in
illustration if the contact is abnormal.




425RS038
Legend

1.
Heel
2.
Toe
3.
Concave Side(Coast)
4.
Convex Side(Drive)

REAR AXLE 4B-31

425RS039

4B-32 REAR AXLE

Differential Cage Assembly
Disassembled View

425R300005
Legend

1. Bolt
2. Ring Gear
3. Lock Pin
4. Cross Pin
5. Pinion Gear
6. Side Gear
7. Thrust Washer (for Side Gear)
8. Differential Cage

REAR AXLE 4B-33

Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Drive out lock pin using a long drift Punch.
425RS042

4. Check the amount of backlash between pinion
gear on side gear before removal of cross pin.
Backlash :
0.13-0.18 mm (0.005–0.007 in)
5. Remove the cross pin by using a brass drift
punch and hammer.





425RS043

6. Take out pinion gear, side gear and thrust
washer.
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
conditions are found through inspection.
Check the following parts:


Ring gear, pinion gear


Bearing


Side gear, pinion gear, cross pin


Differential cage, carrier


Thrust washer


Oil seal
Clearance between pinion gear and cross pin:
mm(in)

Standard Limit
0.06 - 0.12
(0.002 - 0.005) 0.2 (0.008)

425L100012

Clearance between side gear and differential cage.
mm(in)

Standard Limit
0.05 - 0.11
(0.002 - 0.004) 0.15 (0.006)

4B-34 REAR AXLE

425R300010

Play in splines between the side gear and axle shafts.
mm(in)

Standard Limit
0.08 - 0.38
(0.003 - 0.015) 0.5 (0.02)

425L100014
Differential cage
Check the ring gear the side gear fitting faces and the
cross pin hole for scores or roughness. Correct as
necessary. Slight scores or roughness may be
corrected with an oil stone or fine sand paper.
425R300006

Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard use bolts and install new ones.
3.
Apply LOCTITE 271 on bolt from the end of thread
to the middle of straight portion.
4. Tighten the fixing bolts in a diagonal sequence as
illustrated.
Torque : 108 Nm (11 kgm/80 lbft)



425RW033

REAR AXLE 4B-35

Reassembly
1. Install side gear with thrust washer in differential
cage.
2. Install the pinion gear by engaging it with the side
gears while turning both pinion gears
simultaneously in the same direction.


425RS048

3. Install cross pin.


Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the
differential cage.




425RS049

4. Check the amount of backlash.
Backlash between the side gear and the pinion
gear. mm (in)

0.13-0.18 (0.005-0.007)
If the backlash is beyond the limits, adjust with a thrust
washer of selected thickness.
Thicknesses of thrust washers available.
Backlash mm (in
)

0.80
(0.031)0.90
(0.035)1.00
(0.039) 1.10
(0.043) 1.20
(0.047)1.30
(0.051)





425RY00008

5. Install lock pin.
After lock pin installation, stake the case to
secure the lock pin.
6. Install ring gear.
Refer to “Ring gear replacement” on this section.

4B-36 REAR AXLE

LIMITED SLIP DIFFERENTIAL (LSD)
Disassembled View
425R300007
Legend

1. Screw
2. Differential Cage B
3. Thrust Washer
4. Spring Plate
5. Spring Plate
6. Friction plate
7. Friction disc
8. Friction plate
9. Friction disc
10. Pressure Ring
11. Side Gear
12. Pinion and Pinion Shaft
13. Side Gear
14. Pressure Ring
15. Friction Disc
16. Friction Plate
17. Friction Disc
18. Friction Plate
19. Spring Plate
20. Spring Plate
21. Thrust Washer
22. Differential Cage A