differential ISUZU AXIOM 2002 Service Service Manual

DIFFERENTIAL (REAR)4A2±15
8. Remove ring gear from the differential.

Drive the ring gear off with a brass drift if necessary.

Check drive pinion bearing preload.
425RW018

Check the pinion assembly for looseness by
moving it back and forth. (Looseness indicates
excessive bearing wear.)
9. Remove pinion flange nut and washer.

Use flange holder J±8614±01 to hold the pinion
flange.
10. Remove pinion flange.

Use flange holder J±8614±01 to remove the pinion
flange.
415RS018
11. Remove pinion from the axle housing.

Thread the pinion nut halfway onto the pinion.

Drive the pinion out of the housing with a hammer
and a soft drift.

Remove the nut and then remove the pinion.12. Remove collapsible spacer(1).
415RW011
13. Remove outer seal, outer oil slinger and outer pinion
bearing.
14. Remove inner bearing, inner oil slinger and shim from
the pinion.

Press the bearing off the pinion using remover
J±42379.
415RW004

Select insert ; 303174 and collet halves ; 44801 in
remover kit J±42379.

Remove the shim.
15. Remove bearing cups and baffle plate from the axle
housing using a hammer and a punch.

Work the cups out of the housing evenly, moving the
punch back and forth between one side of the cup
and the other.

The baffle plate will be destroyed and should be
replaced with a new one.

4A2±16DIFFERNTIAL (REAR)
16. Remove exciter ring.

Remove the exciter ring from the differential using a
mallet or a brass hammer if it is required.
NOTE: Discard the exciter ring after removal.
425RS097
Cleaning
Do not steam clean drive parts which have ground and
polished surfaces such as gears, bearings, and shafts.
These parts should be cleaned in a suitable solvent. All
parts should be disassembled before cleaning.
Parts should be thoroughly dried immediately after
cleaning. Use soft, clean, lintless rags. Parts may be dried
with cimpressed air. Do not allow the bearings to spin
while drying them with compressed air.
Inspection and Repair
It is very important to carefully and thoroughly inspect all
drive unit parts before reassembly.
Thorough inspection of the drive parts for wear or stress
and subsequent replacement of worn parts will eliminate
costly drive component repair after reassembly.
Axle Housing

The carrier bore for nicks or burrs that would prevent
the outer diameter of the pinion seal from sealing,
Remove any burrs that are found.

The bearing cap bores for nicks or burrs.
Remove any burrs that are found.

The housing for cracks. Replace the housing if any
cracks are found.

The housing for foreign material such as metal chips,
dirt, or rust.
Pinion and Ring Gear

Pinion and ring gear teeth for cracking, chipping,
scoring, or excessive wear.

Pinion splines for wear.

Pinion flange splines for wear.
The sealing surface of the pinion flange for nicks,
burrs, or rough tool marks which would cause
damage to the seal's inside diameter and result in an
oil leak.

Replace all worn or broken parts.

Ring and pinion gears are matched sets and are both
replaced anytime a replacement of either is
necessary.
Bearings

Bearings visually and by feel.

The bearings should feel smooth when oiled and
rotated while applying as much hand pressure as
possible.
The large end of the bearing rollers for wear.
This is where tapered roller bearing wear is most
evident.

Bearing cups for wear, cracks, brinelling and scoring.

Bearing and cups are only replaced as sets.

If the rear axle was operated for an extended period of
time with very loose bearings, the ring gear and drive
pinion will also require replacement.

Low mileage bearings may have minute scratches
and pits on the rollers and the bearing cups from the
initial pre-load. Do not replace a bearing for this
reason.

