ISUZU TFS SERIES 1997 Owner's Manual

REAR AXLE 4B-25
(FOR RING SIZE 220 mm)
Disassembly Steps
1. Bolt
2. Differential cage cover
3. Thrust washer
4. Bellve disc
5. Bellve disc
6. Friction plate
7. Friction disc
8. Friction plate
9. Friction disc
10. Pressure ring
11. Side gear
12. Thrust block13. Pinion gear and pinion spider
14. Side gear
15. Pressure ring
16. Friction disc
17. Friction plate
18. Friction disc
19. Friction plate
20. Bellve disc
21. Bellve disc
22. Thrust washer
23. Thrust washer

4B-26 REAR AXLE
Important Operations
Prepare a side gear holder (An axle shaft must be used) as
shown in the left figure, clamp it with a stock vice, and set a
differential.
1. Bolt
Apply a setting mark to the differential cage cover and
differential cage a remove the bolt using the press.
W hen the differential cage is pressed down with the press,
loosen the four bolts fixing the differential cage evenly and
remove them, and then disconnect the differential cage.

REAR AXLE 4B-27
INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspection.
Gear
Bearing
Differential box
Drive pinion
Visual Check
Inspect the following parts for wear, damage or other abnormal
conditions.
Clearance between pinion gear and cross pin:
194 mm and 220 mm mm(in)
Standard Limit
0.06 - 0.12
(0.002 - 0.005)0.2 (0.008)
Clearance between side gear and differential cage.
mm(in)
Standard Limit
194 mm0.03 - 0.10
(0.001 - 0.004)0.15 (0.006)
220 mm0.05 - 0.11
(0.002 - 0.004)0.15 (0.006)
Play in splines between the side gear and axle shafts.
mm(in)
Standard Limit
194 mm 0.08 - 0.36 (0.003 - 0.014)
220 mm 0.08 - 0.38 (0.003 - 0.015)0.5 (0.02)

4B-28 REAR AXLE
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.

Friction disc and plate assembly.
Check the parts for damage or other abnormal conditions.
Check the friction plate for distortion.
Limit mm(in) 0.07 (0.0027)
Check the friction plate for wear.
Limit (A - B) mm(in) 0.1 (0.0039)
Note : A = Non-sliding face thickness
B = Sliding face thickness
Check the friction disc for distortion.
Limit mm(in) 0.07 (0.0027)

REAR AXLE 4B-29
Check the friction disc for wear.
Limit (A - B) 0.1 (0.0039)
Note : A = Non-sliding face thickness
B = Sliding face thickness
Slide gear and sleeve
Check the parts for damage or other abnormal conditions.
Pinion shaft and pinion gear
Check the parts for damage or other abnormal conditions.

Pressure Ring
Check the parts for damage or other abnormal conditions.
1Sliding part for a pinion
2Sliding part for a disc
3Sliding part for a gear
4V-shape groove for the pinion spider
5Fitting protrusion for a case
6Fitting part for the inner surface of a case
7Sliding part for a side gear or a case

4B-30 REAR AXLE
Friction Disc and Plate Assembly
Check the parts for damage or other abnormal conditions.
1Sliding part
2Protrusion
Check the friction plate for distortion.
Limit mm(in) 0.08 (0.0031)
Check the friction plate for wear.
Limit (A - B) mm(in). 0.1 (0.0039)
Note :
A = Non-sliding face thickness
B = Sliding face thickness
Check the friction disc for distortion.
Limit mm(in) 0.08 (0.0031)
Check the friction plate for wear.
Limit (A - B) mm(in). 0.1 (0.0039)
Note :
A = Non-sliding face thickness
B = Sliding face thickness

REAR AXLE 4B-31
Check the Thrust Washer mm(in)
Limit 1.3 (0.051)

4B-32 REAR AXLE
REASSEMBLY
MINOR COMPONENTS
LIMITED SLIP DIFFERENTIAL (LSD)

Reassembly Steps
1. Friction disc and plate
2. Disc spring
3. Spring plate
4. Sleeve
5. Differential cage
6. Friction disc and plate assembly
7. Side gear8. Friction disc and plate assembly
9. Side gear
10. Pinion gear
11. Pinion washer
12. Thrust block
13. Pinion shaft
14. Spring pin

REAR AXLE 4B-33
Important Operations
1. Friction disc and plate
Measure the thickness of disc and plate pack (A). mm(in)
Thickness (A) 7
0.1 (0.27 0.004)
If the thickness (A) is beyond the limits, adjust with a friction
disc of selected thickness.
Thickness of friction discs available mm(in)
1.4 (0.055), 1.5 (0.059)
Apply molybdenum disuffide grease to the friction discs and
plates.
3. Spring plate
Install the spring plate with dished side turned side turned to
the differential cage side.
10.Pinion gear
11.Pinion washer
(1) Clamp special tool (side gear holder) into a vise. Set the
LSD assembly.
Holder : 5-8840-2010-0
(J-36563)
(2) Set special tools (side pinion expanders and side pinion
rotator) to the LSD.
Expander : 5-8840-2011-0
(J-36564)
Rotator : 5-8840-2012-0
(J-36565)

4B-34 REAR AXLE
(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 proper clearance to install the pinion
gears.
Bar : 5-8840-2013-0
(J-36566)
(4) Attach the pinion gears and washers in the proper order to
the left and right hand side of the differential cage.
(5) W ith a wrench, turn special tool (pinion rotator) to align the
pinion gear and washer holes with the pinion shaft holes on
the differential cage.
Confirmation of operation
Using the side gear holder, measure the starting of the side
gear.
Starting Torque N
m (kgfm/lbft)
Standard 147-225 (15 - 23/108 - 166)
Side gear holder : 5-8840-2010-0
(J-36563)
Side gear rotor : 5-8840-2012-0
(J-36565)