ISUZU AXIOM 2002 Service Repair Manual

DIFFERENTIAL (FRONT) 4A1±8
Differential Assembly
Disassembled View
415R200002
Legend
(1) Differential Assembly
(2) Flange Nut
(3) Flange
(4) Oil Seal
(5) Outer Bearing
(6) Outer Bearing Outer Race
(7) Differential Carrier
(8) Bearing Cap
(9) Bolt
(10) Collapsible Spacer
(11) Inner Bearing Outer Race(12) Inner Bearing
(13) Adjust Shim
(14) Pinion Gear
(15) Diff Cage Assembly
(16) Side Bearing Outer Race
(17) Side Bearing
(18) Adjust Shim
(19) Bolt
(20) Axle Case
(21) Final Drive Damper
(22) Damper Bolt
(23) Damper Bracket

4A1±9 DIFFERENTIAL (FRONT)
Disassembly
1. Remove differential carrier fixing bolt.
2. Remove differential assembly.
3. Using holding fixture J±37264 and holding fixture
base J±3289±20, fix the differential assembly to the
bench.
425RS008
4. Remove bearing cap bolt.
5. Apply a setting mark to the side bearing cap and the
differential carrier then remove bearing cap.
425RS009
6. Remove differential cage assembly.
7. Remove side bearing outer race, after removal, keep
the right and left hand side bearing assemblies
separate to maintain inner and outer race
combinations.
8. Remove side bearing, using remover J±42379 and
adapter J±8107±2.

Select insert; 303173 and collet halves; 44801 in
remover kit J±42379.
415RW003
9. Remove adjust shim, note the thickness and position
of the shims removed.
10. Remove the flange nut using holding wrench
J±8614±01.
415RS018

DIFFERENTIAL (FRONT) 4A1±10
11. Remove flange using a universal puller.
12. Remove the drive pinion assembly using a soft metal
rod and a hammer.
425RS012
13. Remove collapsible spacer.
14. Remove the inner bearing using remover J±42379.

Select insert; 303173 and collet halves; 44801 in
remover kit J±42379.
415RW004
15. Remove adjust shim.
16. Remove oil seal.
17. Remove outer bearing.18. Remove the inner bearing outer race (1) and the outer
bearing outer race (2) by using a brass bar and a
hammer.
425RS014
425RS015

4A1±11 DIFFERENTIAL (FRONT)
19. Remove damper and bracket.
425RW042
Reassembly
1. Using installer J±7817 and grip J±8092, install outer
bearing outer race.
415RW013
2. Using installer J±7818 and grip J±8092, install Inner
bearing outer race.
415RW014
3. Install adjust shim and adjust drive pinion mounting
distance:
1. Apply gear oil to the inner and outer drive pinion
bearing.
Clean the pinion setting gauge set.
Then install the gauge set together with the inner
and outer bearings.

DIFFERENTIAL (FRONT) 4A1±12
2. Tighten the nut to the specified torque.
Torque: 2.3 N´m (20 lb in)
425RW030
Legend
(1) Pilot : J±21777±42
(2) Pilot : J±42479±2
(3) Gauge Plate : J±42479±1
(4) Nut and Stud : J±21777±43
3. 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: 97 N´m (72 lb ft)
425RW031
Legend
(1) Dial Indicator: J±8001
(2) Gauge Plate: J±42479±1
(3) Disc (2 pcs.): J±23597±8
(4) Arbor: J±23597±1
4. Set the dial indicator to ª0º. Place it on the
mounting post of the gauging 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.
425RS020
Legend
(1) Dial Indicator
(2) Ganging Arbor
(3) Plunger
(4) Gauge Plate
5. Position the plunger on the gauge plate. Move the
gauging arbor slowly back and forth and locate
the position at which the dial indicator shows the
greatest defection. At this point, once again set
the dial indicator to ª0º.
Repeat the procedure to verify the ª0º setting.
425RS021

4A1±13 DIFFERENTIAL (FRONT)
6. After the ZERO setting is obtained, rotate the
gauging arbor until the dial indicator rod does not
touch the gauging plate.
Record the number the dial indicator needle
points to.
425RS022
Legend
(1) Example=Dial indicator reading of 0.085
7. 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 indi-
cates 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 ex-
amination reveals pinion depth code ª0º, the pin-
ion is ªnominalº.
425RS023

