oil ISUZU TF SERIES 2004 Owners Manual

FRONT WHEEL DRIVE 4C1-71
4. NOISES IN FRONT AXLE

Checkpoint Trouble Cause Countermeasure

Replenish the gear oilInsufficient gear oil NG
Replace the wheel bearing
Replace the pinion shaft
bearing
Replace the ring gear pinion
gear or side gear
Replace the gear oil
Wheel bearingWorn
Pinion shaft bearingWorn
Worn or chipped
Wrong or poor grade gear oil
Ring gear, pinion gear or side
gear
Adjust the backlashDrive pinion to ring gear
backlashToo much or too little backlash
NG NG NG NG NG
OK OK
OK
OK
Oil level
Tighten or replaceDifferential bearingLoose or worn NG OK

4C1-76 FRONT WHEEL DRIVE
ITEM NO. ILLUSTRATION PART NO. PART NAME


FAL-41

5-8840-2089-0
(J-23597-9)

Nut & bolt


FAL-36

5-8840-2087-0
(J-23597-7)

Gauge plate


FAL-42

5-8840-0126-0
(J-8001)

Dial indicator



FAL-43

5-8840-0128-0
(J-23597-1)

Arbor



FAL-38

5-8840-2088-0
(J-23597-8)

Disc (2 pcs. required)



FAL-59

9-8522-1165-0
(J-6133-01)
Pinion bearing installer
(for 4WD)


FAL-52

9-8522-1275-0
(J-24250)

Pinion oil seal installer



FAL-56

9-8522-1164-0
(J-24244)

Side bearing installer



FAL-57

5-8522-0053-0
(J-29016)
Outer bearing installer
(for 2WD)

FRONT WHEEL DRIVE 4C1-77
ITEM NO. ILLUSTRATION PART NO. PART NAME


FAL-58

5-8522-0054-0
(J-29015)
Inner bearing installer
(for 2WD)


FAL-54

5-8522-0051-0
(J-33161)
Hub oil seal installer
(for 2WD)


FAL-62

5-8840-2117-0
(J-36827)

Hub nut wrench


FAL-17

5-8840-2119-0
(J-36829)
Outer bearing inner race
installer (for 4WD)


FAL-19

5-8840-2120-0
(J-36830)

Oil seal installer (for 4WD)


FAL-18

5-8522-0054-0
(J-29015)
Outer bearing outer race
installer (for 4WD)


FAL-61

5-8840-2137-0
(J-38194)

Inner cam installer


FAL-39


5-8840-2126-0
Auto locking shim gauge
(for 4WD)


FAL-60


5-8840-2125-0
Snap ring installer
(for 4WD)

4C2-4 SHIFT ON THE FLY SYSTEM
Shift On The Fly System and Association Parts







RTW440LF000701
Disassembly steps
1. Filler plug
2. Bolt
3. Front axle drive shaft (LH side)
4. Bolt
5. Actuator assembly
6. Bolt
7. Housing
8. Sleeve
9. Clutch gear
10. Snap ring
11. Inner shaft
12. Snap ring
13. Inner shaft bearing
14. Needing bearing
15. Oil seal
Reassembly steps
To reassemble, follow the disassembly steps in
the reverse order.

SHIFT ON THE FLY SYSTEM 4C2-5



DISASSEMBLY
1. Filler Plug
Remove filler plug and packing and drain oil.
2. Bolt
Loosen mounting bracket fitting bolts and remove front axle
drive shaft from front axle case.
3. Front Axle Drive Shaft (LH side)
4. Bolt
Loosen actuator ASM fitting bolts.
5. Actuator Assembly
Draw out actuator ASM.
6. Bolt
Remove hosing fitting bolts.
7. Housing
8. Sleeve
9. Clutch Gear



412RW017

10. Snap Ring
Remove snap ring from front axle case by using a snap ring
pliers.

11.Inner Shaft
Take out inner shaft from front axle case.



412RW016

12.Snap Ring
Remove snap ring from inner shaft by using a snap ring
pliers.



412RW015
13.Inner Shaft Bearing
Remove inner shaft bearing by using a special tool and
press.
Remove : 5-8840-2197-0 (J-37452)
NOTE:
Be careful not to damage the shaft.

4C2-6 SHIFT ON THE FLY SYSTEM




412RS045
14.Needle Bearing
Remove needle bearing from inner shaft by using a special
tool.
Remover : 5-8840-0027-0 (J-26941)
Sliding hammer : 5-8840-0084-0 (J-2619-01)
NOTE:
Be careful not to damage the shaft.

