check oil ISUZU TF SERIES 2004 Owner's Manual

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

4B-38 REAR AXLE

Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, rust or other problems
are discovered during inspection.

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


Friction disc


Friction plate


Spring plate
1 Sliding surface
2 Protrusion




425RS056

Pressure ring
Check the parts for damage or other abnormal
conditions.
3 Sliding surface for friction disc
If dents or damages are discovered, grind them
with oil stone, and repair them with compound on
surface plate.
4 Sliding surface of pressure ring inner surface and
pinion gear.
5 Slinding surface of pressure ring bore and side
gear.
6 sliding surface of pressure ring and side gear.
7 Sliding surface of pressure ring and pinion shaft.
8 Mating surface to differential cage A.
9 Burrs or dents on sliding surface of pressure ring
and rear differential cage should be repaired,
using oil stone.

425RY00022



Thrust Washer
10 Groove on side gear circumference small burrs of
dens should be repaired, using oil stone.
11 Sliding surface between side gear and thrust
washer.
425RY00024



Differential cage A and B
12 Contact surface to spring plate
13 Differential cage A and B contact surfaces to
thrust washers Small burrs or dents should be
repair, using oil stone.

REAR AXLE 4B-43

TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair
rear axle problems.
Each troubleshooting chart has three headings
arranged from left to right.
(1) Checkpoint
(2) Trouble Cause
(3) Countermeasure
This Section is divided into five sub-sections:
1. Abnormal Rear Axle Noise
1) Noise when the engine is driving the vehicle
2) Noise when the vehicle is coasting
3) Intermittent noise
4) Noise when the vehicle is turning
5) Constant noise
2. Vibration
3. Oil Leakage
1) Differential carrier leakage
2) Axle case leakage
3) Axle case to inside hub leakage
4) Axle case to inside brake drum leakage
4. Power Not Being Transmitted to the Wheels
(Propeller Shaft Operation is Normal)

4B-44 REAR AXLE

1. ABNORMAL REAR AXLE NOISE
1) Noise when the Engine is Driving the Vehicle

Checkpoint Trouble Cause Countermeasure

Replenish the gear oilInsufficient gear oil NG
Differential side bearingAdjust the differential side
bearing preload
Replace the drive pinion
bearings
Adjust the drive pinion bearing
preload
Replace the gear oil
Loose differential side
bearings
Worn drive pinion bearings
Loose drive pinion bearings
Wrong or poor grade gear oil
Drive pinion to ring gear
backlash
Drive pinion end play
Adjust the backlashToo much or too little backlash
Continued on the next pageOK OK
NG NG NG NG NG
OK
OK
Rear axle gear oil
Replace the differential side
bearingsWorn differential side bearings NG

4B-48 REAR AXLE

5) Constant Noise

Checkpoint Trouble Cause Countermeasure

Replace the rear axle shaftBent rear axle shaft NG
Replace the side bearing
Replace the drive pinion
bearing
Replace the drive pinion and
the ring gear as a set
Replace the drive pinion and
the ring gear as a set
Flat spot on the side bearing
oil seal
BearingFlat spot on the drive pinion
Flat spot on the gear teeth
pilot bearing wear
Drive pinionFlat spot on the drive pinion
gear teeth
Ring gear
Replace the drive pinion and
the ring gear as a setWorn pinion splines oil seal
NG NG NG NG NG
OK OK
OK
Rear axle shaft

4B-50 REAR AXLE

3. OIL LEAKAGE
1) Differential Carrier Leakage

Checkpoint Trouble Cause Countermeasure

Correct the oil levelToo much gear oil NG
Reapply the liquid gasket
and/or tighten the lock nut to
the specified torque
Reapply the liquid gasket
Tighten the bolts to the
specified torque
Replace the oil seal
Ring gear thrust boltLoose lock nut and/or liquid
Liquid gasket seal bed
Loose bolts
Oil sealWorn or defective oil seal
Differential carrier
Clean the air breatherAir breatherClogged air breather
NG NG NG NG NG
OK OK OK
OK
Gear oil level

REAR AXLE 4B-51

2) Axle Case Leakage

Checkpoint Trouble Cause Countermeasure

Tighten the drain plug and/or
replace the gasket(s)Loose drain plug and/or
defective gasket(s) NG
Reapply the liquid gasket
Tighten the bolts to the
specified torque
Clean the air breather
Liquid gasket seal bad
Loose bolts
Air breatherClogged air breather
Differential carrier
Replace the axle caseAxle caseCracked axle case
NG NG NG NG
OK OK
OK
Oil filler and drain plug

4B-52 REAR AXLE

3) Axle Case to Inside Brake Drum Leakage

Checkpoint Trouble Cause Countermeasure

Replace the oil sealWorn or defective oil seal NGOil seal

4C1-20 FRONT WHEEL DRIVE
6. Using snap ring pliers, remove the snap ring (1) fastening
the ball retainer to the center shaft.
7. Remove ball retainer, ball guide and bellows.



8. Use a hammer and chisel to remove the 3 pawls (above
the large and small boot bands on the UJ side).
CAUTION :
Take care not to damage the bellows during band removal.

9. Remove band (1).
10. Remove bellows.
11. Remove dust seal from UJ.
12. Remove UJ shaft assembly.
13. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
14. Remove snap ring and bearing.
15. Remove snap ring and oil seal.
16. Remove bracket.


Inspection And Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are found
through inspection.
Check the following parts.
1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal

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)