DIFFERENTIAL (FRONT) 4A1±14
8. Select the shim using chart;
Pinion
marking
Dial
indicator
reading
(Inches)+7+6+5+4+3+2+10±1±2±3±4±5±6±7
0.0230.030
0.0240.0300.030
0.0250.0300.0300.032
0.0260.0300.0300.0320.032
0.0270.0300.0300.0320.0320.034
0.0280.0300.0300.0320.0320.0340.034
0.0290.0300.0300.0320.0320.0340.0340.036
0.0300.0300.0300.0320.0320.0340.0340.0360.036
0.0310.0300.0300.0320.0320.0340.0340.0360.0360.038
0.0320.0300.0300.0320.0320.0340.0340.0360.0360.0380.038
0.0330.0300.0300.0320.0320.0340.0340.0360.0360.0380.0380.040
0.0340.0300.0300.0320.0320.0340.0340.0360.0360.0380.0380.0400.040
0.0350.0300.0300.0320.0320.0340.0340.0360.0360.0380.0380.0400.0400.042
0.0360.0300.0300.0320.0320.0340.0340.0360.0360.0380.0380.0400.0400.0420.042
0.0370.0300.0300.0320.0320.0340.0340.0360.0360.0380.0380.0400.0400.0420.0420.044
0.0380.0300.0320.0320.0340.0340.0360.0360.0380.0380.0400.0400.0420.0420.0440.044
0.0390.0320.0320.0340.0340.0360.0360.0380.0380.0400.0400.0420.0420.0440.0440.046
0.0400.0320.0340.0340.0360.0360.0380.0380.0400.0400.0420.0420.0440.0440.0460.046
0.0410.0340.0340.0360.0360.0380.0380.0400.0400.0420.0420.0440.0440.0460.0460.048
0.0420.0340.0360.0360.0380.0380.0400.0400.0420.0420.0440.0440.0460.0460.0480.048
0.0430.0360.0360.0380.0380.0400.0400.0420.0420.0440.0440.0460.0460.0480.0480.050
0.0440.0360.0380.0380.0400.0400.0420.0420.0440.0440.0460.0460.0480.0480.0500.050
0.0450.0380.0380.0400.0400.0420.0420.0440.0440.0460.0460.0480.0480.0500.0500.052
0.0460.0380.0400.0400.0420.0420.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0470.0400.0400.0420.0420.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0480.0400.0420.0420.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0490.0420.0420.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0500.0420.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0510.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0520.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0530.0460.0460.0480.0480.0500.0500.0520.052
0.0540.0460.0480.0480.0500.0500.0520.052
0.0550.0480.0480.0500.0500.0520.052
0.0560.0480.0500.0500.0520.052
0.0570.0500.0500.0520.052
0.0580.0500.0520.052
0.0590.0520.052
0.0600.052

4A1±15 DIFFERENTIAL (FRONT)
4. Place the shim on the drive pinion. Install the inner
bearing onto the pinion using an installer J±6133±01
and a press.
NOTE: Do not apply pressure to the roller cage and apply
pressure only to the inner race.
425RS024
5. Discard the used collapsible spacer and install a new
one.
6. Install pinion gear.
7. Install outer bearing.
8. Use oil seal installer J±24250 to install a new oil seal
that has been soaked in front axle lubricant.
NOTE: Take care to use a front differential oil seal, NOT
the rear differential oil seal.
415RS011
9. Install flange.
10. Install flange nut.
1. Apply lubricant to the pinion threads.
2. Tighten the nut to the specified torque using the
pinion flange holder J±8614±01.
Torque: 177±275N´m (130±203 lb ft)NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
415RW006
3. Adjust 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 flange nut until the
specified starting torque is obtained.
Starting torque:
New bearing 0.7±1.1 N´m (5.64±9.98 lb in)
Used bearing 0.4±0.5 N´m (2.86±4.94 lb in)
NOTE: D o n o t t ighten the flange nut more than
678 N´m(500 lb ft).
425R200001
4. Using punch J±39209, stake the flange nut at two
points.

DIFFERENTIAL (FRONT) 4A1±16
NOTE: When staking, be sure to turn the nut to insure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3.
415R200004
11. Install adjust shim.
1. Attach the side bearing to the differential
assembly without shims. Support the opposite
side using a pilot to prevent bearing damage.
425RS029
Legend
(1) Drive handle:J±8092
(2) Installer:J±24244
(3) Pilot:J±8107±2
2. Insert the differential cage assembly with bearing
outer races into the side bearing bores of the
carrier.
425RS030
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 play. Make certain the feeler stock is pushed
to the bottom of the bearing bores.
Mount the dial indicator J±8001 on the carrier so
that the indicator stem is at right angles to a tooth
on the ring gear.
425RS031

4A1±17 DIFFERENTIAL (FRONT)
4. Adjust feeler gauge thickness from side to side
until ring gear backlash is in the specified range.
Backlash: 0.13±0.20 mm(0.005 ±0.008 in)
425RS032With zero end play and correct backlash estab-
lished, remove the feeler gauge packs, determine
the thickness of the shims required and add 0.025
mm (0.001 in) to each shim pack to provide side
bearing preload. Always use new shims.
5. Use bearing remover J±42379 and pilot
J±8107±2 to remove side bearing.

Select insert; 303173 and collet halves;44801
in remover kit J±42379.
415RW003
12. Install the side bearings together with the selected
shims.
425RS029
Legend
(1) Drive Handle:J±8092
(2) Installer: J±24244
(3) Pilot: J±8107±2
13. Install side bearing outer race.
14. Install differential cage assembly.
15. Install bearing cap then align the setting marks(1)
applied at disassembly.
425RS035