oil ISUZU TF SERIES 2004 Service Manual

4B-12 REAR AXLE

Legend


1.
Offset Box Wrench

10.
Remove wheel cylinder.
11.
Remove bearing holder fixing nuts.
12.
Take out axle shaft assembly with back plate and
set it on a bench press as following illustration.
Put bolt head on thick steel plate.

When axle shaft is extracted, since axle case oil
seal is damaged, axle case oil seal.
13.
Remove snap ring. Use snap ring pliers to
remove. Snap ring is prohibition of reuse.
14.
Remove shim (If so equipped)
15.
Remove sensor rotor (or spacer), double tape
r
roller bearing, oil seal, bearing holder, and back
plate from axle shaft by means of a press.

Discard used oil seal, double taper roller
bearing, snap ring, ABS sensor rotor and
spacer.
A03R300002
Legend

1.
Bench Press Fitting

2. Steel Plate (25-30 mm thickness)
3. Axle Shaft

16. Remove differential assembly fixing bolts and
nuts and take out differential assembly.
17.
Remove wheel pin from axle shaft, using the
remover 5-8840-0079-0.
420L100009
18.
Remove axle case oil seal.

Discard used oil seal.

4B-14 REAR AXLE

Reassembly
1.
Using the oil seal installer 5-8840-2202-0, install
new axle case oil seal.

420R300004

Note :
Confirm that the dimention : A should be 34.5 –
36.1 mm (1.36 – 1.42 in)







A03R300004

2.
Install new oil seal in bearing holder, using the oil
seal installer 9-8522-1269-0.


F04R300002
Legend


1.
Oil Seal

2.
Bearing Holder

3.
Drive wheel pin into axle shaft flange, using a
hammer.
4.
Differential assembly
a.
Clean the mating surface of axle case and
differential carrier.
b.
Apply Three Bond 1215 (TB1215) or
equivalent on the surface of differential
assembly as flowing illustration.




425RS006

c. Tighten bolts and nuts to the specified torque.

Torque : Bolt
64 N
m (6.5 kg
m/47 lb
ft)

Nut
44 N
m (4.5 kg
m/33 lb
ft)

REAR AXLE 4B-15

5.
Axle Shaft Assembly
a. Insert new double taper roller bearing in the
bearing holder with oil seal.
b. Set special tool (support stand : 9-8522-1271-
0) on a bench press.
c. Put bearing holder with bearing and oil seal
and back plate on the support stand as
following illustration.
d. Insert bolts and axle shaft, aligning center of
holes.
e. Press fit axle shaft into double taper roller
bearing.





420R300010
Legend


1.
Axle shaft

2.
Oil Seal
3.
Bolt

4.
Back Plate

5.
Double Taper Roller Bearing

6.
Put new sensor rotor (or spacer) on the special
tool 9-8522-1271-0.
7.
Press fit axle shaft with the bearing into sensor
rotor and make axle shaft assembly.





420R300011
Legend


1.
Axle shaft

2.
Oil Seal
3.
Bolt

4.
Back Plate

5.
Sensor Rotor (or Spacer)

6.
Double Taper Roller Bearing

4B-16 REAR AXLE

8.
Certainly install new snap ring, use snap ring pliers.
When transform or damage, replace new one.



RTW34BMH000101
Legend


1.
Snap ring

2.
Crevice
3.
Sensor rotor (with ABS)

Spacer (without ABS)


9.
Insert a shim of sufficient thickness between snap
ring and end of sensor rotor (or spacer).


Standard
0 
0.2 mm (0 
0.008 in)


Crevice is measured using thickness gauge, and
when crevice exceeds 0.2 (mm), it adjusts so that
is may become 0.2 (mm) or less using shim.


Shim Pats No.
Thickness

1 9-41519110-
0.18 mm (0.0071 in)

2 8-97130387-

0.50 mm (0.0197 in)


Crevice
No. of shim
Total

Mm (in)
1 2
mm (in)

1.0(0.0394) 
2
1.00(0.0394)

0.9(0.0354)
2
1
0.86(0.0339)

0.8(0.0315)
1
1
0.68(0.0268)

0.7(0.0276)
1
1
0.68(0.0268)

0.6(0.0236)

1
0.50(0.0197)

0.5(0.0197)

1
0.50(0.0197)

0.4(0.0158)
2 
0.36(0.0142)
0.3(0.0118)
1 
0.18(0.0071)
0.2(0.0079)
1 
0.18(0.0071)

10. Install axle shaft assembly in rear axle case
assembly.
Note:
When inserting an axle shaft, it inserts so that an
oil seal may not be damaged.
11. Install and tighten bearing holder fixing nut to the
specified torque.

