wheel ISUZU TF SERIES 2004 Owner's Guide

4B-16 REAR AXLE

8.
Certainly install new snap ring, use snap ring pliers.
When transform or damage, replace new one.



RTW34BMH000101
Legend


1.
Snap ring

2.
Crevice
3.
Sensor rotor (with ABS)

Spacer (without ABS)


9.
Insert a shim of sufficient thickness between snap
ring and end of sensor rotor (or spacer).


Standard
0 
0.2 mm (0 
0.008 in)


Crevice is measured using thickness gauge, and
when crevice exceeds 0.2 (mm), it adjusts so that
is may become 0.2 (mm) or less using shim.


Shim Pats No.
Thickness

1 9-41519110-
0.18 mm (0.0071 in)

2 8-97130387-

0.50 mm (0.0197 in)


Crevice
No. of shim
Total

Mm (in)
1 2
mm (in)

1.0(0.0394) 
2
1.00(0.0394)

0.9(0.0354)
2
1
0.86(0.0339)

0.8(0.0315)
1
1
0.68(0.0268)

0.7(0.0276)
1
1
0.68(0.0268)

0.6(0.0236)

1
0.50(0.0197)

0.5(0.0197)

1
0.50(0.0197)

0.4(0.0158)
2 
0.36(0.0142)
0.3(0.0118)
1 
0.18(0.0071)
0.2(0.0079)
1 
0.18(0.0071)

10. Install axle shaft assembly in rear axle case
assembly.
Note:
When inserting an axle shaft, it inserts so that an
oil seal may not be damaged.
11. Install and tighten bearing holder fixing nut to the
specified torque.

Torque : 84 N
m (8.6 kg
m/62 lb
ft)
12. Install wheel cylinder and tighten the bolt to the
specified torque.

Torque : 9 N
m (0.9 kg
m/78 lb
ft)
13. Install parking brake outer cable in back plate and
inner cable in parking brake lever.

REAR AXLE 4B-17

14.
Install shoe assembly with adjuster lever, shoe
assembly with parking brake lever and spring.
15.
Install return spring.
16.
Install shoe clamp spring and tension pin.


305R300001
Legend


1.
Tension Pin

2.
Shoe Clamp Spring

3.
Return Spring

4.
Shoe Assembly with Parking Brake Lever

5.
Shoe Assembly with Adjuster Lever

6.
Spring

7.
Parking Brake Cable


8.
Adjuster

9.
Parking Brake Lever

10.
Adjuster Spring

11.
Adjuster Lever

12.
Wheel Cylinder

13.
Back plate

4B-18 REAR AXLE

17.
Install brake pipe and ABS sensor and tighten it to
the specified torque.

Torque :

ABS Sensor
8 N
m (0.8 kg
m/69 lb
ft)

Brake Pipe
16 N
m (1.6 kg
m/12 lb
ft)
420R30003

18.
Bleed brake pipe at the wheel cylinder. (Refer to
the section “Power-assisted Brake System”)
19.
Install brake drum.


Install propeller shaft. (Refer to Section “Rear
Propeller Shaft”.)


Refill differential oil.


Install wheel and tire.


Lower vehicle.

REAR AXLE 4B-43

TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair
rear axle problems.
Each troubleshooting chart has three headings
arranged from left to right.
(1) Checkpoint
(2) Trouble Cause
(3) Countermeasure
This Section is divided into five sub-sections:
1. Abnormal Rear Axle Noise
1) Noise when the engine is driving the vehicle
2) Noise when the vehicle is coasting
3) Intermittent noise
4) Noise when the vehicle is turning
5) Constant noise
2. Vibration
3. Oil Leakage
1) Differential carrier leakage
2) Axle case leakage
3) Axle case to inside hub leakage
4) Axle case to inside brake drum leakage
4. Power Not Being Transmitted to the Wheels
(Propeller Shaft Operation is Normal)

REAR AXLE 4B-53

4. POWER NOT BEING TRANSMITTED TO THE WHEELS
(PROPELLER SHAFT OPERATION IS NORMAL)

Checkpoint Trouble Cause Countermeasure

Replace the rear axle shaftBroken rear axle shaft NG
Replace the drive pinion and
the ring gear as a setDrive pinion and ring gearBroken drive pinion and/or ring
gear
Replace the differential gears
and/or the spiderDifferential cage gearsBroken differential cage gears
and/or spider NG NG
OK OK
Rear axle shaft

4B-54 REAR AXLE

SPECIAL SERVICE TOOL
ITEM NO. ILLUSTRATION PART NO. PART NAME





5-8840-0079-0


Wheel Pin Remover





9-8522-1269-0

Oil Seal Installer



5-8840-2202-0

Oil Seal Installer



9-8522-1271-0

Support Stand



5-8840-0275-0

Holding Fixture



5-8840-0003-0

Holding Fixture Base



5-8840-0013-0

Remover



5-8840-0014-0

Remover



5-8840-2196-0

Adapter

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