oil ISUZU TF SERIES 2004 Repair Manual

FRONT WHEEL DRIVE 4C1-3
MAIN DATA AND SPECIFICATIONS
FRONT AXLE AND DIFFERENTIAL
Ring gear size mm (in) 194 (7.6)
Axle tube
Type It consists of the duce, a cast iron housing and the Axle tube.
Gear type Hypoid
Gear ratio (to 1) 4.100, 4.300, 4.555, 4.777, 5125
Differential type Two pinion
Specified gear oil (APL grade) GL-5
Oil capacity liter 1.4
(US/UK gal.) (0.4/0.33)
Axle shaft type Constant velocity joint (Birfield joint type and double offset joint).


FRONT PROPELLER SHAFT mm(in)
4

4 Model
Engine Model 4JA1-T(L) 4JA1-TC 4JH1-TC C24SE 6VE1
Transmission Type 5M/T (MUA) 5M/T
(MUA) 4A/T 5M/T
(MUA) 5M/T
(MUA) 4A/T
Front Axle 194 mm










Outside Diameter mm 40 40 40 40 40 40
(in) (1.57) (1.57) (1.57) (1.57) (1.57) (1.57)
Inside Diameter mm 32 32 32 32 32 32
(in) (1.26) (1.26) (1.26) (1.26) (1.26) (1.26)
Length (L) mm 607 607 676 586 586 607
(in) (23.90) (23.90) (26.61) (23.07) (23.07) (23.90)
Fix Bolt Size T/F M10 M10 M10 M10 M10 M10
Axle M10 M10 M10 M10 M10 M10

FRONT WHEEL DRIVE 4C1-7
SERVICING


Hub Bearing Preload at the Wheel Pin
4
4, 4
2 (High Ride Suspension) Model N (lb)

New bearing and New oil seal 20 - 25 (4.4 - 5.5)
Reuse bearing and New oil seal 12 - 18 (2.6 - 4.0)
42 (Except High Ride Suspension) Model N (lb)

New bearing and New oil seal 8 - 12 (1.8 - 2.2)
Reuse bearing and New oil seal 8 - 12 (1.8 - 2.2)

FRONT WHEEL DRIVE 4C1-15

Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
3. Remove the stone guard.
4. Remove the brake caliper fixing bolt and hang the caliper.
Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front Wheel Speed Sensor in Brake section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to Front Propeller Shaft in
this section.
8. Loosen the height control arm of the torsion bar, then
remove the torsion bar from lower control arm.
Refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock absorber.

12. Remove the tie-rod end from the knuckle.
Refer to Power Steering Unit in Steering Section.
13. Disconnect the breather hose of the front axle.
14. Disconnect the actuator connector. (With shift on the fly)
15. Remove the bolts and nuts of the lower control arm (Frame
side), then disconnect the lower control arm from frame.
16. Disconnect between the right side upper control arm and
the knuckle, then remove the knuckle with lower control
arm.
CAUTION :
When removing the knuckle, be careful not to damage the
oil seal inside of the knuckle.

4C1-16 FRONT WHEEL DRIVE
17. Support the differential case by the jack.
18. Remove the front axle mounting bolts and nuts, lower the
jack slowly. Remove the left side drive shaft end from the
knuckle, then lower the axle assembly from the vehicle.
CAUTION :
1. During the work, be sure that the axle assembly is
supported securly.
2. Be careful not to damage the bellows of the power
steering unit by interference.
3. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.


Installation
1. Support the differential case by the jack.
2. Jack up the front drive axle assembly, install the left side
drive shaft to the knuckle, then install the mount bolts and
nuts.
CAUTION :
1. Be careful not to damage the bellows of the power
steering unit by interference.
2. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.
3. When installing the drive shaft to the knuckle, be
careful not to damage the oil seal inside of the knuckle.

RTW34CSH000101
3. Tighten the mounting bolts and nuts to the specified torque.
Torque : 169 N·m (17.2kg·m/124 lb ft)



4. Install the right side knuckle with lower control arm to the
upper control arm.
Refer to Knuckle in Suspension section.
CAUTION :
When insert the drive shaft to the knuckle, be careful not
to damage the oil seal inside of the knuckle.

5. Align the bolt hole of the lower control arm, install the bolts
and nuts.

4C1-18 FRONT WHEEL DRIVE
FRONT AXLE DRIVE SHAFT
Front Axle Drive Shaft and Associated Parts
RTW34CLF000401
Legend
1. Axle Case and Differential
2. Snap Ring
3. Bearing
4. Snap Ring
5. Oil Seal
6. Bracket
7. DOJ Case
8. Circlip
9. Bolt
10. Drive shaft Joint Assembly
11. Ball


12. Snap Ring
13. Ball Retainer
14. Ball Guide
15. Band
16. Bellows
17. Band
18. Band
19. Bellows
20. Band
21. UJ Shaft
22. Dust 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 4C1-21

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.

4C1-24 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 4C1-29
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)

FRONT WHEEL DRIVE 4C1-33
MAJOR COMPONENTS


Reassembly Steps
1. Diff. carrier


2. Outer bearing outer race


3. Inner bearing outer race


4. Adjust shim


5. Inner bearing


6. Collapsible spacer
7. Pinion gear
8. Outer bearing


9. Oil seal
10. Dust cover


11. Flange


12. Flange nut and washer


13. Adjust shim


14. Side bearing
15. Bearing outer race
16. Diff. cage assembly


17. Bearing cap


18. Bolt
19. Axle case


20. Differential assembly
21. Bolt