ISUZU TF SERIES 2004 Workshop Manual

FRONT WHEEL DRIVE 4C1-1
SECTION 4C1
FRONT WHEEL DRIVE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4C1- 3
Special Parts Fixing Nuts and Bolts ................................................................................ 4C1- 4
Recommended Liquid Gasket .......................................................................................... 4C1- 6
Recommended Thread Locking Agents .......................................................................... 4C1- 6
Servicing............................................................................................................................. 4C1- 7
General Description........................................................................................................... 4C1- 8
Front Drive Axle Assembly ............................................................................................. 4C1- 14
Front Drive Axle Assembly and Associated Parts ................................................... 4C1- 14
Removal ....................................................................................................................... 4C1- 15
Installation ...................................................................................................................4C1- 16
Front Axle Drive Shaft ..................................................................................................... 4C1- 18
Front Axle Drive Shaft and Associated Parts ........................................................... 4C1- 18
Disassembly ................................................................................................................ 4C1- 19
Inspection and Repair................................................................................................. 4C1- 20
Bushing Replacement ............................................................................................... 4C1- 21
Reassembly ................................................................................................................. 4C1- 21
Standard caulk Measure ............................................................................................ 4C1- 22
Differential ...................................................................................................................4C1- 24
Disassembly ................................................................................................................ 4C1- 24
Major Components ................................................................................................ 4C1- 24
Minor Components................................................................................................ 4C1- 27
Inspection and Repair................................................................................................. 4C1- 29
Reassembly ................................................................................................................ 4C1- 31
Minor Components ................................................................................................. 4C1- 31
Major Components ................................................................................................. 4C1- 33

4C1-2 FRONT WHEEL DRIVE
PAGE
Front Hub and Disc (4





2 Except High Ride Suspension Model) ................................. 4C1- 42
Disassembly ................................................................................................................ 4C1- 42
Inspection and Repair................................................................................................. 4C1- 45
Reassembly ................................................................................................................. 4C1- 46
Front Hub and Disc (4




4, 4




2 High Ride Suspension, 4




4 Rigid Hub,
4




4 Shift On The Fly Model) ........................................................................................... 4C1- 50
Disassembly ................................................................................................................ 4C1- 50
Inspection and Repair................................................................................................. 4C1- 52
Reassembly ................................................................................................................. 4C1- 53
Front Hub and Disc (4





4 Manual Locking Hub Model) ................................................. 4C1- 57
Disassembly ................................................................................................................ 4C1- 57
Inspection and Repair................................................................................................. 4C1- 60
Reassembly ................................................................................................................. 4C1- 61
Troubleshooting .............................................................................................................. 4C1-67
Special Service Tool ................................................................................................... 4C1-75

FRONT WHEEL DRIVE 4C1-3
MAIN DATA AND SPECIFICATIONS
FRONT AXLE AND DIFFERENTIAL
Ring gear size mm (in) 194 (7.6)
Axle tube
Type It consists of the duce, a cast iron housing and the Axle tube.
Gear type Hypoid
Gear ratio (to 1) 4.100, 4.300, 4.555, 4.777, 5125
Differential type Two pinion
Specified gear oil (APL grade) GL-5
Oil capacity liter 1.4
(US/UK gal.) (0.4/0.33)
Axle shaft type Constant velocity joint (Birfield joint type and double offset joint).


FRONT PROPELLER SHAFT mm(in)
4

4 Model
Engine Model 4JA1-T(L) 4JA1-TC 4JH1-TC C24SE 6VE1
Transmission Type 5M/T (MUA) 5M/T
(MUA) 4A/T 5M/T
(MUA) 5M/T
(MUA) 4A/T
Front Axle 194 mm










Outside Diameter mm 40 40 40 40 40 40
(in) (1.57) (1.57) (1.57) (1.57) (1.57) (1.57)
Inside Diameter mm 32 32 32 32 32 32
(in) (1.26) (1.26) (1.26) (1.26) (1.26) (1.26)
Length (L) mm 607 607 676 586 586 607
(in) (23.90) (23.90) (26.61) (23.07) (23.07) (23.90)
Fix Bolt Size T/F M10 M10 M10 M10 M10 M10
Axle M10 M10 M10 M10 M10 M10

4C1-4 FRONT WHEEL DRIVE
SPECIAL PARTS FIXING NUTS AND BOLTS
FRONT DRIVE AXLE AND PROPELLER SHAFT
N
m (kgf
m/lb
ft)




RTW440LF000101

FRONT WHEEL DRIVE 4C1-5
FRONT DIFFERENTIAL
Nm (kgfm/lbft)



RTW440LF000901

4C1-6 FRONT WHEEL DRIVE
RECOMMENDED LIQUID GASKET

Type Brand Name Manufacture Remarks

RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
Water Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer

Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacture's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying
the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater
than 0.25 mm (0.01 in). Poor adhesion will result.

RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.

LOCTITE 262

Red 2. Apply LOCTITE to the bolts.


LOCTITE 270

Green

LOCTITE 271

Red
3. Tighten the bolts to the specified torque.
4. Wait at least on hour before continuing the installation procedure.

FRONT WHEEL DRIVE 4C1-7
SERVICING


Hub Bearing Preload at the Wheel Pin
4
4, 4
2 (High Ride Suspension) Model N (lb)

New bearing and New oil seal 20 - 25 (4.4 - 5.5)
Reuse bearing and New oil seal 12 - 18 (2.6 - 4.0)
42 (Except High Ride Suspension) Model N (lb)

New bearing and New oil seal 8 - 12 (1.8 - 2.2)
Reuse bearing and New oil seal 8 - 12 (1.8 - 2.2)

4C1-8 FRONT WHEEL DRIVE
GENERAL DESCRIPTION
FRONT DRIVE AXLE (With Shift On The Fly)



412R300015


(Without Shift On The Fly)



RTW440MF000101

FRONT WHEEL DRIVE 4C1-9
FRONT HUB AND DISC (4





2 Except High Ride Suspension Model)
412R300010

4C1-10 FRONT WHEEL DRIVE
(4





2 High Ride Suspension Model)
RTW34CLF000701