back gear ISUZU TFS SERIES 1997 Workshop Manual

4B-18 REAR AXLE
DISASSEMBLY
MAJOR COMPONENTS
Disassembly Steps
1. Side bearing cap
2. Side bearing outer race
3. Differential cage assembly and ring gear
4. Side bearing
5. Backlash and side bearing preload
adjusting shim
6. Flange nut and washer
7. Flange assembly
8. Drive pinion shaft assembly
9. Inner bearing
10. Pinion depth adjusting shim
11. Drive pinion shaft
12. Collapsible spacer
13. Oil seal
14. Outer bearing
15. Inner bearing outer race
16. Outer bearing outer race

REAR AXLE 4B-19
Important Operations
Before disassembling, make a pattern check using the method
described later in this section under "Gear Tooth Contact
Pattern Check and Adjustments". This check will help
determine what service should be performaed on the
differential components.
On some bench operations, it may be advantageous to use a
holding fixture and a holding fixture base.
Tool 5-8840-0275-0 (J-37264) and 5-8840-0003-0 (J-3289-20)
are available tools that work well for this purpose.
1. Bearing Cap
Apply an alignment mark to the side bearing cap and
differential carrier.
2. Side Bearing Outer Race
After removal, keep the right and left side bearing assemblies
separate to maintain inner and outer race combinations.
4. Side Bearing
5. Backlash and Side Bearing Preload Adjusting Shim
Remover : 5-8840-0013-0 (J-22888)
Adapter : 9-8521-1743-0 (J-8107-2) (194 mm)
5-8840-2196-0 (J-8107-4) (220 mm)
Carefully record the thickness of each side bearing and each
shim pack. Keep them separated and in order for later
reassembly.
6. Flange nut and washer (194 mm)
Holder : 5-8840-0133-0
(J-8614-01)

4B-22 REAR AXLE
Important Operations
1. Ring Gear
Take care not to damage the ring gear or the differential case
when removing the ring gear. Never try to wedge a tool
between the two faces.
2. Lock Pin
Drive out the pinion shaft lock pin with a long drift punch. It
may be necessary to first remove the stakes in the lock pin with
a 5 mm drill.
3. Cross Pin
(1) Check the amount of backlash before removal.
Backlash mm(in)
194 mm 0.03 - 0.08 (0.001 - 0.003)
220 mm 0.13 - 0.18 (0.005-0.007)
(2) Remove the cross pin with a brass drift punch, and take out
the pinion gears, side gears, thrust block and thrust
washers from the differential cage.

4B-24 REAR AXLE
Important Operations
4. Pinion washer
5. Pinion gear
(1) Clamp special tool (side gear holder) into a vice. Set the
LSD assembly.
Holder : 5-8840-2010-0
(J-36563)
(2) Set special tools (side pinion expanders and pinion rotator)
to the LSD.
Expander : 5-8840-2011-0
(J-36564)
Rotor : 5-8840-2012-0
(J-36565)
(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 backlash between the side and
pinion gears.
Bar : 5-8840-2013-0
(J-36566)
(4) W ith a wrench, rotate special tool (pinion rotator) to remove
the pinion gear and the pinion washer.

4B-36 REAR AXLE
Adjustment of Clearance between
Friction Disc and Plate
1) Measuring depth of differential case
mm(in)
Standard (A-B) 80.58 (3.17)
(C) 10.58 (0.41)
2) Measuring overall length of pressure ring, friction disc and
plate assembly
Assembly pinion shaft with pressure ring, then friction
disc and plate.
Measure length between plates at both ends over V-
shape groove. (D)
3) After A, B, C and D dimensions are measured, perform
adjustment with the following procedure.
Measure disc spring :
1.75 mm (0.69 in)
2 pcs (E)
Measure thickness of plate spring
Standard dimension :
1.75 mm (0.069 in)
2 pcs (F)
4) Select a friction disc or plate so that ((A-B+C) - (D+E+F) =
0.06 to 0.20 mm (0.002 to 0.008 in.) and also the difference
in total dimension of friction disc and plate, plate spring and
disc spring (left/right side) does not exceed 0.05 mm (0.002
in.).
Thickness : 1.75, 1.85 mm
Adjusting Backlash of Side Gear in Axial
Direction
1) Measuring depth of differential case
mm(in.)
Standard (F-B) 82.03 (3.23)
(G) 12.03 (0.47)

REAR AXLE 4B-37
2) Measuring dimension between thrust washers at both ends.
Eliminate clearance by pushing pressure ring against the
pinion shaft in axial direction.
Eliminate backlash by connecting side gear to the pinion.
Measure dimension between thrust washers at both
ends. (H)
3) After each dimension is measured, perform adjustment with
the following procedure.
Adjust so that ((F-B) + G-H) = 0.05 to 0.2 mm. Also, select
a proper thrust washer so that the dimension difference
from back face of the pressure ring to thrust washer
(left/right side) does not exceed 0.05 mm.
Thickness : 1.5, 1.6, 1.7 mm
Important Operations
3. 19. Bellve disc
4. 18. Bellve disc
Install the Bellve disc with dished side turned to the differential
cage side.
9. Pressure Ring
1) Fit two side gears in two pressure rings, one from under a
ring and the other from above a ring.
2) Fit two pairs of a friction disc and a friction plate under it on
and under these two pressure rings. Also, fit disc springs
and plate springs for the discs and plates.
23.Bolt
Align the setting marks on the box and box cover and install
the bolts using the press.

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-49
(4) Adjust the feeler gauge thickness from side to side until the
ring gear backlash is in the specified range.
Backlash mm(in)
194 mm 0.13 - 0.18 (0.005 - 0.007)
220 mm 0.15 - 0.20 (0.006 - 0.008)
With zero end play and correct backlash established, remove
feeler gauge packs, determine the thickness of shims required
and add 0.05 mm (0.002 in.) to each shim pack to provide side
bearing preload. Always use new shims.
(5) Remove side bearing
Remover : 5-8840-0013-0
(J-22888)
Adapter : 9-8521-1743-0 (194 mm)
(J-8107-2)
: 5-8840-2196-0 (220 mm)
(J-8107-4)
12.Side Bearing
Install side bearings together with selected shims.
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)
15.Bearing Cap
Align the setting marks applied at the time of disassembly.