Bearing cups for cracks or chips.
Shims

Shims for cracks and chips. Damaged shims should
be replaced with an equally sized service shim.
Reassembly
1. Install pinion bearing races and baffle plate using
outer bearing race installer J±8611±01 / inner bearing
race installer J±42836 and drive handle J±8592.
NOTE: Baffle plate must be installed, when install the
inner pinion bearing race.
425RW019

DIFFERENTIAL (REAR)4A2±17
425RW020
2. Clean all the gauge parts.
3. Lubricate the outer and inner bearings with axle
lubricant.
4. Place the bearings into the pinion bearing races.
5. Place the inner oil slinger onto the inner pinion
bearing.
NOTE: The inner oil slinger must be placed between
gauge plate and inner pinion bearing when measuring the
pinion depth.
6. Install gauge plate J±39837±2, inner J±42827 stud
and nut J±21777±43 and outer pilot J±42824 to the
pinion bore.
420RW005
7. Hold the stud stationary at the flats of the stud (and).
Tighten the stud nut
Torque: 2.2 N´m (1.6 lb ft)
8. Rotate the gauge plate and bearings several
complete revolutions to seat the bearings.
9. Tighten the stud nut until a torque of 1.6 to 2.2 N´m
(1.2 to 1.6 lb ft.) is required to keep the gauge plate in
rotation.10. Assemble discs J±39837±1, arbor J±23597±1 and
dial indicator J±8001 to the side bearing bores.
NOTE: The bearing bores must be clean and burr-free.
420RW005
11. Install the side bearing caps and tighten the bolts to
the specified torque.
Torque: 108 N´m (80 lb ft)
12. Rotate the gauge plate until the gauging area is
parallel with the discs.
13. Position the arbor assembly in the carrier so that the
plunger is centered on the gauge area of the gauge
plate.

DIFFERENTIAL (REAR)4A2±19
18. Select the shim using the chart;
Dial Indicator
ReadingMarking (inches)Reading
(inches)
+3+2+10±1±2±3
0.027 0.030
0.028 0.0300.031
0.029 0.0300.0310.032
0.030 0.0300.0310.0320.033
0.031 0.0300.0310.0320.0330.034
0.032 0.0300.0310.0320.0330.0340.035
0.0330.0300.0310.0320.0330.0340.0350.036
0.0340.0310.0320.0330.0340.0350.0360.037
0.0350.0320.0330.0340.0350.0360.0370.038
0.0360.0330.0340.0350.0360.0370.0380.039
0.0370.0340.0350.0360.0370.0380.0390.040
0.0380.0350.0360.0370.0380.0390.0400.041
0.0390.0360.0370.0380.0390.0400.0410.042
0.0400.0370.0380.0390.0400.0410.0420.043
0.0410.0380.0390.0400.0410.0420.0430.044
0.0420.0390.0400.0410.0420.0430.0440.045
0.0430.0400.0410.0420.0430.0440.0450.046
0.0440.0410.0420.0430.0440.0450.0460.047
0.0450.0420.0430.0440.0450.0460.0470.048
0.0460.0430.0440.0450.0460.0470.0480.049
0.0470.0440.0450.0460.0470.0480.0490.050
0.0480.0450.0460.0470.0480.0490.0500.051
0.0490.0460.0470.0480.0490.0500.0510.052
0.0500.0470.0480.0490.0500.0510.0520.053
0.0510.0480.0490.0500.0510.0520.053
0.0520.0490.0500.0510.0520.053
0.0530.0500.0510.0520.053
0.0540.0510.0520.053
0.0550.0520.053
0.0560.053

4A2±20DIFFERNTIAL (REAR)
19. Remove bearing caps and depth gauging tools.
20. Install the correct pinion shim and inner oil slinger
onto pinion.
NOTE: Do not install pinion gear into housing at this time.
21. If the exciter ring was removed, install the new exciter
ring onto the differential case by pressing using the
ring gear as a pilot.
425RS047
22. Install ring gear(1) to the differential case(2)
425RW021
23. Install new ring gear bolts.

Tighten the ring gear bolts alternately in stages,
gradually pulling the ring gear onto the differential
case.
Tighten the ring gear bolts in sequence
Torque: 108 N´m (80 lb ft)
NOTE: Discard used bolts and install new ones.
415RS016
Side Bearing Preload Adjustment
1. The side bearing preload adjustment must be made
before installing the pinion.
2. The side bearing preload is adjusted by changing the
thickness of both the left and right shims equally. This
maintain the original backlash.
3. Install master side bearings J±39836 onto the case.
Remove all nicks, burrs, dirt etc., from the hubs to
allow the master bearings to rotate freely.
425RW026

