lock ISUZU TROOPER 1998 Service Manual PDF

4A1±1 DIFFERENTIAL (FRONT)
DRIVELINE/AXLE
CONTENTS
Differential (Front) 4A1. . . . . . . . . . . . . . . . . . . . . . .
Differential (Rear/220mm) 4A2A. . . . . . . . . . . . . . . .
Differential (Rear/244mm) 4A2B. . . . . . . . . . . . . . . .
Driveline Control System (Shift on the Fly) 4B1. . Driveline Control System (TOD) 4B2. . . . . . . . . . .
Driveshaft System 4C. . . . . . . . . . . . . . . . . . . . . . .
Transfer Case (Standard Type) 4D1. . . . . . . . . . .
Transfer Case (TOD) 4D2. . . . . . . . . . . . . . . . . . . .
DIFFERENTIAL (FRONT)
CONTENTS
Service Precaution 4A1±1. . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 4A1±2. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal 4A1±3. . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal and Associated Parts 4A1±3
Removal 4A1±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1±4. . . . . . . . . . . . . . . . . .
Installation 4A1±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle Assembly 4A1±5. . . . . . . . . . . . . . .
Front Drive Axle Assembly and
Associated Parts 4A1±5. . . . . . . . . . . . . . . . . . . . . .
Removal 4A1±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A1±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A1±9. . . . . . . . . . . . . . . . . . . .
Disassembled View 4A1±9. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1±9. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A1±12. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A1±21. . . . . . . . . . . . . . .
Disassembled View 4A1±21. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1±22. . . . . . . . . . . . . . . . . .
Reassembly 4A1±23. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A1±25. . . . . . . . . . .
Special Tools 4A1±28. . . . . . . . . . . . . . . . . . . . . . . . . .
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 REFORMING 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 specification. Following these
instructions can help you avoid damage to parts and
systems.

DIFFERENTIAL (FRONT) 4A1±6
3. Remove the drain bolt to drain differential oil.
NOTE:
a. During the work, be sure that the diff case is
supported by the jack.
412RS003
b. Remove the brake caliper fixing bolt and hang the
caliper. Refer to Front Disc Brake Caliper Assembly
in Brake section.
c. Remove the antilock brake system speed sensor (if
equipped). Refer to Front Wheel Speed Sensor in
Brakes section.
4. Remove the hub assembly (Disc, back plate and
knuckle), refer to Front Hub and Disc in this section.
5. Disconnect the knuckle and the suspension arm.
Refer to Suspension section.
6. Remove steering link and arm assembly, refer to
Steering Linkage in Steering section.
7. Remove suspension crossmember.
8. Remove propeller shaft, refer to Front Propeller Shaft
in this section.
9. Remove protector (Shift on the fly model).
10. Remove breather hose (Shift on the fly model).
11. Remove the hose clip (Shift on the fly model).
12. Disconnect breather hose from front drive axle tube
and disconnect housing (Shift on the fly model).
13. Disconnect vacuum hose from actuator (Shift on the
fly model).14. Disconnect shift switch connector (Shift on the fly
model).
412RS031
15. Remove VSV assembly (1) (Shift on the fly model).
NOTE: Be sure not to remove hose and connector from
VSV asm.
412RW002

4A1±13 DIFFERENTIAL (FRONT)
3. Clean the side bearing bores. Install the dial
indicator with the discs and arbor. Install and
tighten the bearing caps to the specified torque.
Torque: 98 N´m (10kg´m/72 lb ft)
415RS010
Legend
(1) Dial Indicator: 5±8840±0126±0
(2) Disc (2 pcs.): 5-8840-2088-0
(3) Arbor: 5±8840±0128±0
(4) Gauge Plate: 5±8840±2087±0
4. Set the dial indicator to ª0º. Place it on the
mounting post of the gauging arbor with the
contact button touching the indicator pad. Force
the dial indicator downward until the needle has
made a half turn clockwise. Tighten down the dial
indicator in this position.
425RS020
Legend
(1) Dial Indicator
(2) Ganging Arbor
(3) Plunger
(4) Gauge Plate
5. Position the plunger on the gauge plate. Move the
gauging arbor slowly back and forth and locate
the position at which the dial indicator shows the
greatest defection. At this point, once again set
the dial indicator to ª0º.
Repeat the procedure to verify the ª0º setting.
425RS021
6. After the ZERO setting is obtained, rotate the
gauging arbor until the dial indicator rod does not
touch the gauging plate.
Record the number the dial indicator needle
points to.
425RS022
Legend
(1) Example=Dial indicator reading of 0.085

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±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

DIFFERENTIAL (REAR 220mm)
4A2A±1
DRIVELINE/AXLE
DIFFERENTIAL (Rear 220mm)
CONTENTS
Service Precaution 4A2A±1. . . . . . . . . . . . . . . . . . . . . .
General Description 4A2A±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A2A±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing 4A2A±4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts 4A2A±4. . . . . .
Removal 4A2A±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4A2A±5. . . . . . . . . . . . . . . . . .
Installation 4A2A±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal 4A2A±6. . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts 4A2A±6. . . . .
Removal 4A2A±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2A±7. . . . . . . . . . . . . . . . . .
Installation 4A2A±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A2A±8. . . . . . . . . . . . . . . . . . . .
Differential Assembly and Associated Parts 4A2A±8
Removal 4A2A±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A2A±9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4A2A±10. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2A±11. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A2A±13. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A2A±21. . . . . . . . . . . . . . .
Disassembled View 4A2A±21. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2A±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2A±22. . . . . . . . . . . . . . . . . .
Reassembly 4A2A±23. . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Slip Differential 4A2A±25. . . . . . . . . . . . . . . . . . .
Disassembled View 4A2A±25. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2A±26. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2A±26. . . . . . . . . . . . . . . . . .
Reassembly 4A2A±28. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A2A±32. . . . . . . . . . .
Special Tools 4A2A±34. . . . . . . . . . . . . . . . . . . . . . . . . .
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 REFORMING 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 specification. Following these
instructions can help you avoid damage to parts and
systems.

4A2A±4
DIFFERENTIAL (REAR 220mm)
Axle Housing
Axle Housing and Associated Parts
420RW022
Legend
(1) Coil Spring and Insulator
(2) Axle Housing Assembly
(3) ABS Speed Sensor and Harness(if equipped)
(4) Nut
(5) Parking Brake Cable
(6) Bolt and Nut
(7) Antilock Brake System (ABS) Connector and
Bracket (if equipped)
(8) Bolt and Nut(9) Nut
(10) Differential Assembly
(11) Axle Shaft Assembly
(12) Brake Disc
(13) Brake Pipe
(14) Brake Caliper
(15) Nut
(16) Breather Hose
(17) Flare Nut
Removal
1. Raise the vehicle and support it with suitable safety
stands.
The hoist must remain under the rear axle housing.
2. Drain brake fluid. Refer to Hydraulic Brakes in Brake
section.
3. Remove rear wheels and tires. Refer to Wheel in
Suspension section.4. Remove propeller shaft. Refer to Rear Propeller
Shaft in this section.
5. Drain the rear axle oil into a proper container.
6. Remove parking brake cable, release the connection
between the cable fixing clip equalizer. Refer to
Parking Brakes in Brake section.
7. Move the clip aside and pull out the breather hose.