lock ISUZU TFS SERIES 1997 Service Manual

FRONT WHEEL DRIVE 4C1-61
6. Hub and Disc Assembly
(1) Apply grease in the hub.
(2) Apply Besco L-2 or equivalent to the outer and inner
bearing.
g(oz)
Hub 35 (1.23)
Outer bearing 10 (0.35)
Inner bearing 15 (0.53)
7. Hub Nut
Turn the place where there is a chamfer in the tapped hole to
the outer side, and attach the nut.
Wrench : 5-8840-2117-0
(J-36827)
Preload Adjustment
Tighten the hub nut at 29.4 N
m (3 kgfm / 21.716 lbft), then
loosen the nut to the full.
Tighten the hub nut at the value given below, using a spring
scale on the wheel pin.
Bearing Preload kg(lb)
New bearing and New oil seal 2 -2.5 (4.4 - 5.5)
Used bearing and New oil seal 1.2 - 1.8 (2.6 - 4.0)
If the measured bearing preload is outside the specifications,
adjust it by loosening or tightening the bearing nut.
8. Lock Washer
Turn the side with larger diameter of the tapered bore to the
vehicle outer side, and attach the washer.
If the bolt holes in the lock plate are not aligned with the
corresponding holes in the nut, reverse the lock plate.
If the bolt holes are still out of alignment, turn in the nut just
enough to obtain alignment,. Screw is to be fastened tightly so
its head may come lower than the surface of the washer.

4C1-62 FRONT WHEEL DRIVE
9. Inner Cam
(1) Before installation, shift the transfer lever to “2H” position.
(2) Clean the flange surface of the hub, the thread holes, the
surface of the lock washer and the spline portion of the axle
shaft.
(3) Install the inner cam by aligning the key way of the inner
cam with the groove of the knuckle.
Hit the inner cam lightly with plastic hammer or equivalent
and make sure the inner cam is in contact with the lock
washer.
If it is difficult to install the inner cam, use the tool (installer)
and a plastic hammer or the equivalent.
Install the special tool.
Use the plastic hammer to lightly tap around the special tool “A”
surface as shown in the illustration.
Installer : 58840-2137-0 (J-38194)
Note: Do not strike the inner cam gear teeth with the plastic
hammer.
Shim Selection
(1) Lower vehicle from hoist.
(2) Support lower link with floor jack, placing axle in normal
horizontal position.

FRONT WHEEL DRIVE 4C1-63
(3) Install special tool 5-8840-2126-0 to axle shaft by 5-8840-
2125-0 until it comes into contact with the lock washer.
(4) Using feeler gauge, measure clearance “t” between the
special tool and the snap ring groove of the axle shaft.
(5) If clearance “t” is larger than snap ring groove, shims must
be installed select shims so that clearance “t” is 0 to 0.1 mm
(0 to 0.0039 in).
Thickness shims; 0.2, 0.3, 0.5, 1.0 mm
(6) Remove special tool 5-8840-2126-0, leaving the inner cam
in position.
10.Drive Clutch Assembly
Apply multipurpose grease or hub bearing grease to the
following portions.
(1) Axle shaft splines

4C1-66 FRONT WHEEL DRIVE
FRONT HUB AND DISC (Manual Locking Hub)
DISASSEMBLY
Disassembly Steps
1. Bolt
2. Housing assembly
3. Snap ring and shim
4. Body assembly
5. Lock washer
6. Hub nut
7. Hub and disc assembly
8. Outer bearing
9. Oil seal
10. Inner bearing
11. Clutch assembly12. Snap ring
13. Knob
14. Compression spring
15. Follower
16. Retaining spring
17. Detent ball and spring
18. X-ring
19. Snap ring
20. Inner assembly
21. Snap ring
22. Ring
23. Spacer

FRONT WHEEL DRIVE 4C1-67
Important Operations
1. Bolt
Before removal, shift transfer lever into “2H” position and set
free wheeling hub knob into “FREE” position.
6. Hub Nut
Wrench : 5-8840-2117-0
(J-36827)
Refer to Section 5 “Brake” for disc brake
caliper removal procedure.7. Hub and Disc Assembly
Before disassembly, remove the disc brake caliper assembly
and hang it on the frame with wires.
11.Clutch Assembly
While pushing follower knob, turn clutch assembly clockwise
and then remove clutch assembly from knob.
16.Retaining Spring
Remove retaining spring from clutch assembly by turning it
counterclockwise.

