torque ISUZU TF SERIES 2004 Owner's Manual

4A-8 PROPELLER SHAFT
Rear Propeller Shaft
General Description
4




2 (Except High Ride Suspension) Model
F04R300001

4





2 (High Ride Suspension), 4





4 Model
401R300007

Torque is transmitted from the transmission to the
axle through propeller shaft and universal joint
assembles. All propeller shafts are the balanced
tubular type. A splined slip joint is provided in some
drivelines.

Since the propeller shaft is total balanced carefully,
welding or any other modification are not permitted. 
Alignment marks should be applied to each
propeller shaft before removal.

Be sure vehicle is stopped, engine is not running,
brake is secured and vehicle is secured to prevent
injury.

Be careful not to grip the propeller shaft tube too
tightly in the bise as this will be cause deformation.

4A-10 PROPELLER SHAFT
Diagnosis of Propeller Shaft and
Universal Joint

Condition Possible cause Correction
Rough surface on splined yoke;
burred nicked or worn. Replace the seal. Minor burrs can
be Smoothed by careful use of
crocus cloth or fine stone honing.
Replace the yoke if badly burred. Leak at the Front Slip Yoke (An
Occasional Drop of Lubricant
Leaking from the Splined Yoke is
Normal)
Defective transmission rear oil seal. Replace the transmission rear oil
seal and replenish the transmission
oil.
Worn universal joint bearings. Replace.
Improper lubrication. Lubricate as directed.
Universal Joint Noise.
Loose flange bolts. Tighten to specifications.
Loose bushing bolts on the rear
springs or upper and lower control
arms. Tighten the bolts to specified
torque. Ping, Snap, or Click in Drive Line
(Usually Heard on Initial Load after
the Transmission is in Forward or
Reverse Gear)
Loose or out-of-phase end yoke. Remove end yoke, turn 180
degrees from its original position,
lubricate the splines and reinstall.
Tighten the bolts and pinion nut to
specified torque.
Squeak Lack of lubricant. Lubricate joints and splines. Also
check for worn or brinelled parts.
Loose or missing bolts at the
flanges. Replace or tighten bolts to specified
torque.
Incorrectly set front joint angle. Install shim under the transmission
support mount to change the front
joint angle.
Shudder on Acceleration (Low
Speed)
Worn universal joint. Replace.
Incorrect shaft runout. Replace.
Shaft out of balance. Adjust.
Transmission rear housing bushing,
transfer case housing bushing worn.Replace.
Vibration
Yoke spline jammed. Replace.

PROPELLER SHAFT 4A-11
Removal and Installation

401RS023
Removal
1. Raise the vehicle on a hoist.
NOTE:
Apply alignment marks on the flange at the rear
propeller shaft both front and rear side.


2. Remove center bearing fixing bolt.
3. Remove rear axle side bolt, nut and washer.
4. Remove rear propeller shaft.

NOTE:
Plug the hole of the transmission rear end to prevent oil
leakage.

401L100007
Installation
NOTE:
Cover the slip yoke with cloth to avoid damage to the oil seal
contact surface, when removing propeller shaft from
transmission. Do not damage the oil seal contact surface of
slip yoke with other parts at removal and installation.
Completely remove the dust or foreign matter from the
connecting surface of flange coupling on each end of the
propeller shaft.

1.
Align the mark which is applied at removal and insert the
propeller shaft in the transmission.
2. Install rear propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 N




m(6.4kg




m/46 lb




ft)
3. Install center bearing and tighten the bolts to the specified
torque.
Torque: 69 N





m(7.0kg





m/51 lb





ft)

4A-18 PROPELLER SHAFT
Disassembly
1. Disassembly the three portions of the journal assemblies.
2. Remove the splined yoke, the 1st tube assembly with cente
r
bearing, the 2nd tube assembly and the flange yoke.
3. Remove the lock nut.
4. Remove the center yoke, the plain washer the cente
r
bearing and the 1st tube assembly.







Reassembly
1. Install the center bearing on the 1st tube assembly.
Clean the bearing fitting face.
Repack the grease.

Amount of grease
required g(oz) Approx. 12 (0.42)




2. Install the plain washer and the center yoke.
3. Install the lock nut and tighten it to the specified torque.
Lock nut Torque : 118 N




m (12.0kg




m/87lb




ft)
(1) Discard the flange nut and install a new one.
(2) Stake the outer face of the flange nut against the slot in the
shaft.
4. Install the splined yoke, the 1st tube assembly with cente
r
bearing, the 2nd tube assembly and the flange yoke by
assembling the universal joint.

