1995 ISUZU TROOPER Workshop Manual

DIFFERENTIAL CAGE ASSEMBLY
2
Fig. 48-53
REAR AXLE 48-23
Disassembly steps 1. Bolt 2. Ring gear 3. Exciter ring (If equipped
with rear wheel anti lock) 4. Lock pin
5. Cross pin 6. Pinion gear
7. Side gear
8. Thrust washer 9. Differential cage
Reassembly steps
To reassemble, follow the
disassembly steps in the
reverse order.
1•! .. 1 DISASSEMBLY 4. Lock pin
1. Bolt
2. Ring gear
3. Exciter
ring (If equipped with rear wheel
antilock)
• Remove exciter ring from the differential cage
using a mallet
or a copper hammer (Fig. 48-54).
Fig. 48-54
• Break staking on the lock pin, using a 5 mm
(0.20 in) diameter drill (Fig. 48-55).
Fig. 48-55

48-24 REAR AXLE
5. Cross pin
• Remove the cross pin, using a soft metal rod
and a hammer (Fig. 48-56).
Fig. 48-56
6. Pinion gear
7. Side gear
8. Thrust washer
9. 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.
1~1 Torque N·m (lb·ft) 108 (80)
5) Tighten the fixing bolts in a diagonal
sequence as illustrated (Fig. 48-57). Fig.
48-57
l'fil Clearance between the differential pinion and
1..!:.1 the cross pin measurement (Fig. 48-58).
mm (in)
Standard Limit
0.06 -0.12
(0.002 -0.005) 0.2
(0.008)
Fig. 48-58
l'fil Clearance between the side gear and the
1..!:.1 differential box (Fig. 48-59) mm (in)
Standard
Limit
0.05 -0.12 (0.002 -0.0043) 0.1 5 (0.006)

Side gear
Differential box
Fig. 4B-59
l'fiil Play in splines between the side gear and the
1.!!.1 axle shaft (Fig. 48-60)
Standard
0.07-0.38 (0.003-0.014)
Fig. 4B-60
l•!•l REASSEMBLY
9. Differential cage
8.
Thrust washer
7. Side gear
6. Pinion gear
mm (in)
Limit
0.5(0.02)
• Install
the pinion gear by engaging it with the
side gears while turning both pinion gears
simultaneously in the same direction (Fig. 4B-
61).
REAR AXLE 48 - 25
Fig. 4B-61
5. 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. 4B-62).
Fig. 4B-62
1§1-... 1 2) Adjust the backlash between the side gear
and the pinion gear (Fig. 4B-63).
Backlash mm (in) I 0.13-0.18 (0.005-0.007)
Thickness of thrust washers available mm (in)
mm 0.80 0.90 1.00
1.10 1.20
1.30
in 0.031
0.035 0.039 0.043
0.047 0.051

48-26 REAR AXLE
Fig. 48-63
4. Lock pin
• After lock pin installation, stake the cage to
secure the lock pin (Fig. 48-64).
Fig. 48-64
3. Exciter ring (If equipped with rear wheel
antilock)
• Press the exciter ring on the differential cage
using the ring gear
as a pilot (Fig. 48-65).
NOTE:
Discard used exciter ring and install new one.
Fig. 48-65
2. Ring gear
r;:::;J • Clean the ring gear threaded holes to remove
D 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.
1. Bolt
• Tighten the bolts in diagonal sequence as
illustrated (Fig. 48-66).
l~l Torque N·m (lb·ft) I 108 (80)
NOTE:
Discard used bolts and install new ones.
Fig. 48-66

LIMITED SLIP DIFFERENTIAL
For ring size 220cf>
9
10
12
3
8
Disassembly steps 1. Screw 10. Pressure ring 2. Differential cage A
11. Side gear 3. Thrust washer 12. Pinion and pinion shaft 4. Spring disc
13. Side gear 5. Spring disc
14. Pressure ring 6. Friction plate 15. Friction disc 7. Friction disc 16. Friction plate 8. Friction plate 17. Friction disc 9. Friction disc 18. Friction plate
Fig. 48-67
REAR AXLE 48-27
16 17
19. Spring disc
20. Spring disc
18
21. Thrust washer
19
22. Differential cage B
Reassembly steps
20
To reassemble, follow the disassembly steps in the reverse order.
21

48 -28 REAR AXLE
l•!-.1 DISASSEMBLY
Using special tool, grip it with a vice, and set the
differential (Fig. 48-68).
I ®.1 Side gear holder: J-41 033
Fig. 48-68
1.
Screw
• Gradually and evenly loosen the 4 fixing
screws of the differential cages A and 8 (Fig.
48-69).
Fig. 48-69
2. Differential cage A
3. Thrust washer
4. Spring disc
• When removing the spring disc, friction disc,
and
friction plate, place them in order for
clear distinction of left and right use.
5. Spring disc
6. Friction plate
7. Friction disc
8. Friction plate
9. Friction disc
10. Pressure ring
11. Side gear
12. Pinion and pinion shaft
13. Side gear
14. Pressure
ring
15. Friction disc
16. Friction plate
17. Friction disc
18.
Friction plate
19. Spring disc
20. Spring disc
21.
Thrust washer
22. Differential cage B
IL•IINSPECTION AND REPAIR
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition is found through inspection.
Visual check
Check
the following parts for wear, damage, noise or
any other abnormal conditions.
• Friction disc, friction plate and spring disc
CD Sliding surfaces
® Projections
Fig. 48-70
• Pressure ring
@ Sliding surface with the friction disc
When nicks or scratches are found, polish
with an oil stone and repair on a level block
using a
compound.
@ Sliding spherical surface with the pinion
gear
® Sliding surface with the side gear
® V-shaped groove of the pressure ring and V­
shaped section
of the pinion shaft
(j) Fitting section with the case
® Face contacting the inner surface of the
differential case
Repair
burrs and nicks using an oil stone.