engine ISUZU TFS SERIES 1997 Workshop Manual

REAR AXLE 4B-5
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.

4B-6 REAR AXLE
REAR AXLE ASSEMBLY
GENERAL DESCRIPTION
194 mm (7.6 in)
220 mm (8.6 in)
The rear axle assembly consists of the rear axle case, the differential carrier assembly, the rear hub assembly, and
the rear axle shaft.
The rear axle assembly supports the greater part of the vehicle weight including the load. It receives the engine
torque through the clutch, the transmission, and the propeller shaft, magnifies the torque at the final gear, and
delivers the torque at a right angle to the rear axle shaft.

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

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)

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.

BRAKES 5-21
Operation
The operation of the P-valve by the master cylinder
pressure is unchanged up to the brake points
A and B.
If master cylinder fluid pressure penetrates into the second
break point
B, the fluid pressure pressing against the seal
2, (which isolated route 4 and route 5), passing the route
4 of the master cylinder side, overcomes the operating
force of the spring
3 + fluid pressure affecting the seal 2 of
the wheel cylinder, and presses the piston
1 to the right
side, resulting in the opening of the routes
4 and 5, and
canceling of the P-valve operation.
Then, because the master cylinder fluid pressure and the
wheel cylinder fluid pressure, up to the point
C, operate on
the identical surface of the seal
2, both have identical
ascending ratio.
However, because of the operation of spring
3 in the wheel
cylinder side, wheel cylinder fluid pressure operate to
preserve the balance against the master cylinder fluid
pressure on the lower level with the difference in pressure
resulting from this spring.
Valve Maintenance
In the case of fluid leak or other abnormalities, faulty valve
should be replaced.
The valve is set up at the right hand side of the 5th
crossmember near the rear axle.
Note:
The blend proportioning valve is not repairable and must
be replaced as a complete assembly.
BLEEDING OF THE BRAKE HYDRAULIC
CIRCUIT
If air enters the bake lines, it will cause poor brake action.
Therefore, bleeding should be performed if the brakes have
been used with the level of brake fluid in the reservoir
excessively low or if brake pipes have been disconnected in
the course of brake servicing.
Bleeding operation calls for co-operative action of 2 persons.
Set the parking brake firmly while bleeding.
Perform bleeding operation with ENGINE RUNNING, to
prevent damage to push rod seal.
Make sure exhaust is suitably ventilated.
Bleed the hydraulic system with the fluid reservoir filled to
the specified level.
Bleed the system starting with the rear wheel cylinder
farthest from the master cylinder.
A : Load sensing proportioning valve (If so equipped).

5-26 BRAKES
ADJUSTMENT PROCEDURE OF BRAKE PEDAL
The push rod serves as the brake pedal stopper when the
pedal is fully released.
Brake pedal height adjustment should be performed as follows.
Brake Pedal - Height
Measure the brake pedal height after making sure the pedal is
fully returned by the pedal return spring.
Note:
Pedal height (L2) must be measured after starting the
engine and increasing the revolution several times by
stepping on the accelerator pedal.
mm(in)
Pedal free play (L1) 6-10 (0.23 - 0.39)
LHD 174-184 (6.85-7.24)
RHD 193-203 (7.60 7.99)Height (L2)
Note:
Pedal free play must be measured after turning off the
engine and stepping on the brake pedal firmly five times or
more.
If the measured value deviates from the above range, adjust
the brake pedal as follows:
a) Disconnect the stop lamp switch.
b) Loosen the lock nut on the push rod.
c) Adjust the brake pedal to the specified height by rotating the
push rod in the appropriate direction.

BRAKES 5-55
2. Vacuum Hose
1) W hen removing or replacing the vacuum hose make sure
that the arrow on the label of the hose is facing the engine.
2) Also confirm that the check valve is facing the engine.

10-2 CAB
SERVICING
Engine Hood Lock
Align the engine hood lock with the installation holes.
Engine Hood Striker
Apply a light coat of grease to the striker.
Door Checker Arm and Pin
Apply a light coat of grease to the checker arm and pin.