DIFFERENTIAL (REAR)4A2±21
4. Assemble the differential case into the housing (less
pinion). Install bearing caps and finger tight bolts.
Mount a dial indicator with a magnetic base to the
housing and indicate on the flange or head of screw.
Force the differential assembly as far as possible in
the dirction towards the indicator.
With force still applied, set indicator at zero(0).
NOTE: Dial indicator set should be capable of a minimum
travel of 5.08 mm (0.2 in).
425RS107
5. Force the differetial assembly as far as it will go in the
opposite direction. Repeat these steps until the same
reading is obtained.
6. RECORD THE READING OF THE INDICATOR.
This amount, in shims, will be included in the final
assembly shim stack to establish side bearing
preload and ring gear and pinion backlash.
7. After marking sure the readings are correct, remove
the indicator and differetial assembly from the
housing.
Pinion Installation

The bearing cups should have been installed in Pinion
Depth Adjustment in this section.
1. Place the shim(1) and inner oil slinger(2) on the pinion
gear, then install the pinion inner bearing(3) using
installer J±42828.
425RW023

Drive the bearing until the bearing cone seats on the
pinion shims.
2. Install a new collapsible spacer.

Lubracate the pinion bearings with axle lublicant.
3. Install pinion to the axle housing.
4. Install outer pinion bearing onto the pinion.

Hold the pinion forward from inside the case while
driving the bearing onto the pinion.
5. Install oil seal slinger.
6. Install pinion oil seal using installer J±37263.
7. Install the pinion flange to the pinion by tapping it with
a rawhide hammer until a few threads show through
the pinion flange.
8. Install pinion washer and a new nut while holding the
pinion flange with flange holder J±8614±01.

Tighten the nut until the pinion end play is just taken
up. Rotate the pinion while tightening the nut to seat
the bearings.
Torque:217-678 N´m (160-500 lb ft)
Once there is no end play in the pinion, the preload
torque should be checked.

Remove flange holder J±8614±01. Using an
inch-pound torque wrench, check the pinion
preload by rotating the pinion with the wrench.

4A2±22DIFFERNTIAL (REAR)
425RW018Preload should be at 1.0 to 1.6 N´m (8 to 14 in lbs.)
on new bearings, or 0.46 to 0.69 N´m (4 to 6 in lbs.)
for used bearings.

If the preload torque is below the preloads given
above, continue torquing the nut in small
increments. Check the preload after each
tightening. Each tightening increases the bearing
preload by several pounds. If the bearing preload is
exceeded, the pinion will have to be removed, and a
new collapsible spacer installed.

Once a preload of 1.0 to 1.4 N´m (8 to 12 in lbs.)
has been obtained, rotate the pinion several times
to assure that the bearings have seated. Recheck
the preload, and adjust if necessary.
Determination of Backlash & Preload
Shims
1. Install master side bearings onto the case.
2. Install differential assembly into the carrier.
3. Install the bearing cap and finger tight bolts.
4. Set up the dial indicator.
5. Force the differential assembly away from the pinion
gear until it is completely seated against the cross
bore face of the carrier.
6. With force still applied to the differential case, place
the tip of dial indicator on a machined surface of the
differential case, if available, or on the head of a ring
gear screw, and set the indicator at zero(0).
7. Force the ring gear to mesh with the pinion gear. Rock
the ring gear slightly to make sure the gear teeth are
meshed. Repeat this procedure several times until
the same reading is obtained each time. Be sure the
indicator reads zero(0) each time the ring gear is
forced back into contact with the cross bore face. This
reading will be the necessary amount of shims to be
placed between the differential case and side bearing
cone on the ring gear side.8. The remaining amount of shims, which is the
difference between the overall found in step 6 of Side
Bearing Pre-load Adjustment and step(7) above,
should be placed on the other side of the differential
case, plus additional 0.38 mm (0.015 in) for obtaining
preload and backlash.
9. Place the required amount of shims on each hub as
determined in the previous steps and assemble side
bearing cone by using installer J±21784 and handle
J±8592.
425RW022
10. Total torque to rotate Ð Increase of pinion torque to
rotate due to differential case assembly shall not
exceed 3.4 N´m (30 in lbs.) divided by the gear ratio.
11. Assembly the spreader J±24385±B and indicator to
the carrier as shown in figure. Spread the carrier
0.5 mm (0.02 in) for differential installation.
420RW004
CAUTION: Do not spread the carrier over 0.5 mm
(0.02 in).
12. Remove the indicator.

