front drive shaft ISUZU TROOPER 1998 Service Service Manual

4C±29 DRIVE SHAFT SYSTEM
7. Remove snap ring from front axle case by using snap
ring pliers.
412RW017
8. Take out inner shaft from front axle case.
9. Remove snap ring from inner shaft by using snap ring
pliers.
412RW016
10. Remove inner shaft bearing by using a remover
5±8840±2197±0 and press.
NOTE: Be careful not to damage the shaft.
412RW015
11. Remove needle bearing from inner shaft by using a
remover 5±8840±0027±0 and sliding hammer
5±8840±0084±0.
NOTE: Be careful not to damage the shaft.
412RS045
12. Remove oil seal from front axle case.
NOTE: Be careful not to damage the front axle case.

4C±33 DRIVE SHAFT SYSTEM
412RS037
Reassembly
1. Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer
5±8840±2407±0 and grip 5±8840±0007±0.
412RS043
2. Force a new needle bearing into inner shaft by using a
installer 5±8840±2408±0 and grip 5±8840±0007±0.
412RS051
3. Place a new snap ring(internal) in inner shaft.
Force a new inner shaft bearing into the inner shaft by
using a installer 5±8840±2197±0 and press.
412RS044
4. Install snap ring(external).
NOTE: Be careful not to damage the inner shaft.
5. Clean the housing contact surface of the front axle
case and insert inner shaft assembly into the front
axle case.

4C±34
DRIVE SHAFT SYSTEM
NOTE: Be careful not to damage seal.
6. Install snap ring (internal) in the groove of front axle
case.
NOTE: Be sure to install the snap ring properly.
412RW017
7. Apply differential gear oil to clutch gear, then install
clutch gear.
8. Apply differential gear oil to sleeve, then install
sleeve.
9. Clean contact surface with the front axle and actuator
mounting surface. Apply liquid gasket to the contact
surface on the front axle case, then install in the
housing.
412RW023
10. Tighten bolts to specified torque.
Torque: 116N´m (11.8 kg´m/85 lb ft)11. Clean the actuator contact surface with the housing
then Install and tighten shift position switch to
specified torque.
Torque: 39N´m (4.0 kg´m/29 lb ft)
12. Apply liquid gasket to the contact surface on the
actuator side.
412RW012
13. Align shift arm with the groove of sleeve and install the
actuator.
14. Tighten bolts to specified torque.
Torque: 13N´m (1.3 kg´m/113 lb in)
15. Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified torque.
Torque: 116N´m (11.8 kg´m/85 lb ft)
16. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity: 1.4lit (1.23 Imp qt/1.48 US qt)
Actuator Housing
Oil Capacity: 0.12lit (0.10 Imp qt/0.13 US qt)
17. Install filler plug through gasket and tighten to
specified torque.
Torque: 78N´m (58lb ft)

4C±35 DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
Front drive axle oil capacity1.4 liter (1.23 Imp qt/1.48 US qt)(Differential)
0.12 liter (0.10 Imp qt/0.13 US qt)(Actuator Housing:Shift on the fly)
Type of lubricantGL±5 (Multi grade type) Refer to chart in General Information
Axle shaft typeConstant velocity joint(Birfield joint type and double offset joint)
Torque Specifications
E04RW020

4C±36
DRIVE SHAFT SYSTEM
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±2309±0
(J±39378)
Remover and Installer;
Front Axle mount
bushing
5±8840±2197±0
(J±37452)
Remover and Installer;
Inner shaft bearing
5±8840±0027±0 (J±
26941)
Remover;Bearing needle
5±8840±0084±0
(J±2619±01)
Hammer; Sliding
5±8840±2407±0
(J±41693)
Installer; Oil seal
5±8840±2408±0
(J±41694)
Installer; Bearing needle
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±0007±0
(J±8092)
Grip

4C±37 DRIVE SHAFT SYSTEM
Front Propeller Shaft
General Description
Since the propeller shaft is balanced carefully, welding or
any other modifications are not permitted.Alignment marks should be applied to each propeller
shaft before removal.
401RW002

4C±38
DRIVE SHAFT SYSTEM
Front Propeller Shaft and Associated Parts
401RW058
Legend
(1) Bolt, Nut and Washer (Front Axle Side)
(2) Front Propeller Shaft
(3) Bolt, Nut and Washer (Transfer Side)(4) Front Propeller Shaft (with TOD)
(5) Coupling
(6) LJ Constant Velocity Joint
(7) BJ Constant Velocity Joint
Removal
1. Jack up the vehicle and support it on the chassis
stands.
2. Gear shift lever should be placed in neutral position
and parking brake released.
3. Remove the exhaust and transfer protectors.
NOTE: Apply alignment marks on the flange at the front
propeller shaft both front and rear side.
401RS020

4C±39 DRIVE SHAFT SYSTEM
401RW053
401RW052
4. Remove bolt, nut and washer (Front axle side).
5. Remove bolt, nut and washer (Transfer side).
6. Remove front propeller shaft.
NOTE: If equipped with torque on demand (TOD), when
removing, installing or carring for front propeller shaft, be
sure to wind a piece of cloth round the part of the boot with
which fittings may interfere so that the boot can be
protected. The boot may be damaged if bending force is
applied to the constant velocity joint of the shaft.
401RW051
Installation
NOTE: Never install the shaft assembly backwards.
Completely remove the black paint from the connecting
surface of flange coupling on each end of propeller shaft.
Clean so that no foreign matter will be caught in between.
1. Align the mark which was applied at removal. Install
front propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 N´m (6.4 kg´m/46 lb ft)
2. Install the exhaust and transfer protectors.
3. After installing the propeller shaft, be sure to apply
black paint (1) to exposed area (other than
connecting surface) of the entire surface of flange
coupling .
401RS019

4C±44
DRIVE SHAFT SYSTEM
401RW047
Front Axle Flange Run-out
1. Set a dial gage at right angle near the outer
circumference of the flange face and check the
run-out of the flange face.
Limit: 0.15 mm (0.006 in)
401RW046
2. Set a dial gage at right angle near the inner
circumference and check the run-out of the flange.
Limit: 0.15 mm (0.006 in)
401RW045
3. If vibration is felt during the 4H AUTO drive, disconnct
the propeller shaft at the front axle. Reinstall the
propeller shaft at 60
, 120
, 180
, 240
, and 300

and conduct test drive in each position and check if
there is vibration.
401RW044

4C±49 DRIVE SHAFT SYSTEM
Removal
1. Jack up the vehicle and support it on the chassis
stands.
2. Gear shift lever should be placed in neutral position
and parking brake released.
NOTE: Apply alignment marks on the flange at the rear
propeller shaft both front and rear side.
401RS023
3. Remove bolt, nut and washer (Rear axle side).
4. Remove bolt, nut and washer (Transfer side).
5. Remove rear propeller shaft.
Installation
NOTE: Never install the shaft assembly backwards.
1. Completely remove the black paint from the
connecting surface of flange coupling on each end of
propeller shaft. Clean so that no foreign matter will be
caught in between.
2. Align the mark which is applied at removal .
Install rear propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 N´m (6.4 kg´m/46 lb ft)3. After installing the propeller shaft, be sure to apply
black paint (1) to exposed area (other than
connecting surface) of the entire surface of flange
coupling .
401RS022