differential ISUZU TFS SERIES 1997 Service Manual

FRONT WHEEL DRIVE 4C1-27
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) W hen installing the ring gear, apply LOCTITE 271 or
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 (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)
For 167 mm
Note that all bolts have a left hand thread.
Clearance Between the Differential Pinion
and the Cross Pin
mm(in)
Standard Limit
167 mm 0.06 - 0.12 (0.002 - 0.005) 0.2 (0.008)
194 mm 0.05 - 0.10 (0.002 - 0.004) 0.2 (0.008)

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

4C1-36 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)

4C1-38 FRONT WHEEL DRIVE
(2) Insert the differential cage assembly with bearing outer
races into the side bearing bores of the carrier.
(3) Using two sets of feeler gauges, insert a feeler stock of
sufficient thickness between each bearing outer race and
the carrier to remove all end plat. Make certain the feeler
stock is pushed to the bottom of the bearing bores.
Mount the dial indicator on the carrier so that the indicator
stem is at right angles to a tooth on the ring gear.
Dial indicator : 5884-0126-0
(J-8001)
(4) Adjust feeler gauge thickness from side to side until ring
gear backlash is in the specified range.
Backlash mm(in)
0.13 - 0.18 (0.005 - 0.007)
W ith zero end play and correct backlash established,
remove the feeler gauge packs, determine the thickness of
the shims required and add 0.05 mm (0.002 in) to each
shim pack to provide side bearing preload. Always use new
shims.
(5) Remove side bearing
Remover : 5-8840-0013-0
(J-22888)
Pilot : 5-8521-0019-0 (167 mm)
9-8521-1743-0 (194 mm)
(J-8107-2)
14.Side Bearing
Install the side bearings together with the selected shims.
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)

4C1-40 FRONT WHEEL DRIVE
20.Differential Assembly
(1) Clean the faces of the front axle case and differential
carrier.
Apply the recommended liquid gasket or its equivalent to
the sealing side of the axle case and the carrier.
(2) Attach the differential case and the carrier assembly to the
front axle case and tighten the nuts and bolts. The axle
case bolt is used for drainage.
Torque N
m (kgfm/lbft)
25.5
5 (2.6 0.5/18.8 3.6)
(3) Install the axle shaft assemblies as instructed earlier in this
section under “Axle Shaft Replacement”.
(4) Fill the axle case with hypoid gear lubricant, to just below
the filler hole.
Lubricant capacity liter (US/UK gal)
167 mm 1.0 (0.26/0.22)
194 mm 1.4 (0.37/0.31)

4C1-74 FRONT WHEEL DRIVE
FRONT PROPELLER SHAFT
REMOVAL AND INSTALLATION
Since the propeller shaft assembly is carefully
balanced, a setting mark should be applied to
the flange before removal to indicate correct
position.Install the parts by aligning the setting marks
made at removal.
Removal Steps
1. Nut ; differential side
2. Bolt ; transfer side
3. Propeller shaft assembly ; rear side
4. Propeller shaft assembly ; front side
Installation Steps
4. Propeller shaft assembly ; front side
3. Propeller shaft assembly ; rear side
2. Bolt ; transfer side
1. Nut ; differential side
Important Operation - Installation
3. Propeller Shaft Assembly ; Rear Side
Align the indexing marks (about 3 mm dia. punched mark) on
the propeller shaft end and the splined yoke.