oil ISUZU TFS SERIES 1997 Owner's Manual

4C1-8 FRONT WHEEL DRIVE
SERVICING
Hub Bearing Preload at the Wheel Pin
44 Model kg(lb)
New bearing and New oil seal 2 - 2.5 (4.4 - 5.5)
Reuse bearing and New oil seal 1.2 - 1.8 (2.6 - 4.0)
42 Model kg(lb)
New bearing and New oil seal 0.8 - 1.0 (1.8 - 2.2)
Reuse bearing and New oil seal 0.8 - 1.0 (1.8 - 2.2)

FRONT WHEEL DRIVE 4C1-15
DISASSEMBLY
Disassembly Steps
1. Band
2. Bellows
3. Circlip
4. BJ shaft assembly
5. Ball
6. Snap ring
7. Ball retainer
8. Ball guide
9. Band
10. Bellows
11. Dust seal12. BJ shaft
13. Bolt
14. DOJ case assembly
15. Snap ring
16. Bearing
17. Snap ring
18. O-ring
19. Oil seal
20. Bracket
21. DOJ case
22. Axle case and differential

4C1-18 FRONT WHEEL DRIVE
INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspection.
BJ assembly
DOJ case, ball, ball guide, ball retainer
Bellows
Bearing
Dust seal, oil seal
Visual Check
Inspect the following parts for wear, damage, or other
abnormal conditions.

FRONT WHEEL DRIVE 4C1-19
REASSEMBLY
Reassembly Steps
1. Axle case and differential
2. DOJ case
3. Bracket
4. Oil seal
5. O-ring
6. Snap ring
7. Bearing
8. Snap ring
9. DOJ case assembly
10. Bolt
11. BJ shaft12. Dust seal
13. Bellows
14. Band
15. Ball guide
16. Ball retainer
17. Snap ring
18. Ball
19. BJ shaft assembly
20. Circlip
21. Bellows
22. Band

4C1-22 FRONT WHEEL DRIVE
DIFFERENTIAL
DISASSEMBLY
MAJOR COMPONENTS
Disassembly Steps
1. Bolt
2. Differential assembly
3. Axle case
4. Bolt
5. Bearing cap
6. Diff. cage assembly
7. Side bearing outer race
8. Side bearing
9. Adjust shims
10. Flange nut
11. Flange12. Dust cover
13. Pinion gear
14. Inner bearing
15. Adjust shim
16. Collapsible spacer
17. Inner bearing outer race
18. Oil seal
19. Outer bearing
20. Outer bearing outer race
21. Diff. carrier

FRONT WHEEL DRIVE 4C1-27
INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspection.
Ring gear, pinion gear
Bearing
Side gear, pinion gear, cross pin
Differential cage, carrier
Thrust washer
Oil seal
Visual Check
Inspect the following parts for wear, damage, or other
abnormal conditions.
Ring Gear Replacement
(1) The ring gear should always be replaced with the drive
pinion as a set.
(2) W hen installing the ring gear, apply LOCTITE 271 or
equivalent to the threaded hole and bolt.
(3) Tighten the fixing bolts in a diagonal sequence as
illustrated.
(4) Discard used bolts and install new ones.
Bolt Torque N
m (kgfm/lbft)
167 mm 78.5
9.8 (8 1/57.9 7.2)
194 mm 107.9 9.8 (11 1/79.6 7.2)
For 167 mm
Note that all bolts have a left hand thread.
Clearance Between the Differential Pinion
and the Cross Pin
mm(in)
Standard Limit
167 mm 0.06 - 0.12 (0.002 - 0.005) 0.2 (0.008)
194 mm 0.05 - 0.10 (0.002 - 0.004) 0.2 (0.008)

FRONT WHEEL DRIVE 4C1-31
MAJOR COMPONENTS
Reassembly Steps
1. Diff. carrier
2. Outer bearing outer race
3. Inner bearing outer race
4. Adjust shim
5. Inner bearing
6. Collapsible spacer
7. Pinion gear
8. Outer bearing
9. Oil seal
10. Dust cover11. Flange
12. Flange nut and washer
13. Adjust shim
14. Side bearing
15. Bearing outer race
16. Diff. cage assembly
17. Bearing cap
18. Bolt
19. Axle case
20. Differential assembly
21. Bolt

4C1-32 FRONT WHEEL DRIVE
Important Operations
2. Outer Bearing Outer Race
Installer : 5-8522-0048-0 (167 mm)
(J-29038)
9-8522-1141-0 (194 mm)
(J-24256)
Grip : 5-8840-0007-0
(J-8092)
3. Inner Bearing Outer Race
Installer : 5-8522-0049-0 (167 mm)
(J-29039)
9-8522-1274-0 (194 mm)
Grip : 5-8840-0007-0
(J-8092)
4. Adjust Shim
Adjustment of drive pinion mounting distance
(1) Apply gear oil to the inner and outer drive pinion bearing.
Clean the pinion setting gage set.
Then install the gage set together with the inner and outer
bearings.
For 167 mm
1Pilot : 5-8840-2092-0
(J-23597-28)
2Nut and bolt : 5-8840-0127-0
(J-21777-43)
3Rear pilot : 5-8840-02091-0
(J-23597-27)
4Gage plate : 5-8840-2090-0
(J-23597-26)
For 194 mm
1Pilot : 5-8840-2085-0
(J-21777-42)
2Nut and bolt : 5-8840-2089-0
(J-23597-9)
4Gage plate : 5-8840-2087-0
(J-23597-7)

4C1-36 FRONT WHEEL DRIVE
5. Inner Bearing
Place the shim on the drive pinion, with the chamfered side
turned towards the pinion head then install the inner bearing on
to the pinion using an installer and a press.
Installer : 9-8522-1165-0 (J-6133-01)
Note:
Do not apply pressure to the roller cage.
Apply pressure only to the inner race.
6. Collapsible Spacer
Discard the used collapsible spacer and install a new one.
9. Oil Seal
Use oil seal installer to install a new oil seal that has been
soaked in rear axle lubricant.
Installer : 5-8522-0046-0 (J-26234) (For 167 mm)
9-8522-1275-0 (J-24250) (For 194 mm)
Note :
Take care not to use a rear differential oil seal instead of
the front differential oil seal.
12.Flange Nut and Washer
For 194 mm
(1) Apply lubricant to the pinion threads.
(2) Tighten the nut to the specified torque using the pinion
flange holder.
Pinion flange holder : 5-8840-0133-0
(J-8614-01)
Torque N
m (kgfm/lbft)
176.6 - 274.7 (18 - 28/130 - 202)
Discard used flange nut and install new one.

FRONT WHEEL DRIVE 4C1-41
FRONT HUB AND DISC (42 model)
DISASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure.
Disassembly Steps
1. Bolt
2. Brake caliper
3. Hub cap
4. Split pin
5. Nut retainer
6. Hub nut
7. Lock washer8. Outer bearing
9. Hub and disc assembly
10. Oil seal
11. Inner bearing and outer race
12. Bolt
13. Wheel pin