ISUZU TFS SERIES 1997 Owners Manual

4C1-28 FRONT WHEEL DRIVE
Clearance Between the Side Gear and the
Differential Box
mm(in)
Standard Limit
167 mm 0.03 - 0.11 (0.001 - 0.004) 0.15 (0.006)
194 mm 0.03 - 0.10 (0.001 - 0.004) 0.15 (0.006)
Play in Splines Between the Side Gear
and the Axle Shaft
mm(in)
Standard Limit
167 mm 0.11 - 0.38 (0.004 - 0.015) 0.30 (0.012)
194 mm 0.07 - 0.36 (0.003 - 0.014) 0.25 (0.010)

FRONT WHEEL DRIVE 4C1-29
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.

4C1-30 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 0.03 - 0.08 (0.001 - 0.003)
Thickness of thrust washers available
mm(in)
167 mm 1.05, 1.15, 1.25 (0.041, 0.043, 0.049)
194 mm 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 (kgfm/lbft)
167 mm 78.5
9.8 (8 1/57.9 7.2)
194 mm 107.9 9.8 (11 1/79.6 7.2)
Note :
Discard used bolts and install new ones.
For 167 mm
Note that all bolts have a left hand thread.

FRONT WHEEL DRIVE 4C1-31
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 cover11. 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

4C1-32 FRONT WHEEL DRIVE
Important Operations
2. Outer Bearing Outer Race
Installer : 5-8522-0048-0 (167 mm)
(J-29038)
9-8522-1141-0 (194 mm)
(J-24256)
Grip : 5-8840-0007-0
(J-8092)
3. Inner Bearing Outer Race
Installer : 5-8522-0049-0 (167 mm)
(J-29039)
9-8522-1274-0 (194 mm)
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 outer
bearings.
For 167 mm
1Pilot : 5-8840-2092-0
(J-23597-28)
2Nut and bolt : 5-8840-0127-0
(J-21777-43)
3Rear pilot : 5-8840-02091-0
(J-23597-27)
4Gage plate : 5-8840-2090-0
(J-23597-26)
For 194 mm
1Pilot : 5-8840-2085-0
(J-21777-42)
2Nut and bolt : 5-8840-2089-0
(J-23597-9)
4Gage plate : 5-8840-2087-0
(J-23597-7)

FRONT WHEEL DRIVE 4C1-33
Tighten the nut to the specified torque.
N
m (kgfm/lbft)
New bearing 2.26 (23/20)
Used bearing0.98 - 1.18
(10 - 12/8.7 - 10.4)
(2) Clean the side bearing bores. Install the dial indicator with
the discs and Arbor. Install and tighten the bearing caps to
the specified torque.
Torque N
m (kgfm/lbft)
167 mm 68.7
9.8 (7.0 1.0/50.6 7.2)
194 mm 98.1 9.8 (10.0 1.0/72.3 7.2)
For 167 mm
1Dial indicator : 5-8840-0126-0
(J-8001)
2Disc (2 pcs.) : 5-8840-2086-0
(J-23597-4)
3Arbor : 5-8840-0128-0
(J-23597-1)
4Gage plate : 5-8840-2090-0
(J-23597-26)
For 194 mm
1Dial indicator : 5-8840-0126-0
(J-8001)
2Disc (2 pcs.) : 5-8840-2088-0
(J-23597-8)
3Arbor : 5-8840-0128-0
(J-23597-1)
4Gage plate : 5-8840-2087-0
(J-23597-7)

4C1-34 FRONT WHEEL DRIVE
(3) Set the dial indicator to “0”. Place it on the mounting post of
the gaging arbor with the contact button touching the
indicator pad. Force the dial indicator downward until the
needle has made a half turn clockwise. Tighten down the
dial indicator in this position.
(4) Position the plunger on the gage plate. Move the gaging
arbor slowly back and forth and locate the position at which
the dial indicator shows the greatest deflection. At this
point, once again set the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.
(5) After the ZERO setting is obtained, rotate the gaging arbor
until the dial indicator rod does not touch the gaging plate.
Record the number the dial indicator needle points to.
(6) Record the pinion depth code on the head of the drive
pinion.
The number indicates a necessary change in the pinion
mounting distance. A plus number indicates the need for a
greater mounting distance (which can be achieved by
decreasing the shim thickness). A minus number indicates
the need for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If examination
reveals pinion depth code “0”, the pinion is “nominal”.