FRONT WHEEL DRIVE 4C1-69
REASSEMBLY
Reassembly Steps
1. Spacer
2. Ring
3. Snap ring
4. Inner assembly
5. Snap ring
6. X-ring
7. Detent ball and spring
8. Knob
9. Snap ring
10. Retaining spring
11. Follower
12. Compression spring
13. Clutch assembly
14. Outer bearing
15. Inner bearing
16. Oil seal
17. Hub and disc assembly
18. Hub nut
19. Lock washer
20. Body assembly
21. Snap ring and shims
22. Cover assembly
23. Bolt

4C1-70 FRONT WHEEL DRIVE
Important Operations
1. Spacer
Apply grease to both faces of spacer.
4. Inner Assembly
Apply grease wheel bearing to inside face of ring.
g(oz)
Amount of grease 3 (0.10)
8. Knob
(1) Apply grease W heel bearing to outer circumference of knob
and inner circumference of cover.
(2) Align detent ball to either groove of cover.
9. Snap Ring
Turn the smoother face to knob side.
10.Retaining Spring
Align the end of spring to the end of cut portion of clutch spring
groove.
11.Follower
Install follower to clutch so that follower nail will come closer to
the bent portion of retaining spring by aligning follower stopper
nail to outer teeth of clutch. Then, hook retaining spring onto
upper portion of hanger nails of follower.
12.Compression Spring
Turn the smaller diameter side to follower.
13.Clutch Assembly
Align follower nail to handle groove, and then assemble clutch
with knob by pushing and turning clutch counterclockwise to
knob.

4C1-72 FRONT WHEEL DRIVE
Preload Adjustment
Tighten the hub nut at 29.4 Nm (3 kgfm / 21.716 lbft), then
loosen the nut to the full.
Tighten the hub nut at the value given below, using a spring
scale on the wheel pin.
Bearing Preload kg(lb)
New bearing and New oil seal 2 -2.5 (4.4 - 5.5)
Used bearing and New oil seal 1.2 - 1.8 (2.6 - 4.0)
If the measured bearing preload is outside the specifications,
adjust it by loosening or tightening the bearing nut.
19.Lock Washer
Turn the side with larger diameter of the tapered bore to the
vehicle outer side, and attach the washer.
If the bolt holes in the lock plate are not aligned with the
corresponding holes in the nut, reverse the lock plate.
If the bolt holes are still out of alignment, turn in the nut just
enough to obtain alignment,. Screw is to be fastened tightly so
its head may come lower than the surface of the washer.
20.Body Assembly
Apply adhesive (Loctite 15 or equivalent) to the both joining
faces.
21.Snap Ring and Shims
Adjust the clearance between the free wheeling hub body and
the snap ring.
Clearance mm(in)
0 - 0.3 (0 - 0.01)
Adjust Shims Available mm(in)
0.2, 0.3, 0.5, 1.0
(0.008, 0.011, 0.020, 0.039)
22.Cover Assembly
Align stopper nails to grooves of body.

4C1-80 FRONT WHEEL DRIVE
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair front 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 ten sub-sections:
42 Model
1. Wanders and pulls
2. Front wheel shimmy
44 Model
1. Oil leak at front axle
2. Oil leak at pinion shaft
3. Noises in front axle drive shaft joint
4. Noises in front axle
5. Wanders and pulls
6. Front wheel shimmy
7. Automatic locking free wheel hub
1) Does not lock or locks only on one side
2) Does not freewheel or freewheels only to one side
3) Noises in automatic locking free wheel hub
Propeller shaft
1. Noise
2. Vibration

FRONT WHEEL DRIVE 4C1-87
7. AUTOMATIC LOCKING FREE WHEEL HUB
(1) DOES NOT LOCK OR LOCKS ONLY ON ONE SIDE
Note :
1. Stop the vehicle
2. Shift the transfer lever to 4H or 4L
3. Now start driving the vehicle and the
hubs will lock automatically.
4. Once the hubs are locked, they will
remain locked, even if the transfer lever
is shifted from 4L or 4H into 2H, as long
as the vehicle travels in a same
direction.
Checkpoint Trouble Cause Countermeasure
ReplaceStill will not lock NGTry locking procedure once
more
(2) DOES NOT FREEWHEEL OR FREEWHEELS ONLY TO ONE SIDE
Note :
Freewheel operation
1. Stop the vehicle
2. Shift the transfer lever to 2H
3. Back up the vehicle for three or four feet;
this will disengage the front differential.
Checkpoint Trouble Cause Countermeasure
ReplaceStill will not freewheel
Driver the vehicle for five
minutes and then try the
freewheel procedure again
Still will not freewheel NGTry freewheel procedure once
more