ISUZU TFS SERIES 1997 User Guide

REAR AXLE 4B-15
Install the axle shaft assembly on the opposite side and push it
in until it fits against the differential thrust block. Then,
measure the clearance (t) between the bearing holder and the
axle case flange and determine the thickness of the shim to be
installed by the following formula :
Measured clearance (t) + 0.3 mm (0.012 in) = thickness of
shim to be installed.
mm(in)
thickness of shims available
1.0, 0.5, 0.13, 0.076, 0.05
(0.036, 0.026, 0.005, 0.003, 0.002)
10.Bolt and Nut
Torque N
m (kgfm/lbft)
74
5 (7.5 0.5 / 54 3.6)
Connect the brake lines to wheel cylinder.
Connect the parking brake rear cable.
Brake air bleeding, refer to servicing to Section 5 brake.
Note :
To install the axle shaft assembly, follow the reassembly
procedure outline under the "BRAKE".
12.Wheel and Tire
Tighten the wheel nut in numerical order.
Torque N
m (kgfm/lbft)
117.7
9.8 (12 1/86.8 7.2)

4B-16 REAR AXLE
DIFFERENTIAL
REMOVAL AND INSTALLATION
Removal Steps
1. Propeller shaft
2. Axle shaft
3. Differential assembly
Installation Steps
3. Differential assembly
2. Axle shaft
1. Propeller shaft
To remove the axle shaft assembly,
follow the disassembly procedure outline
in this Section “Axle shaft”
Important Operation - Removal
2. Axle Shaft
Disengage the axle shafts from the carrier assembly and
partially withdraw the shafts from the axle tube.
It is not necessary to completely remove the axle shafts.
Move them only enough to allow the differential to be removed.
To remove the axle shaft assembly, follow the disassembly
procedure outline in this Section "Axle shaft".

REAR AXLE 4B-17
Important Operations - Installation
3. Differential Assembly
(194 mm)
Torque N
m (kgfm/lbft)
NUT 37.3
3.9 (3.8 0.4/27 2.9)
BOLT 24.5 5 (2.5 0.5/18 3.6)
(220 mm)
Torque N
m (kgfm/lbft)
NUT 44
14.7 (4.5 1.5/32.5 10.8)
BOLT 63.8 5 (6.5 0.5/47 3.6)
Apply the recommended liquid gasket or its equivalent to the
sealing side of the axle case and the carrier.
To install the axle shaft assembly, follow
the reassembly procedure outline in the
“Rear axle shaft” section.
2. Axle Shaft
Torque N
m (kgfm/lbft)
73.6
5 (7.5 0.5/54.2 3.6)
1. Propeller Shaft
Torque N
m (kgfm/lbft)
194 mm 35.3
2.9 (3.6 0.3/26 2.2)
220 mm 62.8 3.9 (6.4 0.4/46.3 2.9)

4B-18 REAR AXLE
DISASSEMBLY
MAJOR COMPONENTS
Disassembly Steps
1. Side bearing cap
2. Side bearing outer race
3. Differential cage assembly and ring gear
4. Side bearing
5. Backlash and side bearing preload
adjusting shim
6. Flange nut and washer
7. Flange assembly
8. Drive pinion shaft assembly
9. Inner bearing
10. Pinion depth adjusting shim
11. Drive pinion shaft
12. Collapsible spacer
13. Oil seal
14. Outer bearing
15. Inner bearing outer race
16. Outer bearing outer race

REAR AXLE 4B-19
Important Operations
Before disassembling, make a pattern check using the method
described later in this section under "Gear Tooth Contact
Pattern Check and Adjustments". This check will help
determine what service should be performaed on the
differential components.
On some bench operations, it may be advantageous to use a
holding fixture and a holding fixture base.
Tool 5-8840-0275-0 (J-37264) and 5-8840-0003-0 (J-3289-20)
are available tools that work well for this purpose.
1. Bearing Cap
Apply an alignment mark to the side bearing cap and
differential carrier.
2. Side Bearing Outer Race
After removal, keep the right and left side bearing assemblies
separate to maintain inner and outer race combinations.
4. Side Bearing
5. Backlash and Side Bearing Preload Adjusting Shim
Remover : 5-8840-0013-0 (J-22888)
Adapter : 9-8521-1743-0 (J-8107-2) (194 mm)
5-8840-2196-0 (J-8107-4) (220 mm)
Carefully record the thickness of each side bearing and each
shim pack. Keep them separated and in order for later
reassembly.
6. Flange nut and washer (194 mm)
Holder : 5-8840-0133-0
(J-8614-01)

4B-20 REAR AXLE
Flange Nut and Washer (220 mm)
Holder : 5-8840-2157-0
(J-37221)
8. Drive Pinion Shaft Assembly
Hold a soft metal rod against the end of the drive pinion. Drive
out the pinion from the carrier by tapping the hammer against
the metal rod.
Installer : 9-8521-5032-0
9. Inner Bearing
Remove the pinion bearing using a separator and a press.
Separator : 5-8840-0015-0 (194 mm)
(J-22912-01)
: 5-8840-2197-0 (220 mm)
(J-37452)
Inner bearing outer
race15.Inner Bearing Outer Race
16.Outer Bearing Outer Race
Remove the inner bearing outer race and the outer bearing
outer race by using a brass bar and a hammer.
Other bearing outer
race

REAR AXLE 4B-21
MINOR COMPONENTS
DIFFERENTIAL ASSEMBLY
Disassembly Steps
1. Ring gear
2. Lock pin
3. Cross pin
4. Pinion gear
5. Thrust block6. Side gear
7. Thrust washer
8. Differential cage

4B-22 REAR AXLE
Important Operations
1. Ring Gear
Take care not to damage the ring gear or the differential case
when removing the ring gear. Never try to wedge a tool
between the two faces.
2. Lock Pin
Drive out the pinion shaft lock pin with a long drift punch. It
may be necessary to first remove the stakes in the lock pin with
a 5 mm drill.
3. Cross Pin
(1) Check the amount of backlash before removal.
Backlash mm(in)
194 mm 0.03 - 0.08 (0.001 - 0.003)
220 mm 0.13 - 0.18 (0.005-0.007)
(2) Remove the cross pin with a brass drift punch, and take out
the pinion gears, side gears, thrust block and thrust
washers from the differential cage.

REAR AXLE 4B-23
LIMITED SLIP DIFFERENTIAL (LSD)
(FOR RING SIZE 194 mm)
Disassembly Steps
1. Spring pin
2. Pinion spider
3. Thrust block
4. Pinion washer
5. Pinion gear
6. Side gear
7. Friction disc and plate assembly8. Side gear
9. Friction disc and plate assembly
10. Differential cage
11. Sleeve
12. Spring plate
13. Disc spring
14. Disc and plate

4B-24 REAR AXLE
Important Operations
4. Pinion washer
5. Pinion gear
(1) Clamp special tool (side gear holder) into a vice. Set the
LSD assembly.
Holder : 5-8840-2010-0
(J-36563)
(2) Set special tools (side pinion expanders and pinion rotator)
to the LSD.
Expander : 5-8840-2011-0
(J-36564)
Rotor : 5-8840-2012-0
(J-36565)
(3) Set special tool (cage lock bar) through a ring gear fixing
hole to a vice.
Then rotate side pinion expanders with a wrench one half to
one full turn to provide backlash between the side and
pinion gears.
Bar : 5-8840-2013-0
(J-36566)
(4) W ith a wrench, rotate special tool (pinion rotator) to remove
the pinion gear and the pinion washer.