1995 ISUZU TROOPER Workshop Manual

__,.
9. Ball retainer
10. Ball guide
11. Bellows
12. Band
13. 14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24. 25.
• Raise the hooked end of the band with a
screwdriver or equivalent (Fig. 4C-18).
Bellows band
Fig. 4C-18
Band
Bellows
Dust seal
BJ shaft assembly
Bolt
• Remove the mounting bracket fixing bolts,
and then remove the front axle drive shaft
from the axle case.
DOJ case assembly
Axle case and differential
Snap ring
Bearing
Snap ring
Oil seal
Bracket
DOJ case
I L•IINSPECTION 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.
• Drive shaft joint assembly
• DOJ
case, ball, ball guide, ball retainer
• Bellows
• Bearing
• Dust seal, oil seal
~ BUSHING REPLACEMENT
• Remove the bushings using a remover and
hammer (Fig. 4C-19).
FRONT DRIVING AXLE 4C -11
1 (ij),_j Remover: J-39378-1
Fig. 4C-19
• Press fit the bushings into the bracket (Fig.
4C-20).
j(ij),_jlnstaller:
J-39378-2
Base: J-39378-3
Fig.
4C-20
l•!•l REASSEMBLY
25. DOJ case
24. Bracket
23.
Oil seal
22. Snap ring
21.
Bearing
20.
Snap ring
19. Axle case and differential
18. DOJ case assembly
17. Bolt
• Tighten the bracket bolt to the specified torque.
~~~ Torque N-m (lb-ft) I 116 (85)
16. BJ
shaft assembly
1-c:::lcll • Inclose 150g ofthe specified grease in BJ.

4C-12 FRONT DRIVING AXLE
15. Dust seal
14.
Bellows
c::::1 • Apply a thin coat of grease to the shaft for
D smooth installation.
13. Band (fig. 4C-21)
r=l • Note the setting direction.
'-=.1 • After installation, check that the bellows is free
from distortion.
12. Band
11.
Bellows
10. Ball
guide
~ Front
Fig. 4C-21
fiiil • Install the ball guide with the smaller diameter
U side ahead onto the shaft.
9. Ball retainer
8. Snap ring
• Using snap ring pliers, install the snap ring
securing the
ball retainer to the shaft (Fig. 4C-
17.
7. Ball (Fig. 4C-22)
• Align the track on the ball retainer with the
window in the cage, and install the six balls into
position.
Ball
Fig. 4C-22
6. Spacer
5. Snap ring
4. Drive shaft joint assembly
c::::1 • Inclose 150 g of the specified grease in DOJ
D case, and after reassembly, move the DOJ
longitudinally several
times to get to fit.
3. Circlip (Fig. 4C-23, 4C-24)
fiiil • Install the circlip so that open ends are
U positioned away from the ball groove.
Fig.
4C-23
Outer case
~-J.r~
Open ends Circlip
Fig. 4C-24
2. Bellows
c::::1 • Before installation, insert the appropriate
D amount of specified grease into the DOJ case.
m=J • Adjust the air pressure within the bellows by
I§C.I inserting a screwdriver or equivalent, so that it
equals atmospheric pressure (Fig. 4C-25).
1111

171 mm (6.98 in)
Fig. 4C-25
1. Band
• After installation, check that the bellows is free
from distortion.
FRONT DRIVING AXLE 4C-13

4C-14 FRONT DRIVING AXLE
DIFFERENTIAL ASSEMBL V
Disassembly steps 1. Bolt
2. Differential assembly 3. Axle case 4. Bolt 5. Bearing cap
6. Diff. cage assernbly 7. Side bearing outer race 8. Side bearing 9. Adjust shim 10. Flange nut 11. Flange
3
12. Dust cover 13. Pinion gear 14. Collapsible spacer
15. Inner bearing
16. Adjust shim
17.1nner bearing outer race 18.0il seal 19. Outer bearing 20. Outer bearing outer race
21. Diff. carrier
Reassembly steps
21. Diff. carrier 20. Outer bearing outer race
17.1nner bearing outer race
16. Adjust shim 15.1nner bearing
14. Collapsible spacer
13. Pinion
gear 19. Outer bearing
18. Oil seal 12. Dust cover
Fig. 4C-26
11. Flange
10. Flange nut
9. Adjust shim 8. Side bearing 7. Side bearing outer race
6. Diff. cage assembly 5. Bearing cap
4. Bolt 3. Axle case 2. Differential assembly 1. Bolt
..

l•!•l DISASSEMBLY
1. Bolt
2. Differential assembly
3. Axle case
rr.i\1 • Using special tools, fix the differential
I.:Sil assembly to the bench (Fig. 4C-27).
Holding fixture: J-37264
Holding fixture base: J-3289-20
Fig.
4C-27
4. Bolt
5. Bearing cap
IE41 • Apply a setting mark to the side bearing cap
and
the differential carrier (Fig. 4C-28).
Fig.
4C-28
6. Differential cage assembly
7. Side bearing outer race
• After removal, keep the right and left hand
side bearing assemblies separate
to maintain
inner and outer race combinations.
FRONT DRIVING AXLE 4C-15
8. Side bearing
1®.1 • Using special tools, remove the side bearing
(Fig. 4C-29).
Remover: J-22888
Adapter: J-8107-2
Fig.
4C-29
9. Adjust shim
J-22888
• Note the thickness and position of the shims
removed.
10. Flange nut
• Remove the flange nut using special tool after
raising
up its staked parts completely (Fig. 4C-
30).
1®.1 Holding wrench: J-37221
Fig.
4C-30
11. Flange
12.
Dust cover