15.Oil Seal
Remove oil seal from front axle case.
NOTE:
Be careful not to damage the front axle case.

Inspection and Repair
Inspect the removed parts. If there are abnormalities such as
wear and damage, take corrective action or replace.

Visual Check


Check and see if the inner shaft has such
abnormalities as wear and damage.







412RW014




412RS008


When inspecting the inner shaft, be sure to check and
see if its splined part is twisted, worn, or cracked. If so,
replace with a new shaft. In case such an abnormality
in its gear part (a slide with sleeve), replace the shaft.
















412RS026
Inner Shaft Run-Out
With both end centers supported, rotate the shaft slowly
and measure deflection with a dial gauge.
Inner Shaft Run-Out (Limit) mm (in)
0.5 (0.02)
NOTE:
Do not heat the shaft to correct its bend.

SHIFT ON THE FLY SYSTEM 4C2-7



RTW440SH000101
Inner Shaft Bearing
Inspect the state of inner shaft bearing. If any abnormality
such as smoothlessness is found, replace with a new inner
shaft bearing.
Insert a clutch gear and check the state of needle bearing.
If there is an abnormality such as smoothlessness, replace
the needle bearing.

Sleeve
Visual Check
Check and see that there is not wear, damage, or crecking
in the sleeve.
NOTE:
Close inspection of the groove and inner gear are required
because those are important parts.










412RW011
Functional Check
Operate the sleeve with the inner shaft combined with the
clutch gear.
If smoothlessness is felt, replace the sleeve.
NOTE:
Gear oil should be applied to the contact surface of gear.




412RW022
Dimensional Check
Check the width of sleeve center groove.
Sleeve Center Groove (Limit) mm (in)
7.1 (0.28)

4C2-8 SHIFT ON THE FLY SYSTEM



RTW440SH000201
Clutch Gear
Visual Check
Check and see the there is not wear, damage, crack, or
any other abnormality in the clutch gear.
Functional Check
If there is an abnormality such as soothlessness when
operated in combination with sleeve, replace the clutch
gear.
NOTE:
When inspection, gear oil should be applied to the contact
surface of gear.




RTW440SH000301
Dimensional Check
Make sure of the size illustrated.
Clutch Gear Out Side Diameter (Limit) mm (in)
36.98 (1.46)



RTW440SH000501



RTW440SH000401
Actuator
Visual Check
Check and see that there is no damage, cracking, or other
abnormality.
Functional Check
Make sure of function with voltage (12V) applied to
terminal
3, 4 and set the tester to terminal 1, 2 in
accordance with the table below.
State Port 3Port 4Port 1, 2
Conducting Function
A






C
B







D
If there is an abnormality, replace the actuator as an
assembly.
NOTE:
Be careful not to permit the entry of water or dust into the ports
of the actuator.
Do not open the actuator cover, if the actuator will be reused.

SHIFT ON THE FLY SYSTEM 4C2-9


RTW440SH000601








RTW440SH000801
Dimension Check
Measure illustration sized A, B, and C
Limit mm (in)

A 64.3 (2.53)
B 6.7 (0.26)
C 6.7 (0.26)













RTW440SH000701




REASSEMBLY
15. Oil seal
Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer.
Installer 5-8840-2407-0 (J-41693)
Grip 5-8840-0007-0 (J-8092)
























412RS051



14. Needle Bearing
Force a new needle bearing into inner shaft by using a
special tool.
Installer : 5-8840-2408-0 (J-41694)
Grip : 5-8840-0007-0 (J-8092)

4C2-10 SHIFT ON THE FLY SYSTEM



412RS044





















13. Inner Shaft Bearing


Place a new snap ring in inner shaft.


Force a new inner shaft bearing into the inner shaft.
Installer : 5-8840-2197-0 (J-37452)


12. Snap Ring
NOTE;
Be careful not to damage the inner shaft.

11.inner Shaft


Clean the housing contact surface of the front axle
case.


Insert inner shaft assembly into the front axle case.
NOTE:
Be careful not to damage oil seal.




412RW017

10. Snap Ring
Install snap ring in the groove of front axle case.
NOTE:
Be sure to install the snap ring properly.


9. Clutch Gear
Apply differential gear oil to clutch oil.
8. Sleeve
Apply differential gear oil to sleeve.




412RW023


7. Housing


Clean contact surface with the front axle and sctuator
mounting surface.

Apply liquid gasket to the contact surface on the front
axle case and install in the housing.

6. Bolt
Tighten bolts to specified tightening torque.
Housing Bolt Torque N m (kg m/lb ft)
75 (7.6/55)