differential ISUZU TF SERIES 2004 Owner's Manual

4B-40 REAR AXLE




425RS063


Reassembly
Adjustment of Clearance between
Friction Disc and Plate
1. Measuring depth of differential case
mm(in)

Standard (A-B) 80.58 (3.17)
(C) 10.58 (0.42)



425RS064

2. Measuring overall length of pressure ring, friction
disc and plate assembly

Assemble pinion shaft with pressure ring,
then friction disc and plate.


Measure length between plates at both ends
over V-shape groove. (D)




425
RS065

3. After A, B, C and D dimensions are measured,
perform adjustment with the following procedure.


Measure spring plate :
1.75 mm (0.69 in) 
4 pcs (E)


Measure thickness of plate spring
Standard dimension :
1.75 mm (0.069 in) 
2 pcs (F)
4. Select a friction disc or plate so that ((A-B+C) -
(D+E) = 0.06 to 0.20 mm (0.002 to 0.008 in.) and
also the difference in total dimension of friction
disc and plate and spring plate (left/right side)
does not exceed 0.05 mm (0.002 in.).
Thickness : 1.65, 1.75, 1.85 mm (0.065, 0.069,
0.073 in)

Adjusting Backlash of Side Gear in
Axial Direction
1. Measuring depth of differential case
mm(in)

Standard (F-B) 82.03 (3.23)
(G) 12.03 (0.47)

REAR AXLE 4B-41



425RS066

2. Measuring dimension between thrust washers at
both ends.
Assemble side gear, pinion, pinion shaft pressure
ring and thrust washer.

Eliminate clearance by pushing pressure ring
against the pinion shaft in axial direction.


Eliminate backlash by connecting side gear to
the pinion.


Measure dimension between thrust washers at
both ends. (H)




425RS067

3. After each dimension is measured, perform
adjustment with the following procedure.
Adjust so that ((F-B) + G-H) = 0.05 to 0.2 mm
(0.002 to 0.008 in). Also, select a proper thrust
washer so that the dimension difference from
back face of the pressure ring to thrust washer
(left/right side) does not exceed 0.05 mm (0.002
in).
Thickness : 1.5, 1.6, 1.7 mm (0.059, 0.063,
0.067 in)

Note :
When reassembling, sufficiently apply gear oil on
every part, especially on sliding surface.
1. Install thrust washer in differential cage A and
B.
2. Assemble spring plate, friction plate and
friction disc as following illustration.





Install spring plate with dished side turned
to the differential cage side.
425R300009
Legend

1. Friction Plate
2. Spring Plate
3. Friction Disc

4. Install pressure ring and side gear.


Fit two side gears in two pressure rings, one
from under a ring and the other from above a
ring.


Fit two pairs of a friction disc and a friction
plate under it on and under these two pressure
rings.
5. Set pinion and pinion shaft on differential cage A
assembly.
6. Assemble differential cage A and B.
7. Align the setting marks on differential cage A and
B and tighten screws in diagonal order evenly.

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-46 REAR AXLE

3) Intermittent Noise

Checkpoint Trouble Cause Countermeasure

Axle case inside
Ring gear
Remove the foreign material
Replace the drive pinion and
the ring gear as a set
Foreign material in the axle
case
Warped ring gear
Differential cageTighten the differential cage
bolts
Replace the shaft
Loose differential cage bolts
Too much spline play
OK
NG NG NG NO
OK OKAxle shaft

REAR AXLE 4B-47

4) Noise when the Vehicle is Turning

Checkpoint Trouble Cause Countermeasure

Differential cross pin
Side gear
Replace the differential cross
pin
Replace the side gear
Worn differential cross pin
Worn side gear
Differential pinionReplace the differential pinion
Replace the rear axle shaft
Worn differential pinion
Worn rear axle shaft splines
OK
NG NG NG NO
OK OKRear 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

REAR AXLE 4B-53

4. POWER NOT BEING TRANSMITTED TO THE WHEELS
(PROPELLER SHAFT OPERATION IS NORMAL)

Checkpoint Trouble Cause Countermeasure

Replace the rear axle shaftBroken rear axle shaft NG
Replace the drive pinion and
the ring gear as a setDrive pinion and ring gearBroken drive pinion and/or ring
gear
Replace the differential gears
and/or the spiderDifferential cage gearsBroken differential cage gears
and/or spider NG NG
OK OK
Rear axle shaft

FRONT WHEEL DRIVE 4C1-1
SECTION 4C1
FRONT WHEEL DRIVE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4C1- 3
Special Parts Fixing Nuts and Bolts ................................................................................ 4C1- 4
Recommended Liquid Gasket .......................................................................................... 4C1- 6
Recommended Thread Locking Agents .......................................................................... 4C1- 6
Servicing............................................................................................................................. 4C1- 7
General Description........................................................................................................... 4C1- 8
Front Drive Axle Assembly ............................................................................................. 4C1- 14
Front Drive Axle Assembly and Associated Parts ................................................... 4C1- 14
Removal ....................................................................................................................... 4C1- 15
Installation ...................................................................................................................4C1- 16
Front Axle Drive Shaft ..................................................................................................... 4C1- 18
Front Axle Drive Shaft and Associated Parts ........................................................... 4C1- 18
Disassembly ................................................................................................................ 4C1- 19
Inspection and Repair................................................................................................. 4C1- 20
Bushing Replacement ............................................................................................... 4C1- 21
Reassembly ................................................................................................................. 4C1- 21
Standard caulk Measure ............................................................................................ 4C1- 22
Differential ...................................................................................................................4C1- 24
Disassembly ................................................................................................................ 4C1- 24
Major Components ................................................................................................ 4C1- 24
Minor Components................................................................................................ 4C1- 27
Inspection and Repair................................................................................................. 4C1- 29
Reassembly ................................................................................................................ 4C1- 31
Minor Components ................................................................................................. 4C1- 31
Major Components ................................................................................................. 4C1- 33