ISUZU TROOPER 1998 Service Repair Manual

4A2B±28DIFFERENTIAL (REAR 244mm)
Torque Specifications
E04RW019

DIFFERENTIAL (REAR 244mm)
4A2B±29
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±2294±0
(J±39210)
Installer; Axle shaft inner
seal
5±8840±0133±0
(J±8614±01)
Pinion flange holder
5±8840±2165±0
(J±37263)
Installer; Pinion oil seal
5±8840±2029±0
(J±42832)
Holding fixture
5±8840±0003±0
(J±3289±20)
Holding fixture base
5±8840±2587±0
(J±42379)
Remover; Bearing
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±2576±0
(J±8107±3)
Adapter; Side bearing
plug
5±8840±0008±0
(J±8611±01)
Installer; Outer bearing
outer race
5±8840±0007±0
(J±8092)
Grip
5±8840±2571±0
(J±42831)
Installer; Inner bearing
outer race
5±8840±2575±0
(J±42824)
Pilot;Outer
5±8840±0127±0
(J±21777±43)
Nut & Stud

4A2B±30DIFFERENTIAL (REAR 244mm)
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±2573±0
(J±42827)
Pilot;Inner
5±8840±2572±0
(J±42826)
Gage plate
5±8840±0126±0
(J±8001)
Dial indicator
5±8840±2577±0
(J±42825)
Disc (2 required)
5±8840±0128±0
(J±23597±1)
Arbor
5±8840±2574±0
(J±42828)
Installer; Pinion bearing
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±2293±0
(J±39209)
Punch; End nut lock
5±8840±2570±0
(J±42829)
Installer; Side bearing
5±8840±2323±0
(J±39602)
Remover; Outer bearing
5±8840±2586±0
(J±39858)
Clutch pack unloading
tool kit Includes
Screw cap, Cap and
Forcing screw

4B1±1 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)
CONTENTS
Service Precaution 4B1±1. . . . . . . . . . . . . . . . . . . . . .
Shift on the Fly System (Lever Type) 4B1±2. . . . . . .
Outline of Shift on the Fly System
(Lever Type) 4B1±2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift on the Fly Vacuum Piping and Electric
Equipment (For Lever Control Type) 4B1±3. . . . . .
Vacuum Piping Diagram 4B1±3. . . . . . . . . . . . . . . .
Inspection and Repair 4B1±4. . . . . . . . . . . . . . . . . .
Shift on the Fly System (Push Button Type) 4B1±7.
Outline of Shift on the Fly System
(Push Button Type) 4B1±7. . . . . . . . . . . . . . . . . . . . Functions of Indicator Lamp 4B1±11. . . . . . . . . . . . . . .
Diagnosis 4B1±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Axle Diagnosis 4B1±30. . . . . . . . . . . . . . . . . . .
Shift on the Fly Vacuum Piping and Electric
Equipment (For Push Button Type) 4B1±32. . . . . . . .
Vacuum Piping Diagram 4B1±32. . . . . . . . . . . . . . . .
Inspection and Repair 4B1±33. . . . . . . . . . . . . . . . . .
4WD Control Unit (For Push Button Type) 4B1±36. .
4WD Control Unit Associated Parts 4B1±36. . . . . .
Removal 4B1±37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4B1±37. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: I F S O E Q U IPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

4B1±2
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Shift on the Fly System (Lever Type)
Outline of Shift on the Fly System
(Lever Type)
The shift on the fly system (Lever type) switches between
2 wheel drive (2WD) and 4 wheel drive (4WD) by driver's
shifting the transfer control lever on the floor.
This system controls below operations.
1. Connecting front wheels to, and disconnecting them
from, the front axles by vacuum actuator.
2. Indicator on instrument panel.
3. 4WD signal to Electronic Hydraulic Control Unit for
brake system (If anti±lock brake system is equipped).

4B1±3 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Shift on the Fly Vacuum Piping and Electric Equipment
(For Lever Control Type)
Vacuum Piping Diagram
C04RW015
VSV Assembly, Actuator Assembly
412RS032
Vacuum Tank
412RS033

4B1±4
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Inspection and Repair
Vacuum Piping
C04RW016
1. Pull out the Hose A in figure and install a vacuum
gauge.
2. Plug up Hose B in figure to prevent the leak of
vacuum.
3. Start the engine and measure vacuum 2 or 3 minutes
afterward.
4. Repeat 1) and 2) but with Hose A plugged and Hose B
pulled out.
5. If vacuum measures ±400mmHg, or if it shows a
sudden drop immediately after engine stop, inspect
the hose, tank, and pipe for damage.
NOTE: Be careful not to permit the entry of dust and
water during inspection.
6. Pull out Hose D in above illustration.
7. Plug Hose E in above illustration.
8. Make sure that Hose D in above illustration is under
atmospheric pressure.
9. Pull out Hose E and plug Hose D, and make sure that
Hose E is under atmospheric pressure.
10. If Check 8) or 9) has revealed stoppage, check and
see that there is no bend, foreign matter in the hose or
in the filter. If there is trouble, repair or replace.Check Valve
C04RS004
1. Apply vacuum from the orange colored side(1).
Vacuum:±400mmHg
2. Check leakage of vacuum.
3. Make sure that vacuum cannot be applied from the
black colored side(2).

4B1±5 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
4. If vacuum is not applicable as much as ±400mmHg,
and if there is resistance on the intake side, replace
with a new check valve.
VSV Assembly
Inspect the vehicle side harness as follows:
412RS071
Legend
(1) Grey
(2) Blue
1. Remove connector.
2. Shift transfer lever to 2H and start the engine.
NOTE: Do not move the vehicle while inspection.
3. Make sure that there is continuity in the vehicle side of
harness. If there is no continuity, check transfer shift
switch and wiring.
Inspect both VSVs as follows:
F04RS004
1. With battery not connected (Usual).
A±C:There is continuity
B:Closed
2. With battery connected
A ± B:There is continuity
C:Closed
3. If 1) and 2) fail, replace with a new VSV.
Axle Position Switch
412RS048
1. With ball (1) being free
A ± B:There is continuity
2. With ball forced into the switch
A ± B:No continuity
3. If 1) and 2) fail, replace with a new switch.

4B1±6
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Transfer Position Switch
412RW040
Legend
(1) Ball
1. With ball being free.
A±B : There is continuity.
2. With ball forced into the switch.
A±B : No continuity.
3. If 1) and 2) fail, replace with a new switch.

4B1±7 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Shift on the Fly System (Push Button Type)
Outline of Shift on the Fly System (Push Button Type)
The shift on the fly system switches between 2 wheel
drive (2WD) and 4 wheel drive (4WD) electrically by
driver's pressing the 4WD switch (push button type) on
instrument panel.
This system controls below operations. (Shifting between
ª4Hº and ª4Lº must be performed by transfer control lever
on the floor.)
1. Shifting the transfer front output gear (Connecting to,
and disconnecting from, front propeller shaft by motor
actuator).2. Retrial of shifting the transfer front output gear.
3. Connecting front wheels to, and disconnecting them
from, the front axles by vacuum actuator.
4. Indicator on instrument panel.
5. 4WD out signal to other Electronic Hydraulic Control
Unit (If anti±lock brake system is equipped).
System Diagrams
412RW050