differential ISUZU TF SERIES 2004 User Guide

4B-20 REAR AXLE

Disassembly
1.
Using holding fixture 5-8840-0275-0 and holding
fixture base 5-8840-0003-0, fix the differential
assembly to the bench.
425L100007

2.
Apply a setting mark to the side bearing cap and
the differential carrier then remove bearing cap.



425RS009

3.
Remove differential cage assembly.
4.
Remove side bearing outer race. After removal,
keep the right and left hand side bearing
assemblies separate to maintain inner and outer
race combinations.
5.
Remove side bearing by using remover 5-8840-
0013-0, 5-8840-0014-0 and adapter 5-8840-2196-
0.

415L100001

6.
Note the thickness and position of the shims then
remove adjust shim.
7.
Remove the flange nut by using pinion flange
holder 5-8840-0133-0 after raising up its staked
parts completely.
415RW040

REAR AXLE 4B-27

Note :





Do not overtighten or loosen and then
retighten the nut.





Pinion nut torque will be in the range of 245-
294 N
 m (25-30 kg
 m/181-217 lb
 ft).
425RW018
d. Using punch 5-8840-2293-0, stake the flange
nut at two points.
Note :
When staking, be sure to turn the nut to ensure
that there is no change in bearing preload. Make
sure NOTE: of preload again as instructed in c.

RTW34BSH000201

11. Adjust ring gear backlash.
a.
Attach the side bearing to the differential
assembly without shims by using installer 5-
8840-2162-0 and grip 5-8840-0007-0.

425L100010
b. Insert the differential cage assembly with
bearing outer races into the side bearing bores
of the carrier.

REAR AXLE 4B-29

12. Install the side bearings together with the selected
shims by using installer 5-8840-2162-0, drive
handle 5-8840-0007-0.

425L100010
13. Install side bearing outer race.
14. Install differential cage assembly.
15. Align the setting marks (1) applied at disassembly
then install the bearing cap.




425RS035



16. Tighten the bolt to the specified torque.
Torque :
108 N
m (11 kg
m/80 lb
ft)

4B-32 REAR AXLE

Differential Cage Assembly
Disassembled View

425R300005
Legend

1. Bolt
2. Ring Gear
3. Lock Pin
4. Cross Pin
5. Pinion Gear
6. Side Gear
7. Thrust Washer (for Side Gear)
8. Differential Cage

REAR AXLE 4B-33

Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Drive out lock pin using a long drift Punch.
425RS042

4. Check the amount of backlash between pinion
gear on side gear before removal of cross pin.
Backlash :
0.13-0.18 mm (0.005–0.007 in)
5. Remove the cross pin by using a brass drift
punch and hammer.





425RS043

6. Take out pinion gear, side gear and thrust
washer.
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
conditions are found through inspection.
Check the following parts:


Ring gear, pinion gear


Bearing


Side gear, pinion gear, cross pin


Differential cage, carrier


Thrust washer


Oil seal
Clearance between pinion gear and cross pin:
mm(in)

Standard Limit
0.06 - 0.12
(0.002 - 0.005) 0.2 (0.008)

425L100012

Clearance between side gear and differential cage.
mm(in)

Standard Limit
0.05 - 0.11
(0.002 - 0.004) 0.15 (0.006)

4B-34 REAR AXLE

425R300010

Play in splines between the side gear and axle shafts.
mm(in)

Standard Limit
0.08 - 0.38
(0.003 - 0.015) 0.5 (0.02)

425L100014
Differential cage
Check the ring gear the side gear fitting faces and the
cross pin hole for scores or roughness. Correct as
necessary. Slight scores or roughness may be
corrected with an oil stone or fine sand paper.
425R300006

Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard use bolts and install new ones.
3.
Apply LOCTITE 271 on bolt from the end of thread
to the middle of straight portion.
4. Tighten the fixing bolts in a diagonal sequence as
illustrated.
Torque : 108 Nm (11 kgm/80 lbft)



425RW033

REAR AXLE 4B-35

Reassembly
1. Install side gear with thrust washer in differential
cage.
2. Install the pinion gear by engaging it with the side
gears while turning both pinion gears
simultaneously in the same direction.


425RS048

3. Install cross pin.


Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the
differential cage.




425RS049

4. Check the amount of backlash.
Backlash between the side gear and the pinion
gear. mm (in)

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.
Backlash mm (in
)

0.80
(0.031)0.90
(0.035)1.00
(0.039) 1.10
(0.043) 1.20
(0.047)1.30
(0.051)





425RY00008

5. Install lock pin.
After lock pin installation, stake the case to
secure the lock pin.
6. Install ring gear.
Refer to “Ring gear replacement” on this section.

4B-36 REAR AXLE

LIMITED SLIP DIFFERENTIAL (LSD)
Disassembled View
425R300007
Legend

1. Screw
2. Differential Cage B
3. Thrust Washer
4. Spring Plate
5. Spring Plate
6. Friction plate
7. Friction disc
8. Friction plate
9. Friction disc
10. Pressure Ring
11. Side Gear
12. Pinion and Pinion Shaft
13. Side Gear
14. Pressure Ring
15. Friction Disc
16. Friction Plate
17. Friction Disc
18. Friction Plate
19. Spring Plate
20. Spring Plate
21. Thrust Washer
22. Differential Cage A

REAR AXLE 4B-37

Disassembly

Prepare a side gear holder : 5-8840-2682-0 as
shown in the left figure, clamp it with a stock vice,
and set a differential.
425R300008

1. Screw


Apply a setting mark to the differential cage
A and differential cage B remove the bolt
using the press.


Loosen four screws fixing differential cage A
to cage B equally and remove them.

425RS055

2. Remove differential cage A and B.
3. Remove thrust washer and two spring plates.
4. Remove friction plate and friction disc.
5. Remove friction plate and friction disc.
6. Remove pressure ring and side gear.
7. Remove pinion and pinion shaft.
8. Remove side gear and pressure ring.
9. Remove friction disc and friction plate.
10. Remove friction disc and friction plate.
11. Remove two spring plates and thrust washer.

4B-38 REAR AXLE

Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, rust or other problems
are discovered during inspection.

Visual Check
Inspect the following parts for wear, damage or other
abnormal conditions.


Friction disc


Friction plate


Spring plate
1 Sliding surface
2 Protrusion




425RS056

Pressure ring
Check the parts for damage or other abnormal
conditions.
3 Sliding surface for friction disc
If dents or damages are discovered, grind them
with oil stone, and repair them with compound on
surface plate.
4 Sliding surface of pressure ring inner surface and
pinion gear.
5 Slinding surface of pressure ring bore and side
gear.
6 sliding surface of pressure ring and side gear.
7 Sliding surface of pressure ring and pinion shaft.
8 Mating surface to differential cage A.
9 Burrs or dents on sliding surface of pressure ring
and rear differential cage should be repaired,
using oil stone.

425RY00022



Thrust Washer
10 Groove on side gear circumference small burrs of
dens should be repaired, using oil stone.
11 Sliding surface between side gear and thrust
washer.
425RY00024



Differential cage A and B
12 Contact surface to spring plate
13 Differential cage A and B contact surfaces to
thrust washers Small burrs or dents should be
repair, using oil stone.