ISUZU TFS SERIES 1997 Repair Manual
Manufacturer: ISUZU, Model Year: 1997, Model line: TFS SERIES, Model: ISUZU TFS SERIES 1997Pages: 1600, PDF Size: 40.98 MB
Page 61 of 1600
REAR AXLE 4B-65
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-56
5-8840-0015-0
(J-22912-01) Separator (for 194mm)
RAL-57
5-8840-2197-0
(J-37452) Separator (for 220mm)
RAL-54
5-8840-2010-0
(J-36563)Side gear holder
(194mm L.S.D only)
RAL-59
5-8840-2011-0
(J-36564)Side gear expander
(194mm L.S.D only)
RAL-55
5-8840-2012-0
(J-36565)Side gear rotor
(194mm L.S.D only)
RAL-70
5-8840-2013-0
(J-36566)Diff. Cage lock bar
(194mm L.S.D only)
RAL-12
9-8522-1141-0
(J-24256)Outer bearing outer race
installer (for 194mm)
RAL-13
5-8840-2164-0
(J-37262)Outer bearing outer race
installer (for 220mm)
RAL-14
9-8522-1274-0
(J-24252)Outer bearing outer race
installer (for 194mm)
Page 62 of 1600
4B-66 REAR AXLE
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-15
5-8840-2163-0
(J-37261)Inner bearing outer race
installer (for 220mm)
RAL-60
5-8840-2085-0
(J-21777-42) Pilot (for 194mm, 220mm)
RAL-67
5-8840-2089-0
(J-23597-9) Bolt & nut (for 194mm)
RAL-63
5-8840-2087-0
(J-23597-7) Gauge plate (for 194mm)
RAL-66
5-8840-0127-0
(J-21777-43) Bolt & nut (for 220mm)
RAL-61
5-8840-0129-0
(J-23597-12) Pilot (for 220mm)
RAL-62
5-8840-2166-0
(J-23597-42) Gauge plate (for 220mm)
RAL-68
5-8840-0126-0
(J-8001)Dial gauge set
(for 194mm, 220mm)
RAL-65
5-8840-2088-0
(J-23597-8)Disc (2 pcs. Required)
(for 194mm)
Page 63 of 1600
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)
Page 64 of 1600
FRONT WHEEL DRIVE 4C1-1
SECTION 4C1
FRONT WHEEL DRIVE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ...................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[ 4C1- 3
Special Parts Fixing Nuts and Bolts ............................................................................. 4C1- 4
Recommended Liquid Gasket ....................................................................................... 4C1- 7
Recommended Thread Locking Agents ....................................................................... 4C1- 7
Servicing<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..... 4C1- 8
General Description........................................................................................................ 4C1-9
Front Drive Axle Assembly............................................................................................ 4C1-12
Removal and Installation .......................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[ 4C1-12
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-15
Inspection and Repair................................................................................................ 4C1-18
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-19
Differential ....................................................................................................................... 4C1-22
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-22
Major Components ............................................................................................... 4C1-22
Minor Components............................................................................................... 4C1-25
Inspection and Repair................................................................................................ 4C1-27
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-29
Minor Components............................................................................................... 4C1-29
Major Components ............................................................................................... 4C1-31
Front Hub and Disc (4
2 Model) .................................................................................... 4C1-41
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-41
Inspection and Repair................................................................................................ 4C1-44
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-45
Front Hub and Disc (4
4 Model) .................................................................................... 4C1-48
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-48
Inspection and Repair................................................................................................ 4C1-50
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-51
Front Hub and Disc (Automatic Locking Hub) ............................................................. 4C1-54
INDEX
Page 65 of 1600
4C1-2 FRONT WHEEL DRIVE
PAGE
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-54
Inspection and Repair................................................................................................ 4C1-57
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-59
Front Hub and Disc (Manual Locking Hub) .................................................................. 4C1-66
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-66
Inspection and Repair................................................................................................ 4C1-68
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-69
Front Propeller Shaft ...................................................................................................... 4C1-74
Removal and Installation .......................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[ 4C1-74
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-76
Inspection and Repair................................................................................................ 4C1-77
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-78
Troubleshooting ............................................................................................................. 4C1-80
Page 66 of 1600
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)
Page 67 of 1600
4C1-4 FRONT WHEEL DRIVE
SPECIAL PARTS FIXING NUTS AND BOLTS
FRONT DRIVE AXLE AND PROPELLER SHAFT
Nm (kgfm/lbft)
152.114.7 (15.51.5/112.10.8)82.4
7.8 (8.40.8/60.85.8) 167mm 35.3
2.9 (3.60.3/26.02.2)
194mm 62.8
3.9 (6.40.4/46.32.9)194mm 62.8
3.9
(6.4
0. 2/46.32.9) 167mm 35.3
2.9
(3.6
0.3/26.00.2)
Page 68 of 1600
FRONT WHEEL DRIVE 4C1-5
FRONT DIFFERENTIAL
Nm (kgfm/lbft)
25.55 (2.60.5/18.83.6) 167mm 147-294 (15-30/109-217)
194mm 176.6-274.7 (18-28/130-202)
68.7
4.9 (7.00.5/50.63.6) 167mm 78.5
9.8 (81/57.97.2)
194mm 107.9
9.8 (111/79.57.2)167mm 68.7
9.8 (71/50.67.2)
194mm 98.1
9.8 (101/72.37.2)
Page 69 of 1600
4C1-6 FRONT WHEEL DRIVE
FREE WHEELING HUB
Nm (kgfm/lbft)
11.82.0 (1.20.2/8.71.4) 58.9
5 (60.5/43.43.6)103
5 (10.51/75.97.2) 58.9
5 (60.5/43.43.6)
Page 70 of 1600
FRONT WHEEL DRIVE 4C1-7
RECOMMENDED LIQUID GASKET
Type Brand Name Manufacture Remarks
RTV*
Silicon BaseThreeBond 1207B
ThreeBond 1207C
ThreeBond 1215Three Bond
Three Bond
Three BondFor Engine Repairs
For Axle Case
Repairs, T/M
Water Base ThreeBond 1141E Three Bond For Engine Repairs
SolventThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402Three bond
Isuzu
Isuzu
IsuzuFor Engine Repairs
AnerobicLOCTITE 515
LOCTITE 518Loctite
LoctiteAll
* RTV : Room Temperature Vulcanizer
Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacture's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying
the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater
than 0.25 mm (0.01 in). Poor adhesion will result.
RECOMMENDED THREAD LOCKING AGENTS
LOCTITE Type LOCTITE Color Application Steps
LOCTITE 242 Blue1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.
LOCTITE 262 Red2. Apply LOCTITE to the bolts.
LOCTITE 270 Green
LOCTITE 271 Red3. Tighten the bolts to the specified torque.
4. Wait at least on hour before continuing the installation procedure.