ISUZU TROOPER 1995 Workshop Manual

TOE CONTACT
INCREASE BACKLASH
HIGH FACE CONTACT 1
INCREASE PINION SHIM
FRONT DRIVING AXLE 4C-23
LOW FLANK CONTACT
DECREASE PINION SHIM
HEEL CONTACT
DECREASE BACKLASH
Fig. 4C-58
3. Axle case
2. Differential assembly
m 1) Clean the faces of the front axle case and
Lail differential carrier.
~~I Apply Three Bond TB1215 or equivalent to
the sealing side of the axle case and the
carrier.
2) Attach the differential case and the carrier
assembly to the front axle case and tighten
the nuts and bolts.
The axle case bolt is used for drainage (Fig.
4C-59).
~~~ Torque N-m (lb·ft) 25 (19)
Fig.
4C59
1~1 3) Fill the axle case with hypoid gear lubricant,
to just below the filler hole.
Lubricant capacity
Lubricant capacity liter (US GAL) 11.5 (0.4)
1. Bolt

4C-24 FRONT DRIVING AXLE
DIFFERENTIAL CAGE ASSEMBLY
~~~------------6
~----------------4
Fig. 4C-60
4. Cross pin
Disassembly steps 1. Bolt 2. Ring gear
3. Lock pin 4. Cross pin 5. Pinion gear 6. Side gear 7. Thrust washer 8. Differential cage
Reassembly steps
To reassemble, follow the disassembly steps in the
reverse order.
l•!•l DISASSEMBLY
1. Bolt
• Remove the cross pin, using a soft metal rod
and a hammer (Fig. 4C-62).
2. Ring
gear
3. Lock pin
• Break staking on the lock pin, using a 5 mm
(0.20 in) diameter drill (Fig. 4C-61 ).
Fig. 4C-61
Fig. 4C-62
5. Pinion gear
6. Side gear
7. Thrust washer
8. Differential cage
•

(1!] INSPECTION AND REPAIR
Make necessary correction or parts replacement if
~ wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the
following parts.
• Ring gear, pinion gear
• Bearing
• Side gear, pinion gear, cross pin
• Differential cage, carrier
• Thrust washer
• Oil seal
Ring gear replacement
1) The ring gear should always be replaced with
the drive pinion as a set.
2) Clean the ring gear threaded holes to remove
the
locking agent.
~~~3) When installing the ring gear, apply LOCTITE
271 or equivalent to all the threaded area and
half of the unthreaded area of the bolt.
4) Discard used bolts and install new ones.
I~I __ T_o_rq~u_e __ N_·m~(l_b·_ft~l_IL_ ___ 1_0_8~(8_0_l __ __
5) Tighten the fixing bolts in a diagonal
sequence as illustrated (Fig. 4C-63).
Fig. 4C-63
H'ffil Clearance between the differential pinion and
L!l!l the cross pin measurement (Fig. 4C-64).
mm (in)
Standard Limit
0.06 -0.12 (0.002 -0.005)
0.2 (0.008)
FRONT DRIVING AXLE 4C-25
Fig. 4C-64
rfi:i1 Clearance between the side gear and the
L!l!l differential box (Fig. 4C-65)
mm (in)
Standard Limit
0.03 -0.10 (0.001 -0.004)
0.15
(0.006)
Side gear
Differential box
Fig. 4C-65
rfi:il Play in splines between the side gear and the
L!l!l axle shaft (Fig. 4C-66)
mm (in)
Standard Limit
0.08 -0.36
(0.003 -0.014) 0.5 (0.02)

4C -26 FRONT DRIVING AXLE
l•!•l REASSEMBLY
8. Differential cage
7. Thrust washer
6. Side gear
5. Pinion gear
Fig. 4C-66
• Install the pinion gear by engaging it with the
side gears
while turning both pinion gears
simultaneously in the same direction (Fig. 4C-
67).
Fig. 4C-67
4. 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 (Fig. 4C-68). Fig.
4C-68
!EEl 2) Adjust the backlash between the side gear
and the
pinion gear (Fig. 4C-69).
Backlash
mm (in) I 0.03-0.08 (0.001 -0.003)
Thickness of thrust washers available mm (in)
1.00, 1.05, 1.10 (0.039, 0.041, 0.043)
Fig. 4C-69
3. Lock pin
• After lock pin installation, stake the cage to
secure the lock pin (Fig. 4C-70).
2. Ring gear
1~1 • Clean the ring gear threaded holes to remove
the locking agent.
• When installing the ring gear, apply LOCTITE
271 or equivalent to all the threaded area and
half of the unthreaded area of the bolt.
•

Fig. 4C-70
1. Bolt
-..... .._ .... _ _,~JII' 2
• Tighten the bolts in diagonal sequence as
illustrated (Fig. 4C-71 ).
~~~ Torque N·m (lb·ft) j 108 (80)
NOTE:
Discard used bolts and install new ones.
Fig.
4C-71
F~ DRIVING AXLE 4C 27

