Pin ISUZU TROOPER 1998 Service Manual PDF

DIFFERENTIAL (FRONT) 4A1±14
7. Record the pinion depth code on the head of the
drive pinion.
The number indicates a necessary change in the
pinion mounting distance. A plus number indi-
cates the need for a greater mounting distance
(which can be achieved by decreasing the shim
thickness). A minus number indicates the need
for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If ex-
amination reveals pinion depth code ª0º, the pin-
ion is ªnominalº.
425RS023

4A1±15 DIFFERENTIAL (FRONT)
8. Select the shim using the chart;
Pinion marking+10+8+6+4+20±2±4±6±8±10
Dial indicator
reading
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)mm
(Inches)
0.0812.18
(0.0858)
0.0822.18
(0.0858)2.20
(0.0866)
0.0832.18
(0.0858)2.20
(0.0866)2.23
(0.0882)
0.0842.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)
0.0852.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)
0.0862.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)
0.0872.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)
0.0882.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)
0.0892.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)
0.0902.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)
0.0912.18
(0.0858)2.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)
0.0922.20
(0.0866)2.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)
0.0932.24
(0.0882)2.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)
0.0942.26
(0.0890)2.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)
0.0952.28
(0.0898)2.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)
0.0962.32
(0.0914)2.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0972.34
(0.0921)2.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0982.36
(0.0929)2.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0992.38
(0.0937)2.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
02.42
(0.0953)2.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0012.44
(0.0961)2.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0022.46
(0.0969)2.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0032.48
(0.0977)2.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0042.52
(0.0992)2.54
(0.1000)2.56
(0.1008)
0.0052.54
(0.1000)2.56
(0.1008)
0.0062.56
(0.1008)
NOTE: When ordering shims, find the part number in the
parts catalog by using the thickness of shims listed in the
above table.4. Place the shim on the drive pinion, with the chamfered
side turned towards the pinion head then install the
inner bearing onto the pinion using an installer
9±8522±1165±0 and a press.

DIFFERENTIAL (FRONT) 4A1±16
NOTE: Do not apply pressure to the roller cage and apply
pressure only to the inner race.
425RW048
5. Discard the used collapsible spacer and install a new
one.
6. Install pinion gear.
7. Install outer bearing.
8. Use oil seal installer 9±8522±1275±0 to install a new
oil seal that has been soaked in rear axle lubricant.
NOTE: Take care to use a front differential oil seal, NOT
the rear differential oil seal.
415RW024
9. Install dust cover.
10. Install flange.
11. Install flange nut.
1. Apply lubricant to the pinion threads.2. Tighten the nut to the specified torque using the
pinion flange holder 5±8840±2157±0.
Torque: 177±275N´m (18±28kg´m/130±203 lb ft)
NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
425RW047
3. Adjust pinion bearing preload.
a. Measure the bearing preload by using a torque
meter. Note the scale reading required to
rotate the flange.
b. Continue tightening flange nut until the
specified starting torque is obtained.
Starting torque:
New bear-
ing 0.7±1.1 N´m(0.065±0.115kg´m/5.64±9.98 lb in)
Used bear-
ing 0.4±0.5N´m(0.033±0.057kg´m/2.86±4.94 Ib in)
425RS027
4. Using punch 5-8840-2293-0, stake the flange nut
at two points.

4A1±21 DIFFERENTIAL (FRONT)
Differential Cage Assembly
Disassembled View
415RS015
Legend
(1) Pinion Gear
(2) Thrust Washer
(3) Side Gear
(4) Cross Pin(5) Ring Gear
(6) Bolt
(7) Differential Cage
(8) Lock Pin
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin, break staking on the lock pin, using
a 5 mm (0.20 in) diameter drill.
425RS042