FRONT WHEEL DRIVE 4C1-35
(7) Select the shim using the chart;
For 167 mmmm(in)Pinion
marking
+6 +4 +2 +0 -2 -4 -6
Dial indicator
reading (inches)
0.0521.39 (0.0547)
0.0531.39 (0.0547) 1.41 (0.0555)
0.054 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563)
0.055 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571)
0.056 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587)
0.057 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594)
0.058 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602)
0.059 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610)
0.060 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626)
0.061 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634)
0.062 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642)
0.063 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657)
0.064 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665)
0.065 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673)
0.066 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681)
0.067 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)
0.068 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)
0.069 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)
0.070 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)
0.071 1.75 (0.0689) 1.77 (0.0697)
0.072 1.77 (0.0697)
For 194 mmmm(in)
Pinion
marking
+10 +8 +6 +4 +2 0 -2 -4 -6 -8 -10Dial indicator
reading (inches)
0.0812.18 (0.0858)0.0822.18 (0.0858) 2.20 (0.0866)0.0832.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882)0.0842.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890)0.0852.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898)0.0862.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914)0.087 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921)0.088 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929)0.089 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937)0.090 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953)0.091 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961)0.092 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969)0.093 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977)0.094 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992)0.095 2.28 (0.0898) 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000)0.096 2.32 (0.0914) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.097 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.098 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.099 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.001 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.002 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.003 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.004 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.005 2.54 (0.1000) 2.56 (0.1008)0.006 2.56 (0.1008)
Note :
When ordering shims, find the part number in the Parts Catalog by using the thickness of the shims listed
in the above table.

4C1-36 FRONT WHEEL DRIVE
5. Inner Bearing
Place the shim on the drive pinion, with the chamfered side
turned towards the pinion head then install the inner bearing on
to the pinion using an installer and a press.
Installer : 9-8522-1165-0 (J-6133-01)
Note:
Do not apply pressure to the roller cage.
Apply pressure only to the inner race.
6. Collapsible Spacer
Discard the used collapsible spacer and install a new one.
9. Oil Seal
Use oil seal installer to install a new oil seal that has been
soaked in rear axle lubricant.
Installer : 5-8522-0046-0 (J-26234) (For 167 mm)
9-8522-1275-0 (J-24250) (For 194 mm)
Note :
Take care not to use a rear differential oil seal instead of
the front differential oil seal.
12.Flange Nut and Washer
For 194 mm
(1) Apply lubricant to the pinion threads.
(2) Tighten the nut to the specified torque using the pinion
flange holder.
Pinion flange holder : 5-8840-0133-0
(J-8614-01)
Torque N
m (kgfm/lbft)
176.6 - 274.7 (18 - 28/130 - 202)
Discard used flange nut and install new one.

FRONT WHEEL DRIVE 4C1-37
(3) Pinion bearing preload
(a) Measure the bearing preload by using a torque meter. Note
the scale reading required to rotate the flange.
(b) continue tightening until the specified starting torque is
obtained.
Starting Torque N
m (kgfcm/lbin)
0.63 - 1.13 (6.5 - 11.5/5.7 - 9.9)
For 167 mm
(1) Apply lubricant to the pinion threads.
(2) Tighten the nut to the specified torque using the pinion
flange holder.
Pinion flange holder : 5-8840-0133-0 (J-8614-01)
Torque N
m (kgfm/lbft)
117 - 127 (12 - 13/87 - 94)
Discard used flange nut and install new one.
(3) Continue tightening until the specified starting torque is
obtained.
Starting Torque N
m (kgfcm/lbin)
0.59 - 1.0 (6 - 11/5.2 - 9.5)
13.Adjust Shim
(1) Attach the side bearing to the differential assembly without
shims. Support the opposite side using a pilot to prevent
bearing damage.
For 167 mm
1Installer : 5-8840-0138-0
(J-29036)
2Drive handle : 5-8840-0007-0
(J-8092)
3Pilot : 5-8521-0019-0
For 194 mm
1Installer : 9-8521-1164-0
(J-24244)
2Drive handle : 5-8840-0007-0
(J-8092)
3Pilot : 9-8521-1743-0
(J-8107-2)