.
fi•28 FRONT DRIVINGk "
;: ~ ·~-¢,,
FRONT HUB AND D1SC (4WD Model with Automatic Locking Hub)
Disassembly steps 1. Bolt
2. Hub cap 3. Housing
4. Snap ring and shim
5. Drive clutch assembly 6. Inner cam assembly
7. Lock washer and lock screw 8. Hub nut
9. Hub and disc assembly 10. ABS sensor ring
11. Outer bearing outer race 12. Oil seal
13. Inner bearing outer race 14. Bolt
15. Wheel pin
Fig. 4C-72
10
9
Reassembly steps 15. Wheel pin 14. Bolt 13. Inner bearing outer race 11. Outer bearing outer race
12. Oil seal 10. ABS sensor ring 9. Hub and disc assembly 8. Hub nut 7. Lock washer and lock screw
6. Inner cam assembly 5. Drive clutch assembly 4. Snap ring and shim 3. Housing
2. Hub cap 1. Bolt
'
.f,
c. ' . .,;
)
t
~::
•

1•! .. 1 DISASSEMBLY
•
Shift the transfer lever to the "2H" position and
move the vehicle forward and rearward about
one meter.
• Remove the 14mm hex bolts.
• Before disassembly, jack up the front of vehicle
and
support frame with jack stands.
• Remove the disc brake caliper assembly and
hang
it on the frame with wires. Refer to Section
5A2
"DISC BRAKES".
1. Bolt (Fig. 4C-73)
Fig. 4C-73
2. Hub cap
3. Housing
4. Snap ring and shim
5. Drive clutch assembly
6. Inner cam assembly
7. Lock washer and lock screw
8. Hub nut (Fig. 4C-74)
1®.1 Wrench: J-36827
Fig. 4C-74
Front hub nut wrench (J-36827)
FRONT DRIVING AXLE 4C-29
9. Hub and disc assembly
10. ABS
sensor ring (if so equipped)
11.
Outer bearing outer race
12.
Oil seal
13. Inner bearing outer race
1) Remove the outer bearing from the hub with
fingers. The inner bearing will remain in the
hub and may be removed after prying out the
inner bearing lip seal assembly (Fig. 4C-75).
2) Remove the outer race by driving out the
race from the hub with a brass drift inserted
behind
the race in the notches in the hubs.
Inner bearing
outer race
Fig. 4C-75
14.
Bolt (Fig. 4C-76)
• If necessary, replace the wheel pin in the
following manner.
1) Apply a scribe mark to disc to hub.
2) Clamp the hub and disc assembly in a vise,
using protective pads. Remove
the 6 disc­
to-hub retaining bolts.
Scribe mark
Fig. 4C-76

