lock 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-8 REAR AXLE
AXLE SHAFT
DISASSEMBLY
1. Refer to Section 3E "WHEEL and TIRE" for road wheel Disassembly procedure.
2. Refer to Section 5 "BRAKE" for rear brake removal procedure.
Disassembly Steps
1. Wheel and tire
2. Brake drum
3. Bolt and nut
4. Axle shaft assembly
5. Shim
6. Bearing nut and lock washer
7. Bearing holder
8. Bearing
9. Oil seal
10. Bearing outer race
11. Wheel pin
12. Oil seal

REAR AXLE 4B-9
Important Operations
1. Wheel and Tire
Raise vehicle to the working level.
Support the axle assembly with the proper jack and chassis
stands.
6. Bearing Nut and Washer

(1) Remove the stake from the lock nut.
(2) Mount axle shaft into vise, clamping vise jaws around the
lock nut.
Vise should not be tightened excessively on lock nut.
(3) Install special tool onto flange studs, lock into position with
two wheel nuts, and turn axle shaft loose from lock nut.
Remover and installer : 58840-2003-0 (J-24246)

(1) Remove the stake from the lock nut.
(2) Install special tool onto lock nut, and remove the lock nut.
Remover and installer : 5-8840-2329-0
7. Bearing Holder
Remove the bearing holder and bearing from the axle shaft by
means of a press.
NOTE :
Only a slight amount of pressure from the press is
required to separate the bearing from the shaft. Be sure to
support the backing plate solidly, and to hold onto the
axle shaft to prevent it from falling to the floor.
10.Bearing Outer Race
Drive off the bearing outer race using a brass drift.

4B-12 REAR AXLE
REASSEMBLY
1. Refer to Section 3E "WHEEL and TIRE" for road wheel reassembly procedure.
2. Refer to Section 5 "BRAKE" for rear brake installation procedure.
Reassembly Steps
1. Wheel pin
2. Bearing outer race
3. Oil seal
4. Bearing holder
5. Bearing
6. Axle shaft assembly
7. Bearing nut and lock washer
8. Oil seal
9. Shim
10. Bolt and nut
11. Brake drum
12. Wheel and tire

REAR AXLE 4B-13
Important Operations
2. Bearing Outer Race
Installer : 5-8522-1268-0
(194 mm standard suspension)
(J-24259)
: 5-8840-2201-0
(194 mm heavy-duty suspension and 220 mm)
Grip : 5-8840-0007-0 (J-8092)
3. Oil Seal ; Bearing Holder
Installer : 9-8522-1269-0
(194 mm standard suspension)
(J-24255)
: 5-8840-2202-0(194 mm H/D, 220 mm)
5. Bearing
Apply a generous amount of grease to the bearing inner race.
g(oz)
Approx. 30 (1)
6. Axle Shaft Assembly
7. Bearing Nut and Lock Washer
(1) Insert four through-bolts into the back plate.
(2) Install bearing holder to the back plate.
(3) Install the above parts onto the axle shaft.
(4) Install bearing over axle shaft and press it into bearing
holder.
Axle shaft bearing Installer : 9-8522-1271-0 (J-8609-01)

4B-14 REAR AXLE
(5) Install the bearing nut into position by using a vise and the
special tool.
Installer : 5-8840-2003-0
(J-24246)
Torque N
m (kgfm/lbft)
260
5 (26.5 0.5/192 3.6)
(6) Position the chisel perpendicular to the center of the lock
nut groove.
Stake the lock nut.
8. Oil Seal ; Axle Case
Oil seal installer : 9-8522-1272-0 (J-24254)
(1) Apply measured amount of good quality grease to the inner
face of the rear axle case.
g(oz)
Type of greaseW heel bearing grease or
Multipurpose type grease
Amount of grease required 80 (2.8)
9. Shim
Install the axle shaft assembly to the axle case with a 2 mm
(0.08 in) thick shim fit into position between the bearing holder
and axle case flange. Install and tighten the bolts evenly in
progression.
Torque N
m (kgm/lbft)
74
5 (7.5 0.5/54 3.6)

REAR AXLE 4B-15
Install the axle shaft assembly on the opposite side and push it
in until it fits against the differential thrust block. Then,
measure the clearance (t) between the bearing holder and the
axle case flange and determine the thickness of the shim to be
installed by the following formula :
Measured clearance (t) + 0.3 mm (0.012 in) = thickness of
shim to be installed.
mm(in)
thickness of shims available
1.0, 0.5, 0.13, 0.076, 0.05
(0.036, 0.026, 0.005, 0.003, 0.002)
10.Bolt and Nut
Torque N
m (kgfm/lbft)
74
5 (7.5 0.5 / 54 3.6)
Connect the brake lines to wheel cylinder.
Connect the parking brake rear cable.
Brake air bleeding, refer to servicing to Section 5 brake.
Note :
To install the axle shaft assembly, follow the reassembly
procedure outline under the "BRAKE".
12.Wheel and Tire
Tighten the wheel nut in numerical order.
Torque N
m (kgfm/lbft)
117.7
9.8 (12 1/86.8 7.2)

REAR AXLE 4B-21
MINOR COMPONENTS
DIFFERENTIAL ASSEMBLY
Disassembly Steps
1. Ring gear
2. Lock pin
3. Cross pin
4. Pinion gear
5. Thrust block6. Side gear
7. Thrust washer
8. Differential cage

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.

REAR AXLE 4B-23
LIMITED SLIP DIFFERENTIAL (LSD)
(FOR RING SIZE 194 mm)
Disassembly Steps
1. Spring pin
2. Pinion spider
3. Thrust block
4. Pinion washer
5. Pinion gear
6. Side gear
7. Friction disc and plate assembly8. Side gear
9. Friction disc and plate assembly
10. Differential cage
11. Sleeve
12. Spring plate
13. Disc spring
14. Disc and plate