DIFFERENTIAL (REAR)4A2±23
Backlash Adjustment
1. Install the differential case assembly and bearing
caps.
2. Rotate the case several times to seat the bearings.
3. Remove the spreader.
4. Install the side bearing cap bolts.
Tighten side bearing cap bolts
Torque: 108 N´m (80 lb ft)
5. Install a dial indicator to the case using a magnetic
base.
6. Place the indicator stem at the heel end of a tooth.

Set the dial indicator so that the stem is in line with
the gear rotation and perpendicular to the tooth
angle.
425RS087
7. Check and record the backlash at three points around
the ring gear.

The pinion must be held stationary when checking
backlash.

The backlash should be the same at each point
within 0.07 mm (0.003 in). If the backlash varies
more than 0.07 mm (0.003 in), check for burrs, a
distorted case flange, or uneven bolting conditions.
8. Backlash at the minimum lash point measured should
be between 0.13 and 0.20 mm (0.005 and 0.008 in)
for all new gear sets.
9. If the backlash is not within specifications, move the
ring gear in or out from the pinion by increasing the
thickness of one shims, and decreasing the thickness
of the other shim by the same amount.
This will maintain the correct rear axls side bearing
preload.

Moving 0.05 mm (0.002 in) worth of shim from one
side of the differential to the other will change the
backlash adjustment by 0.03 mm (0.001 in).
10. After obtaining correct tooth contact described in
later, install ABS speed sensor.11. Install the cover with sealant.
Torque: 40 N´m (30 lb ft)
12. Fill the axle lubricant.
Gear Tooth Pattern Check
Checking the ring gear to pinion tooth pattern is to be
done only after setting up the axle according to the
methods in this section. The pattern check is NEVER to
be used as an initial check, or instead of checking pinion
depth and backlash adjustments.
This check is only to be verify the correct adjustment of
the gear set after set up.
425RS038
Legend
(1) Heel
(2) Toe
(3) Concave Side (Coast)
(4) Convex Side (Drive)
1. Wipe all oil out of the carrier, and carefully clean each
tooth of the ring gear.
2. Use gear marking compound 1052351 or equivalent
and apply this mixture sparingly to all ring gear teeth,
using a medium-stiff brush. When properly used, the
area of pinion tooth contact will be visible when hand
load is applied.
3. Tighten the bearing cap bolts to the specified torque.
4. Expand the brake shoes until a torque of 54 to 68 N´m
(40 to 50 lb ft.) is required to turn the pinion. A test
made without loading the gears will not give a
satisfactory pattern. Turn the pinion flange with a
wrench so that the ring gear rotates one full
revolution, then reverse the rotation so that the ring
gear rotates one revolution in the opposite direction.
5. Observe the pattern on the ring gear teeth and
compare this with figure.

DIFFERENTIAL (REAR)4A2±25
Differential Case Assembly
Disassembled View
425RW014
Legend
(1) Thrust Washer (for Pinion Gear)
(2) Pinion Mate Gear
(3) Thrust Washer(for Side Gear)
(4) Side Gear(5) Differential Shaft
(6) Lock Pin
(7) Bolt
(8) Differential Case

4A2±26DIFFERNTIAL (REAR)
Disassembly
1. Remove lock pin using a small drift.
425RS098
2. Remove the differential shaft by using a soft metal rod
and a hammer.
425RS043
3. Remove pinion mate gear and thrust washer.
4. Remove side gear and thrust washer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts.

Ring gear, pinion gear

Bearing

Side gear, pinion mate gear, differential shaft

Differential case, carrier

Thrust washer

Oil seal
Reassembly
1. Install side gear with thrust washer.
2. Install the pinion mate gear with thrust washer by
engaging it with the side gears while turning both
pinion mate gears simultaneously in the same
direction.
425RS048
3. Install differential shaft.
1. Be sure to install the differential shaft so that it is in
alignment with the lock pin hole in the differential
case.
425RS049
4. Install lock pin.
After lock pin installation, stake the case to secure the
lock pin.