4C -30 FRONT DRIVING AXLE
15. Wheel pin (Fig. 4C-77)
• Place
hub on a suitable work surface and
remove the
wheel studs, as required, using a
hammer.
Fig. 4C-77
I L•IINSPECTION AND REPAIR
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check
the following parts.
• Hub
• Hub bearing oil seal
• Knuckle spindle
•
Disc
• Caliper
•
Automatic locking hubs
• ABS sensor ring
For inspection and servicing
of disc caliper and
related parts, refer to Section 5A2 "DISC BRAKES".
rfil Inside diameter of housing measurement (Fig.
~ 4C-78)
mm(in)
Standard Limit
65.04 (2.561)
65.24 (2.568)
Inspect flange surface A and 8 for excessive wear.
A ---....
1 I
'-/ I
i/ 8mm (Measuring point) I I
~.
e
Fig. 4C-78
rfil Drive clutch section
~ measurement (Fig. 4C-79)
Standard
8.2 (0.323)
L
Fig. 4C-79 dimensions
ulu
mm(in)
Limit
7.8
(0.307)
1@ 1 Hold ring sliding resistance check (Fig. 4C-80)
Check the sliding resistance along opening
direction as shown in the figure.
N (lb)
Sliding Resistance 16.7-34.3 (3.8-7.7)
......
Fig. 4C-80

r.r.il Holdout ring axial play of the drive clutch
1..!!:.1 assembly (Fig. 4C-81 ).
mm (in)
Standard Limit
----~----------------0.3 (0.012) or less 0.4 (0.016)
Fig. 4C-81
r.r.il Outside diameter of the drive clutch assembly
1..!!:.1 (D) measurement (Fig. 4C-82)
Standard
64.75 (2.55)
Fig. 4C-82
l•! .. l REASSEMBLY
15. Wheel pin (Fig. 4C-83)
mm (in)
Limit
64.55 (2.54)
1) Place the hub on a wood workbench or a block
of wood approx. 6" by 6" to protect the wheel
stud ends and threads.
2) Insert a wheel stud using a hammer.
Be sure the wheel stud is started squarely and
seats completely.
FRONT DRIVING AXLE 4C-31
...____[)
Fig. 4C-83
14.
Bolt (Fig. 4C-84)
0 • A.lign scribe marks and attach the hub to the
1!!:!1 diSC.
Tighten the bolts to the specified torque.
~~~ Torque N·m (lb·ft) I 103 (76)
Scribe mark
Fig. 4C-84
13.
Inner bearing outer race (Fig. 4C-85)
1'?.:\1 • Install the outer race; inner bearing by driving it
l..::5::il into the hub.
Installer: J-36829
Grip:
J-8092
Fig. 4C-85

4C-32 FRONT DRIVING AXLE
11. Outer bearing and outer race (Fig. 4C-86)
li5\l • Install the outer race; outer bearing by driving it
L::!iil into the hub.
Installer: J-36828
Grip: J-8092
Fig. 4C-86
12. Oil seal (Fig. 4C-87)
r::::l • Place the inner bearing onto the outer race in
D the hub and install a new oil seal and retaining
~. ring.
Apply Besco L-2 or equivalent to the lip portion.
Installer: J-36830
Grip: J-8092
Fig. 4C-87
10. ABS sensor ring (if so equipped)
~~~ Torque N·m (lb·ft) [ 18 (13)
9. Hub and disc assembly (Fig. 4C-88)
r::::l 1) Put grease in the hub.
D 2) Place Besco L-2 or equivalent to the outer and
inner bearing.
g (oz)
Hub 35 (1.23)
Outer bearing 10 (0.35)
Inner bearing 15 (0.53)
Outer bearing Inner
bearing
Fig. 4C-88
8. Hub nut (Fig. 4C-89)
r=1 • Install the nut with the chamfered edge of
~ inside diameter outward.
1®..1 Wrench: J-36827
Front hub nut wrench (J-36827)
Fig. 4C-89
IEEI Preload adjustment (Fig. 4C-90)
Tighten the hub nut to 29.4 N·m (21.7 lb·ft), then
loosen the
nut fully.
Tighten the hub nut to reach the bearing preload
given below, using a spring scale on the wheel
pin.
Bearing
Preload
New bearing and
New oil seal
Used bearing and
New
oil seal
19.6-24.5
(4.4-5.5)
11.8-17.7
(2.6-4.0)
N (lb)
If the measured bearing preload is outside the
specifications, adjust
it by loosening or tightening
the bearing nut.
•