differential ISUZU TFS SERIES 1997 Owner's Manual

4B-40 REAR AXLE
Important Operations
4. Pinion Gear
Install the pinion gear by engaging it with the side gears while
turning both pinion gears simultaneously in the same direction.
6. Cross Pin
(1) Be sure to install the cross pin so that it is in alignment with
the lock pin hole in the differential cage.
(2) Backlash between the side gear and the pinion gear.
Backlash mm(in)
194 mm 0.03 - 0.08 (0.001 - 0.003)
220 mm 0.13 - 0.18 (0.005 - 0.007)
If the backlash is beyond the limits, adjust with a thrust washer
of selected thickness.
Thicknesses of thrust washers available.
mm(in)
194 mm1.00
(0.039)1.05
(0.041)1.10
(0.043)
220 mm0.80
(0.031)0.90
(0.035)1.00
(0.039)1.10
(0.043)1.20
(0.047)1.30
(0.051)
7. Lock Pin
After lock pin installation, stake the cage to prevent the lock pin
from falling out.

4B-42 REAR AXLE
MAJOR COMPONENTS
Reassembly Steps
1. Outer bearing outer race
2. Inner bearing outer race
3. Pinion depth adjusting ; shim
4. Inner bearing
5. Collapsible spacer
6. Friction disc
7. Outer bearing
8. Oil seal
9. Pinion flange assembly
10. Flange nut and washer
11. Backlash and pre-load adjusting shim
12. Side bearings
13. Side bearing outer race
14. Differential cage assembly and ring gear
15. Bearing cap
16. Bolt
17. Differential assembly

4B-48 REAR AXLE
(3) Pinion bearing preload.
(a) Measure the bearing preload by using a torque wrench.
Note the scale reading required to rotate the flange.
(b) Continue tightening until the specified starting torque is
obtained.
Pinion Bearing Preload Starting Torque N
m (kgfm/lbft)
194 mm 64 - 113 (6.5 - 11.5/47 - 72)
220 mm 69 - 127 (7 - 13/51 - 94)
11.Backlash and Pre-load Adjusting Shim
(1) Attach the side bearing to the differential assembly without
shims. Support the opposite side using a pilot to prevent
bearing damage.
1Installer : 9-8522-1164-0 (194 mm)
(J-24244)
: 5-8840-2162-0 (220 mm)
(J-37257)
2Drive handle : 5-8840-0007-0
(J-8092)
3Pilot : 9-8521-1743-0
(J-8107-2)
(2) Position the differential cage assembly with the bearing
outer races to the side bearing bores of the carrier.
(3) Using two sets of feeler gauges, insert a feeler stock of
sufficient thickness between each bearing outer race and
the carrier to remove all end play. Make certain the feeler
stock is pushed to the bottom of the bearing bores.
Mount the dial indicator on the carrier so that the indicator
stem is at right angles to a tooth on the ring gear.
Dial indicator : 5-8840-0126-0
(J-8001)

REAR AXLE 4B-51
17.Differential Assembly
(1) Clean the faces of the rear axle case and differential carrier
and apply the recommended liquid gasket or its equivalent.
(2) Mount the differential case and the carrier assembly to the
rear axle case and tighten the nuts and bolts.
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)
Nut 44 14.7 (4.5 1.5/32.5 10.8)
Bolt 68.5 5 (6.5 0.5/47 3.6)220 mm 194 mm
(3) Install the axle shaft assemblies as instructed earlier in this
section under "Axle Shaft Reassembly".
(4) Fill the axle case with hypoid gear lubricant to just below the
filler hole.
Lubricant Capacity liter (US/UK gal.)
194 mm 1.5 (0.4/0.33)
220 mm 1.8 (0.48/0.4)
Check owners manual for correct type and viscosity of gear
lubricant required.

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-55
3) Intermittent Noise
Checkpoint Trouble Cause Countermeasure
Axle case inside
Ring gear
Remove the foreign material
Replace the drive pinion and
the ring gear as a set
Foreign material in the axle
case
W arped ring gear
Differential cageTighten the differential cage
bolts
Replace the shaft
Loose differential cage bolts
Too much spline play
OK
NG NG NG NO
OK OKAxle shaft

4B-56 REAR AXLE
4) Noise when the Vehicle is Turning
Checkpoint Trouble Cause Countermeasure
Differential cross pin
Side gear
Replace the differential cross
pin
Replace the side gear
W orn differential cross pin
W orn side gear
Differential pinionReplace the differential pinion
Replace the rear axle shaft
W orn differential pinion
W orn rear axle shaft splines
OK
NG NG NG NO
OK OKRear 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