4A-20 PROPELLER SHAFT

Installation
NOTE:
Never install the shaft assembly backwards. Completel
y
remove the black paint from the connecting surface of flange
coupling on each end of propeller shaft. Clean so that no
foreign matter will be caught in between.
1.
Align the mark which was applied at removal. Install front
propeller shaft and tighten the bolts and nuts to the
specified torque.
Torque: 59 N




m (6.0 kg




m/43 lb ft)
2. Install the exhaust and transfer protectors.
401RS019

3. After installing the propeller shaft, be sure to apply black
paint (1) to exposed area (other than connecting surface) o
f
the entire surface of flange coupling.

REAR AXLE 4B-1

SECTION 4B
REAR AXLE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4B- 3
Torque Specifications....................................................................................................................4B- 4
Recommended Liquid Gasket .......................................................................................... 4B- 6
Recommended Thread Locking Agents .......................................................................... 4B- 6
Rear Axle Assembly .......................................................................................................... 4B- 7
General Description ...................................................................................................... 4B- 7
Servicing............................................................................................................................. 4B- 8
Rear Axle ............................................................................................................................ 4B- 9
Disassembly .................................................................................................................. 4B- 10
Inspection and Repair................................................................................................... 4B- 13
Reassembly ................................................................................................................... 4B- 14
Differential Assembly.....................................................................................................................4B- 19
Disassembly .................................................................................................................. 4B- 20
Reassembly ................................................................................................................... 4B- 22
Differential Cage Assembly..........................................................................................................4B- 32
Disassembly .................................................................................................................. 4B- 33
Inspection and Repair...............................................................................................................4B- 33
Reassembly.................................................................................................................................4B- 35
Limited Slip Differential (LSD) .......................................................................................... 4B- 36
Disassembly................................................................................................................................4B- 37
Inspection and Repair................................................................................................... 4B- 38
Reassembly ................................................................................................................... 4B- 40
Troubleshooting ............................................................................................................ 4B- 43
Special Service Tool..................................................................................................................4B- 54

4B-2 REAR AXLE

Service Precaution
WARNING:

THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE REFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE
TO FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS
SYSTEM REPAIRS.

CAUTION:

Always use the correct fastener in the prope
r
location. When you replace a fastener, use ONLY
the exact part number for that application. ISUZU
will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers o
r
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (Paints,
greases, or other corrosion inhibitors) on threaded
fasteners or fastener joint interfaces. Generally,
such coatings adversely affect the fastener torque
and the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specification.
Following these instructions can help you avoid
damage to parts and systems.

REAR AXLE 4B-3

MAIN DATA AND SPECIFICATIONS
REAR AXLE
Ring gear size mm(in)220 (8.66)
Rear axle type Banjo, semi-floating
Rear axle capacity N (kg/lb)16475 (1680/3700)
Rear axle case 16965 (1730/3815) (EC)
Axle tube section
Outside diameter mm(in)80 (3.15)
Thickness mm(in)4.5 (0.118)
Final drive type Single speed
Final gear type Hypoid
Drive pinion bearing preload kg-cm(lb.in)
Starting torque (At drive pinion flange nut) 7-13 (6.1-11.3)
Preload adjusting method Collapsible
Final gear backlash mm(in)0.15-0.20 (0.006-0.008)
Differential carrier assembly
Weight (Dry) kg/lb29.0/63.9
Lubrication
Specified gear oil (APL grade) GL5 (STD), GL5LSD (LSD)
Oil capacity lit (US/UK gal)2.4 (0.63/0.53)

4B-4 REAR AXLE

Torque Specifications
Rear Axle
N

m (kgf

m/lb

ft)


RTW34BLF000501

4B-6 REAR AXLE

RECOMMENDED LIQUID GASKET

Type Brand Name Manufacture Remarks

RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
Water Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer
Note :
1. It is very important that the liquid gaskets listed
above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid
gasket.
Follow the manufacture's instructions at all
times.

3. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon
contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518
between two metal surfaces having a clearance
of greater than 0.25 mm (0.01 in). Poor
adhesion will result.



RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.

The surfaces must be perfectly dry.

LOCTITE 262

Red 2. Apply LOCTITE to the bolts.


LOCTITE 270

Green

LOCTITE 271

Red
3. Tighten the bolts to the specified torque.
4. Wait at least one hour before continuing the installation procedure.