DIFFERENTIAL (FRONT) 4A1±22
4. Remove the cross pin, using a soft metal rod and a
hammer.
425RS043
5. Remove pinion gear.
6. Remove side gear.
7. Remove thrust washer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. 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.
Torque: 108 N´m (11kg´m/80 lb ft)5. Tighten the fixing bolts in a diagonal sequence as
illustrated.
415RS016
Clearance between the differential pinion
and the cross pin measurement:
Standard: 0.06 ± 0.12 mm (0.002±0.005 in)
Limit: 0.2 mm (0.008 in)
425RS045

4A1±23 DIFFERENTIAL (FRONT)
Clearance between the side gear and the
differential box:
Standard: 0.03±0.10 mm (0.001±0.004 in)
Limit: 0.15 mm(0.006 in)
425RS046
Legend
(1) Side Gear
(2) Differential Box
Play in splines between the side gear and
the axle shaft:
Standard: 0.08±0.36 mm(0.003 ±0.014 in)
Limit:0.5m (0.02 in)
425RS047
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear by engaging it with the side
gears while turning both pinion gears simultaneously
in the same direction.
425RS048
4. Install 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.
425RS049
2. Adjust the backlash between the side gear and
the pinion gear.
Backlash:0.03 ± 0.08 mm (0.001± 0.003 in)

DIFFERENTIAL (FRONT) 4A1±24
Thickness of thrust washers available:
1.00 mm, 1.05 mm, 1.10 mm (0.039 in, 0.041 in,
0.043 in)
425RS050
5. Install lock pin. After lock pin installation, stake the
cage to secure the lock pin.
425RS051
Legend
(1) Staked Portion
(2) Lock Pin
6. 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.7. Tighten the bolts in diagonal sequence as illustrated.
Torque: 108 N´m (11kg´m/80 lb ft)
NOTE: Discard used bolts and install new ones.
415RS016

4A1±25 DIFFERENTIAL (FRONT)
Main Data and Specifications
General Specifications
Axle tube TypeIt consists of the duct, a cast iron housing and the axle
tube.
Gear typeHypoid
Gear ratio(to 1)4.100(6VE1)
4.300(4JX1, 6VE1)
4.555(4JG2±TC, 6VD1)
4.777(4JG2)
Differential typeTwo pinion
Oil capacityliter
(Imp qt/US qt)1.4 (1.2/1.5) (Differential)
0.12 (0.11/0.13) (Actuator Housing: Shift on the fly)
Type of lubricant75W±90 GL±5 (Multi grade type)
Refer to General Information
Axle shaft typeConstant velocity joint
(Birfield joint type and double offset joint)

DIFFERENTIAL (FRONT) 4A1±28
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±2157±0
(J±37221)
Holder; Pinion flange
9±8522±1275±0
(J±24250)
Installer; Oil seal
5±8840±0275±0
(J±37264)
Differential holding
fixture
(Use with
5±8840±0003±0 base)
5±8840±0003±0
(J±3289±20)
Holding fixture base
5±8840±0013±0
5±8840±0014±0
(J±22888)
Puller; Side bearing
9±8521±1743±0
(J±8107±2)
Adapter; Side bearing
plug
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±0015±0
(J±22912±01)
Separator
9±8522±1141±0
(J±24256)
Installer; Outer bearing
outer race
5±8840±0007±0
(J±8092)
Driver handle
9±8522±1274±0
(J±24252)
Installer; Inner bearing
outer race
5±8840±2085±0
(J±21777±42)
Pilot
5±8840±2089±0
(J±23597±9)
Nut and bolt

4A1±29 DIFFERENTIAL (FRONT)
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±2087±0
(J±23597±7)
Gauge plate
5±8840±0126±0
(J±8001)
Dial indicator
5±8840±2088±0
(J±23597±8)
Disc
5±8840±0128±0
(J±23597±1)
Arbor
9±8522±1165±0
(J±6133±01)
Installer; Pinion bearing
5±8840±2293±0
(J±39209)
Punch; End nut lock
ILLUSTRATIONTOOL NO.
TOOL NAME
9±8522±1164±0
(J±24244)
Installer; Side bearing
5±8840±2323±0
(J±39602)
Remover; Outer bearing