wheel ISUZU TF SERIES 2004 Repair Manual

FRONT WHEEL DRIVE 4C1-25



Important Operations
5. Bearing Cap
Apply a setting mark to the side bearing cap and the differential
carrier.



7. Side Bearing Outer Race
After removal, keep the right and left hand side bearing
assemblies separate to maintain inner and outer race
combinations.


8. Side Bearing
Remover : 5-8840-0013-0
(J-22888)
Adapter : 9-8521-1743-0
(J-8107-2)


9. Adjust Shims
Note the thickness and position of the shims removed.

10. Flange Nut
Holding wrench : 5-8840-0133-0
(J-8614-01)

4C1-26 FRONT WHEEL DRIVE

13. Pinion Gear
Remove the drive pinion assembly using a soft metal rod and a
hammer.
Spindle : 9-8521-5032-0


14. Inner Bearing
Remove the inner bearing using a separator and a press.
Separator : 5-8840-0015-0
(J-22912-01)



17. Inner Bearing Outer Race
20. Outer Bearing Outer Race
Remove the inner bearing outer race and the outer bearing
outer race by using a brass bar and a hammer.

FRONT WHEEL DRIVE 4C1-27
MINOR COMPONENTS


Disassembly Steps
1. Bolt
2. Ring gear


3. Lock pin


4. Cross pin


5. Pinion gear
6. Side gear
7. Thrust washer
8. Differential cage

4C1-28 FRONT WHEEL DRIVE

Important Operations
3. Lock Pin
Break staking on the lock pin using a 5 mm (0.20 in.) diameter
drill.


4. Cross Pin
Remove the cross pin using a soft metal rod and a hammer.

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)

4C1-30 FRONT WHEEL DRIVE


Play in Splines Between the Side Gear
and the Axle Shaft
mm(in)

Standard Limit
0.07 - 0.36 (0.003 - 0.014) 0.25 (0.010)

FRONT WHEEL DRIVE 4C1-31
REASSEMBLY
MINOR COMPONENTS


Reassembly Steps
1. Differential cage
2. Thrust washer
3. Side gear


4. Pinion gear




5. Cross pin


6. Lock pin


7. Ring gear


8. Bolt




Important Operations
4. Pinion Gear
Install the pinion gear by engaging it with the side gears while
turning both pinion gears simultaneously in the same direction.

4C1-32 FRONT WHEEL DRIVE


5. Cross Pin
(1) Be sure to install the cross pin so that it is in alignment with
the lock pin hole in the differential cage.


(2)
Adjust the backlash between the side gear and the pinion
gear.
mm(in)
Backlash 0.10 - 0.20 (0.004 - 0.008)
Thickness of thrust washers available
mm(in)

1.00, 1.05, 1.10 (0.039, 0.041, 0.043)



6. Lock Pin
After lock pin installation, stake the cage to prevent discharge
of the lock pin.


7. Ring Gear
When installing the ring gear, apply LOCTITE 271 or
equivalent to the threaded hole and bolt.







8. Bolt
Tighten the bolts in diagonal sequence as illustrated.
Bolt Torque N
m (kgf
m/lb
ft)

107.9
9.8 (11
1/79.6
7.2)
Note :
Discard used bolts and install new ones.
Note that all bolts have a left hand thread.

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

4C1-34 FRONT WHEEL DRIVE




Important Operations
2. Outer Bearing Outer Race
Installer : 9-8522-1141-0
(J-24256)
Grip : 5-8840-0007-0
(J-8092)


3. Inner Bearing Outer Race
Installer : 9-8522-1274-0
Grip : 5-8840-0007-0
(J-8092)







4. Adjust Shim
Adjustment of drive pinion mounting distance
(1) Apply gear oil to the inner and outer drive pinion bearing.
Clean the pinion setting gage set.
Then install the gage set together with the inner and oute
r
bearings.

1. Pilot : 5-8840-2085-0
(J-21777-42)
2. Nut and bolt : 5-8840-2089-0
(J-23597-9)
3. Gage plate : 5-8840-2087-0
(J-23597-7)