transmission ISUZU TFS SERIES 1997 Workshop Manual

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.

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 4C1-89
PROPELLER SHAFT
1. NOISE
Checkpoint Trouble Cause Countermeasure
Spider bearingReplaceWorn or jammed
ReplaceDamaged or worn
NG NG
OKYoke spline
2. VIBRATION
Shaft balanceAdjustUnbalance
ReplaceIncorrect
NG NG
OKShaft runout
Transmission rear housing
bushing, transfer case
housing bushing
ReplaceWorn NG OK
Yoke splineReplaceJammed NG OK

CLUTCH 7C-15
CLUTCH
REMOVAL AND INSTALLATION
HEC Engine Series
4J Engine Series
6VD1
Removal Steps
1. Transmission assembly
2. Pressure Plate assembly
3. Driven plate assembly
4. Release bearing
5. Shift fork
6. Flywheel assembly and cran bearing
(HEC Engine Series)7. Fulcrum bridge (6VD1)Installation Steps
To install, follow the removal steps in the
reverse order.

7C-16 CLUTCH
Important Operations - Removal
1. Transmission Assembly
Refer to “MANUAL TRANSMISSION” of section 7B and 7B1
for “REMOVAL AND INSTALLATION” procedure.
2. Clutch Pressure Plate Assembly (HEC Engine Series)
3. Driven Plate Assembly (HEC Engine Series)
(1) Use the clutch pilot aligner

1 to prevent the driven plate
assembly

2 from falling free.
Clutch Pilot Aligner : 5-8840-2634-0
(2) Loosen the clutch cover bolts in the numerical order shown
in the illustration.
(3) Remove the pressure plate assembly

3 from the flywheel.
(4) Remove the driven plate from the flywheel.
3. Driven Plate Assembly (Except HEC Engine Series)
(1) Use the pilot aligner to prevent the driven plate assembly
from falling free.
Pilot aligner: 5-8525-3001-0 (J-24547)
(2) Mark the flywheel, clutch cover and pressure plate lug for
alignment when installing.
6VD14. Release Bearing (6VD1)
Remove the release bearing from the transmission case.

CLUTCH 7C-17
6VD15. Shift Fork (6VD1)
(1) Remove the snap pin.
(2) Remove the shift fork pin and shift fork from the fulcrum
bridge.
6VD17. Fulcrum Bridge (6VD1)
(1) Remove the fulcrum bridge bolts.
(2) Remove the fulcrum bridge from the transmission case.
Important Operations - Installation
Follow the removal procedure in reverse order to perform the
installation procedure.
Pay careful attention to the important points during the
installation procedure.
3. Driven plate Assembly (HEC Engine Series)
2. Clutch Pressure Plate Assembly (HEC Engine Series)
(1) Clean the flywheel surface.
(2) Clean the facing surface.
(3) Use the clutch pilot aligner

1 to install the driven plate
assembly

2 to the flywheel
3.
Clutch Pilot Aligner : 5-8840-2634-0
(4) Clean the pressure plate surfaces.
(5) Align the pressure plate assembly

4 with the flywheel
knock pin

5.
(6) Install the pressure plate assembly to the flywheel.
(7) Tighten the clutch cover bolts a little at a time in the
numerical order shown in the illustration.
Clutch Cover Bolt Torque N
m (kgfm/lbft)
17.6
4.9 (1.8 0.5/13.0 3.6)

7C-18 CLUTCH
8. Remove the clutch pilot aligner.
Note:
Do not strike the clutch pilot aligner with a hammer to
remove it.
6VD17. Fulcrum Bridge (6VD1)
(1) Install the fulcrum bridge to the transmission case.
(2) Tighten three fulcrum bridge bolts to the specified torque.
Fulcrum Bridge Bolt Torque N
m (kgm/lbft)
39 (3.9/28)
6VD15. Shift Fork (6VD1)
(1) Apply molybdenum disulfide contained type grease to the
pin hole inner circumferences and thrust surfaces.
(2) Attach the shift fork to the fulcrum bridge and insert the pin
from below of the fulcrum bridge.
(3) Install the washer and snap pin.
6VD14. Release Bearing (6VD1)
(1) Apply molybdenum disulfide contained type grease to the
areas shown in illustration.

CLUTCH 7C-19
6VD1(2) Install the release bearing in the proper direction.
3. Driven Plate Assembly (Except HEC Engine Series)
Use the pilot aligner to install the driven plate assembly.
Pilot aligner: 5-8525-3001-0 (J-24547)
6VD12. Pressure Plate Assembly (6VD1)
(1) Tighten the bolts holding the pressure plate assembly in the
order shown in illustration.
Pressure Plate Bolt Torque N
m (kgfm/lbft)
20.6
2.9 (2.10.3/15.22.2)
(2) Remove the aligner.
NOTE:
Do not strike the aligner with a hammer to remove it.
1. Transmission Assembly

CLUTCH 7C-25
3. Check that the driven plate moves smoothly on the
transmission top gear shaft spline.
Minor ridges on the top gear shaft spline may be removed
with an oil stone.
Driven Plate Warpage
1. Insert the clutch pilot aligner into the driven plate splined
hub.
The clutch pilot aligner must be held perfectly horizontal.
Clutch Pilot Aligner : 5-8840-2634-0 (HEC Engine Series)
5-8525-3001-0 (J-24547) (Except HEC Engine Series)
2. Set a dial indicator to the driven plate outside
circumference.
3. Slowly turn the driven plate.
Read the dial indicator as you turn the driven plate.
If the measured value exceeds the specified limit, the driven
plate assembly and/or the facing must be replaced.
Driven Plate Warpage mm(in)
Standard Limit
0.7 (0.028) 1.0 (0.039)
Driven Plate Splined Hub Spline Wear
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaft
spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
Measure the spline rotation play as you turn the driven
plate.
If the measured value exceeds the specified limit, the driven
plate assembly must be replaced.
Driven Plate Splined Hub Spline Wear mm(in)
Standard Limit
0.5 (0.020) 1.0 (0.039)

7C-42 CLUTCH
1. CLUTCH SLIPPAGE
Checkpoint Trouble Cause Countermeasure
Adjust the push rod playNo push rod play in the master
cylinder NG
Clean the related parts and/or
replace the facing
Replace the transmission front
cover oil seal
Clean the related parts and/or
replace the facing
Repair or replace the
transmission front cover
Adjust the push rod play
Defective transmission front
cover oil seal
Continued on the next page
Grease or oil adhering to the
facingToo much grease
Transmission front cover
unevenly worn
No push rod play in the slave
cylinder
Clean and grease the shift
blockShift blockInsufficient grease on the front
cover contact surfaces
NG NG NG NG NG
OK
OK
Clutch pedal free play
OK