oil ISUZU TFS SERIES 1997 User Guide

4B-52 REAR AXLE
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
1. ABNORMAL REAR AXLE NOISE
1) Noise when the Engine is Driving the Vehicle
Checkpoint Trouble Cause Countermeasure
Replenish the gear oilInsufficient gear oil NG
Differential side bearingAdjust the differential side
bearing preload
Replace the drive pinion
bearings
Adjust the drive pinion bearing
preload
Replace the gear oil
Loose differential side
bearings
W orn drive pinion bearings
Loose drive pinion bearings
W rong or poor grade gear oil
Drive pinion to ring gear
backlash
Drive pinion end play
Adjust the backlashToo much or too little backlash
Continued on the next pageOK OK
NG NG NG NG NG
OK
OK
Rear axle gear oil
Replace the differential side
bearingsW orn differential side bearings NG

REAR AXLE 4B-57
5) Constant Noise
Checkpoint Trouble Cause Countermeasure
Replace the rear axle shaftBent rear axle shaft NG
Replace the side bearing
Replace the drive pinion
bearing
Replace the drive pinion and
the ring gear as a set
Replace the drive pinion and
the ring gear as a set
Flat spot on the side bearing
oil seal
BearingFlat spot on the drive pinion
Flat spot on the gear teeth
pilot bearing wear
Drive pinionFlat spot on the drive pinion
gear teeth
Ring gear
Replace the drive pinion and
the ring gear as a setW orn pinion splines oil seal
NG NG NG NG NG
OK OK
OK
Rear axle shaft

REAR AXLE 4B-59
3. OIL LEAKAGE
1) Differential Carrier Leakage
Checkpoint Trouble Cause Countermeasure
Correct the oil levelToo much gear oil NG
Reapply the liquid gasket
and/or tighten the lock nut to
the specified torque
Reapply the liquid gasket
Tighten the bolts to the
specified torque
Replace the oil seal
Ring gear thrust boltLoose lock nut and/or liquid
Liquid gasket seal bed
Loose bolts
Oil sealW orn or defective oil seal
Differential carrier
Clean the air breatherAir breatherClogged air breather
NG NG NG NG NG
OK OK OK
OK
Gear oil level

4B-60 REAR AXLE
2) Axle Case Leakage
Checkpoint Trouble Cause Countermeasure
Tighten the drain plug and/or
replace the gasket(s)Loose drain plug and/or
defective gasket(s) NG
Reapply the liquid gasket
Tighten the bolts to the
specified torque
Clean the air breather
Liquid gasket seal bad
Loose bolts
Air breatherClogged air breather
Differential carrier
Replace the axle caseAxle caseCracked axle case
NG NG NG NG
OK OK
OK
Oil filler and drain plug

REAR AXLE 4B-61
3) Axle Case to Inside Brake Drum Leakage
Checkpoint Trouble Cause Countermeasure
Replace the oil sealW orn or defective oil seal NGOil seal

REAR AXLE 4B-63
SPECIAL SERVICE TOOL
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-1
5-8840-2003-0
(J-24246)Axle shaft bearing nut
remover & installer
RAL-25-8840-2329-0Axle shaft bearing nut
remover & installer
(Heavy-Duty type)
RAL-3
5-8840-0079-0
(J-6627-A) Wheel pin remover
RAL-4
5-8522-1268-0
(J-24259)Axle shaft bearing outer
race installer (for 194mm)
5-8840-2201-0 194mm (H/D), 220mm
OTL-1
5-8840-0007-0
(J-8092) Driver handle
RAL-35
9-8522-1269-0
(J-24255)Bearing holder oil seal
installer (for 194mm)
RAL-115-8840-2202-0Bearing holder oil seal
installer (for 194mm H/D,
220mm)
RAL-6
9-8522-1271-0
(J-8609-01) Axle shaft bearing installer

4B-64 REAR AXLE
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-34
9-8522-1272-0
(J-24254)Axle case oil seal installer
(for 194mm)
RAL-41
5-8840-0275-0
(J-37264) Differential holding fixture
RAL-40
5-8840-0003-0
(J-3289-20) Holding fixture base
RAL-44
5-8840-0013-0
(J-22888) Side bearing puller
RAL-9
9-8521-1743-0
(J-8107-2)Side bearing plug adapter
(for 194mm)
RAL-10
5-8840-2196-0
(J-8107-4)Side bearing plug adapter
(for 220mm)
RAL-50
5-8840-0133-0
(J-8614-01)Pinion flange holder
(for 194mm)
RAL-51
5-8840-2157-0
(J-37211)Pinion flange holder
(for 220mm)
RAL-539-8521-5032-0 Final pinion spindle

REAR AXLE 4B-67
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-69
5-8840-0128-0
(J-23597-1)Arbor
(for 194mm, 220mm)
RAL-64
5-8840-2167-0
(J-21777-86)Disc (2 pcs. Required)
(for 220mm)
RAL-279-8522-1165-0
(J-6133-01)Inner bearing installer
RAL-36
9-8522-1275-0
(J-24250)Pinion oil seal installer
(for 194mm)
RAL-37
5-8840-2165-0
(J-37263)Oil seal installer
(for 220mm)
RAL-29
9-8522-1164-0
(J-24244)Side bearing installer
(for 194mm)
RAL-285-8840-2162-0
(J-37257)Side bearing installer
(for 220mm)

FRONT WHEEL DRIVE 4C1-3
MAIN DATA AND SPECIFICATIONS
FRONT AXLE AND DIFFERENTIAL
Ring gear size mm(in) 167 (6.6) 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)
HEC.2.0L engine - -
HEC.2.2L engine 4.555 4.777
Differential type Two pinion
Oil capacity liter 1.0 1.4
(US/UK gal.) (0.26/0.22) (0.4/0.33)
Axle shaft type Constant velocity joint (Birfield joint type and double offset joint).
Hub locking type Automatic locking and Manual locking free wheel hubs.
FRONT PROPELLER SHAFT
Transmission type MSG MUA
Outside diameter mm(in) 40 (1.57) 40 (1.57)
Inside diameter mm(in) 33 (1.30) 32 (1.26)
Length mm(in) 505 (19.88) 471 (18.54)
(between two spiders center)