lock ISUZU TFS SERIES 1997 User Guide

4B-24 REAR AXLE
Important Operations
4. Pinion washer
5. Pinion gear
(1) Clamp special tool (side gear holder) into a vice. Set the
LSD assembly.
Holder : 5-8840-2010-0
(J-36563)
(2) Set special tools (side pinion expanders and pinion rotator)
to the LSD.
Expander : 5-8840-2011-0
(J-36564)
Rotor : 5-8840-2012-0
(J-36565)
(3) Set special tool (cage lock bar) through a ring gear fixing
hole to a vice.
Then rotate side pinion expanders with a wrench one half to
one full turn to provide backlash between the side and
pinion gears.
Bar : 5-8840-2013-0
(J-36566)
(4) W ith a wrench, rotate special tool (pinion rotator) to remove
the pinion gear and the pinion washer.

REAR AXLE 4B-25
(FOR RING SIZE 220 mm)
Disassembly Steps
1. Bolt
2. Differential cage cover
3. Thrust washer
4. Bellve disc
5. Bellve disc
6. Friction plate
7. Friction disc
8. Friction plate
9. Friction disc
10. Pressure ring
11. Side gear
12. Thrust block13. Pinion gear and pinion spider
14. Side gear
15. Pressure ring
16. Friction disc
17. Friction plate
18. Friction disc
19. Friction plate
20. Bellve disc
21. Bellve disc
22. Thrust washer
23. Thrust washer

4B-32 REAR AXLE
REASSEMBLY
MINOR COMPONENTS
LIMITED SLIP DIFFERENTIAL (LSD)
<FOR RING SIZE 194 mm>
Reassembly Steps
1. Friction disc and plate
2. Disc spring
3. Spring plate
4. Sleeve
5. Differential cage
6. Friction disc and plate assembly
7. Side gear8. Friction disc and plate assembly
9. Side gear
10. Pinion gear
11. Pinion washer
12. Thrust block
13. Pinion shaft
14. Spring pin

4B-34 REAR AXLE
(3) Set special tool (cage lock bar) through a ring gear fixing
hole to a vice.
Then rotate side pinion expanders with a wrench one half to
one full turn to provide proper clearance to install the pinion
gears.
Bar : 5-8840-2013-0
(J-36566)
(4) Attach the pinion gears and washers in the proper order to
the left and right hand side of the differential cage.
(5) W ith a wrench, turn special tool (pinion rotator) to align the
pinion gear and washer holes with the pinion shaft holes on
the differential cage.
Confirmation of operation
Using the side gear holder, measure the starting of the side
gear.
Starting Torque N
m (kgfm/lbft)
Standard 147-225 (15 - 23/108 - 166)
Side gear holder : 5-8840-2010-0
(J-36563)
Side gear rotor : 5-8840-2012-0
(J-36565)

REAR AXLE 4B-35
<FOR RING SIZE 220 mm>
Reassembly Steps
1. Differential cage
2. Thrust washer
3. Bellve disc
4. Bellve disc
5. Friction plate
6. Friction disc
7. Friction plate
8. Friction disc
9. Pressure ring
10. Side gear
11. Pinion gear and pinion spider
12. Thrust block13. Side gear
14. Pressure ring
15. Friction disc
16. Friction plate
17. Friction disc
18. Friction plate
19. Bellve disc
20. Bellve disc
21. Thrust washer
22. Differential cage cover
23. Bolt

REAR AXLE 4B-39
DIFFERENTIAL ASSEMBLY (STD)
Reassembly Steps
1. Differential cage
2. Thrust washer
3. Side gear
4. Pinion gear
5. Thrust block
6. Cross pin
7. Lock pin
8. Ring gear

4B-40 REAR AXLE
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.
6. 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) Backlash between the side gear and the pinion gear.
Backlash mm(in)
194 mm 0.03 - 0.08 (0.001 - 0.003)
220 mm 0.13 - 0.18 (0.005 - 0.007)
If the backlash is beyond the limits, adjust with a thrust washer
of selected thickness.
Thicknesses of thrust washers available.
mm(in)
194 mm1.00
(0.039)1.05
(0.041)1.10
(0.043)
220 mm0.80
(0.031)0.90
(0.035)1.00
(0.039)1.10
(0.043)1.20
(0.047)1.30
(0.051)
7. Lock Pin
After lock pin installation, stake the cage to prevent the lock pin
from falling out.

4B-44 REAR AXLE
(2) Clean the side bearing bores. Install a dial indicator with
discs and arbor. Then install and tighten the bearing caps
to the specified torque.
Torque N
m (kgfm/lbft)
194 mm 98.1
9.8 (10 1/72 7.2)
220 mm 107.9 9.8 (11 1/79.6 7.2)
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)
For 220 mm
1Dial indicator : 5-8840-0126-0 (J-8001)
2Disc (2 pcs.) : 5-8840-2167-0 (J-21777-86)
3Arbor : 5-8840-0128-0 (J-23597-1)
4Gage plate : 5-8840-2166-0 (J-23597-42)
(3) Set the dial indicator to &#34;0&#34;. 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 &#34;0&#34;.
Repeat the procedure to verify the &#34;0&#34; 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.

REAR AXLE 4B-59
3. OIL LEAKAGE
1) Differential Carrier Leakage
Checkpoint Trouble Cause Countermeasure
Correct the oil levelToo much gear oil NG
Reapply the liquid gasket
and/or tighten the lock nut to
the specified torque
Reapply the liquid gasket
Tighten the bolts to the
specified torque
Replace the oil seal
Ring gear thrust boltLoose lock nut and/or liquid
Liquid gasket seal bed
Loose bolts
Oil sealW orn or defective oil seal
Differential carrier
Clean the air breatherAir breatherClogged air breather
NG NG NG NG NG
OK OK OK
OK
Gear oil level

REAR AXLE 4B-65
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-56
5-8840-0015-0
(J-22912-01) Separator (for 194mm)
RAL-57
5-8840-2197-0
(J-37452) Separator (for 220mm)
RAL-54
5-8840-2010-0
(J-36563)Side gear holder
(194mm L.S.D only)
RAL-59
5-8840-2011-0
(J-36564)Side gear expander
(194mm L.S.D only)
RAL-55
5-8840-2012-0
(J-36565)Side gear rotor
(194mm L.S.D only)
RAL-70
5-8840-2013-0
(J-36566)Diff. Cage lock bar
(194mm L.S.D only)
RAL-12
9-8522-1141-0
(J-24256)Outer bearing outer race
installer (for 194mm)
RAL-13
5-8840-2164-0
(J-37262)Outer bearing outer race
installer (for 220mm)
RAL-14
9-8522-1274-0
(J-24252)Outer bearing outer race
installer (for 194mm)