Torque : 84 N
m (8.6 kg
m/62 lb
ft)
12. Install wheel cylinder and tighten the bolt to the
specified torque.

Torque : 9 N
m (0.9 kg
m/78 lb
ft)
13. Install parking brake outer cable in back plate and
inner cable in parking brake lever.

4B-18 REAR AXLE

17.
Install brake pipe and ABS sensor and tighten it to
the specified torque.

Torque :

ABS Sensor
8 N
m (0.8 kg
m/69 lb
ft)

Brake Pipe
16 N
m (1.6 kg
m/12 lb
ft)
420R30003

18.
Bleed brake pipe at the wheel cylinder. (Refer to
the section “Power-assisted Brake System”)
19.
Install brake drum.


Install propeller shaft. (Refer to Section “Rear
Propeller Shaft”.)


Refill differential oil.


Install wheel and tire.


Lower vehicle.

REAR AXLE 4B-19

Differential Assembly
Disassemble View
Legend


1.
Bolt

2.
Bearing Cap

3.
Differential Cage Assembly

4.
Side Bearing Outer Race

5.
Side Bearing

6.
Adjust Shim

7.
Flange Nut

8.
Flange Assembly

9.
Drive Pinion Shaft Assembly
415RY 00005


10.
Collapsible Spacer

11.
Inner Bearing

12.
Adjust Shim

13.
Oil Seal

14.
Outer Bearing

15.
Inner Bearing Outer Race

16.
Outer Bearing Outer Race

17.
Differential Carrier

REAR AXLE 4B-21

8.
Removed flange assembly.
9.
Remove the drive pinion assembly using a soft
metal rod and a hammer.




425RY005

10.
Remove collapsible spacer.
11.
Remove the inner bearing by using separator 5-
8840-2197-0


415L100002

12.
Remove adjust shim.
13.
Remove oil seal.
14.
Remove outer bearing.
15.
Remove the inner bearing outer race (1) and the
outer bearing outer race (2) by using a brass bar
and a hammer.


425RS014


425RS015

4B-22 REAR AXLE

Reassembly
1.
Install outer bearing outer race by using installer 5-
8840-2164-0 and grip 5-8840-0007-0.

425L100002
2.
Install inner bearing outer race by using installer 5-
8840-2163-0 and grip 5-8840-0007-0.

425L100003



3.
Adjust the drive pinion mounting distance as
follows:
a.
Apply gear oil to the inner and outer drive
pinion bearing. Clean the pinion setting
gauge set. Then install the gauge set
together with the inner and outer bearings.
Install gauge plate 5-8840-2166-0 (3), inner
pilot 5-8840-0129-0 (2), stud and nut 5-8840-
0127-0 (4) and outer pilot 5-8840-2085-0 (1)
through inner and outer bearings.
b.
Tighten the nut to the specified torque.

Torque: 2.3 N
m (0.23 kg
m/20 lb in)



425RW030

4B-26 REAR AXLE

4. Place the shim on the drive pinion, then install the
inner bearing onto the pinion by using installer 9-
8522-1165-0 and a press.
Note:
Do not apply pressure to the roller cage. Apply
NOTE: pressure only to the inner race.
425L100008

5. Install collapsible spacer. Discard the used
collapsible spacer and install a new one.
6. Install drive pinion shaft assembly.
7. Install outer bearing and oil seal.
8. Use oil seal installer 5-8840-2165-0 to install a
new oil seal that has grease on seal lip.

415RW029

9. Install flange assembly.
10. Install flange nut.
a. Apply lubricant to the pinion threads.
b. Using the pinion flange holder 5-8840-0133-0,
tighten the nut only enough to remove the shaft
end play.
Note :
Discard used flange nut and install new one.
415RW040

c. Adjust pinion bearing preload.


Measure the bearing preload by using a torque
meter and note the scale reading required to
rotate the flange.


Continue tightening flange nut until the specified
starting torque is obtained.
Starting torque :
0.7-1.3 N
m (0.07-0.13 kg
m/6-11 lb
ft)

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)