ISUZU TF SERIES 2004 Workshop Manual

FRONT WHEEL DRIVE 4C1-21

Bushing Replacement
 Remove the bushings using a remover 5-8840-2309-0 and
hammer.




By using installer and base 5-8840-2309-0, press fit the
bushings into the bracket.

Reassembly
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
Discard the used oil seal, snap ring and install a new one.
3. Install bearing and fix snap ring.
Discard the used snap ring and install a new one.
4. Install bracket to axle case. Tighten the bracket bolt to the
specified torque.
Torque : 116 N·m (11.8kg·m/85 lb ft)
5. Apply 135g of the specified grease in UJ.
6. Install dust seal for UJ.
Discard the used dust seal and install a new one.

Legend
1. Bellows
2. Shaft
7.
Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
CAUTION :
During bellows assembly, be sure to insert both ends of
the bellows into the case and shaft grooves.

4C1-22 FRONT WHEEL DRIVE

Legend
1. UJ Case
2. Bellows



8. Install band. Note the setting direction. After installation,
check Standard Caulk Measure.
Discard the used band and install a new one.
Use the special tool pliers 5-8840-2745-0 to caulk the band
to the specified value.
For both sides on UJ bellows.





Standard Caulk Measure

1.2mm (0.05in) <= (1), (2) <= 4.0mm (0.16in)

(1) - (2) or (2) - (1) <= 0.4mm (0.016in)
9. Install another bellows and fix band.
Discard the used band and install a new one.
10. Install the ball guide with the smaller diameter side ahead
onto the shaft.
11. Install ball retainer.

12. Using snap ring pliers, install the snap ring (1) securing the
ball retainer to the shaft.
Discard the used snap ring and install a new one.

FRONT WHEEL DRIVE 4C1-23
13. Align the track on the ball (1) retainer with the window in
the cage, and install the six balls into position.




14. Pack 150g of the specified grease in DOJ case, then install
drive shaft joint assembly. After reassembly, move the DOJ
longitudinally several times to get to fit.

15. Install the circlip (1) so that open ends are positioned away
from the ball groove.
Discard the used circlip and install a new one.


Legend
1. Outer Case
2. Circlip
3. Open Ends



16. Install band. After installation, check that the bellows is free
from distortion.
Discard the used band and install a new one.
Use the special tool pliers 5-8840-2745-0 to caulk the band
to the specified valve.
For both sides on UJ bellows.

4C1-24 FRONT WHEEL DRIVE
DIFFERENTIAL
DISASSEMBLY
MAJOR COMPONENTS
RTW34CLF000501
Disassembly Steps
1. Bolt
2. Differential assembly
3. Axle case
4. Bolt


5. Bearing cap
6. Diff. cage assembly


7. Side bearing outer race


8. Side bearing


9. Adjust shims


10. Flange nut
11. Flange


12. Dust cover


13. Pinion gear


14. Inner bearing
15. Adjust shim
16. Collapsible spacer


17. Inner bearing outer race
18. Oil seal
19. Outer bearing


20. Outer bearing outer race
21. Diff. carrier

FRONT WHEEL DRIVE 4C1-25



Important Operations
5. Bearing Cap
Apply a setting mark to the side bearing cap and the differential
carrier.



7. Side Bearing Outer Race
After removal, keep the right and left hand side bearing
assemblies separate to maintain inner and outer race
combinations.


8. Side Bearing
Remover : 5-8840-0013-0
(J-22888)
Adapter : 9-8521-1743-0
(J-8107-2)


9. Adjust Shims
Note the thickness and position of the shims removed.

10. Flange Nut
Holding wrench : 5-8840-0133-0
(J-8614-01)

4C1-26 FRONT WHEEL DRIVE

13. Pinion Gear
Remove the drive pinion assembly using a soft metal rod and a
hammer.
Spindle : 9-8521-5032-0


14. Inner Bearing
Remove the inner bearing using a separator and a press.
Separator : 5-8840-0015-0
(J-22912-01)



17. Inner Bearing Outer Race
20. Outer Bearing Outer Race
Remove the inner bearing outer race and the outer bearing
outer race by using a brass bar and a hammer.

FRONT WHEEL DRIVE 4C1-27
MINOR COMPONENTS


Disassembly Steps
1. Bolt
2. Ring gear


3. Lock pin


4. Cross pin


5. Pinion gear
6. Side gear
7. Thrust washer
8. Differential cage

4C1-28 FRONT WHEEL DRIVE

Important Operations
3. Lock Pin
Break staking on the lock pin using a 5 mm (0.20 in.) diameter
drill.


4. Cross Pin
Remove the cross pin using a soft metal rod and a hammer.

FRONT WHEEL DRIVE 4C1-29
INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspection.



Ring gear, pinion gear

Bearing


Side gear, pinion gear, cross pin


Differential cage, carrier


Thrust washer


Oil seal


Visual Check
Inspect the following parts for wear, damage, or other
abnormal conditions.



Ring Gear Replacement
(1) The ring gear should always be replaced with the drive
pinion as a set.
(2) When installing the ring gear, apply LOCTITE 271 o
r
equivalent to the threaded hole and bolt.
(3) Tighten the fixing bolts in a diagonal sequence as
illustrated.
(4) Discard used bolts and install new ones.
Bolt Torque N
m (kgf
m/lb
ft)

107.9
9.8 (11
1/79.6
7.2)




Clearance Between the Differential Pinion
and the Cross Pin
mm(in)

Standard Limit
0.05 - 0.10 (0.002 - 0.004) 0.2 (0.008)



Clearance Between the Side Gear and the
Differential Box
mm(in)

Standard Limit
0.03 - 0.10 (0.001 - 0.004) 0.15 (0.006)

4C1-30 FRONT WHEEL DRIVE


Play in Splines Between the Side Gear
and the Axle Shaft
mm(in)

Standard Limit
0.07 - 0.36 (0.003 - 0.014) 0.25 (0.010)