1995 ISUZU TROOPER Workshop Manual

FRONT DRIVING AXLE 4C-19
7) Select the shim using the chart;
Pinion marking +10 +8 +6 +4 +2 0 -2 -4 -6 -8 -10 Dial indicator reading !Inches)
0.081 2.18(0.0858)
0.082 2.18(0.0858) 2.20(0.0866)
0.083
2.1 8(0.0858) 2.20(0.0866)
2.23(0.0882)
0.084 2.1 8(0.0858) 2.20(0.0866) 2.24(0.0882) 2.26(0.0890)
0.085 2.18(0.0858) 2.20(0.0866) 2.24(0.0882)
2.26(0.0890) 2.28(0.0898)
0.086 2.18(0.0858) 2.20(0.0866) 2.24(0.0882)
2.26(0.0890) 2.28(0.0898) 2.32(0.0914)
0.087 2.18(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) 0.088 2.18(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) 0.089 2.18(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)
0.090 2.18(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)
0.091 2.18(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
I
0.092 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)
2.46(0.0969) 0.093 2.24(0.0882)
2.26(0.0890) 2.28(0.0898) 2.32(0.0914) 2.34(0.0921 I 2.36(0.0929) 2.38(0.0937) 2.42(0.0953) 2.44(0.0961 I 2.46(0.0969) 2.48(0.0977)
0.094 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
I 2.46(0.0969) 2.48(0.0977) 2.52(0.0992)
0.095 2.28(0.0898) 2.32(0.0914)
2.34(0.0921 I 2.36(0.0929) 2.38(0.0937) 2.42(0.0953) 2.44(0.0961 I 2.46(0.0969) 2.48(0.0977) 2.52(0.0992) 2.54(0.1 000)
0.096 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)
2.56(0.1
008)
0.097 2.34(0.0921) 2.36(0.0929)
2.38(0.0937) 2.42(0.0953) 2.44(0.0961 I 2.46(0.0969) 2.48(0.0977) 2.52(0.0992)
2.54(0.1 000) 2.56(0.1 008)
0.098 2.36(0.0929)
2.38(0.0937) 2.42(0.0953) 2.44(0.0961 I 2.46(0.0969) 2.48(0.0977)
2.52(0.0992) 2.54(0.1 000) 2.56(0.1 008)
0.099 . 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(0.1 008)
0 2.42(0.0953) 2.44(0.0961) 2.46(0.0969) 2.48(0.0977) 2.52(0.0992) 2.54(0.1 000) 2.56(0.1008)
0.001 2.44(0.0961)
2.46(0.0969) 2.48(0.0977) 2.52(0.0992) 2.54(0.1 000) 2.56(0.1008)
0.002 2.46(0.0969) 2.48(0.0977) 2.52(0.0992) 2.54(0.1 000) 2.56(0.1 008)
0.003 2.48(0.0977) 2.52(0.0992) 2.54(0.1 000) 2.56(0.1 008)
0.004 2.52(0.0992) 2.54(0.1 000) 2.56(0.1 008)
0.005 2.54(0.1 000) 2.56(0.1 008)
0.006 2.56(0.1 008)
NOTE:
When ordering shims, find the part number in the parts catalog by using the thickness of shims listed in the above
table.
15. Inner bearing
ria\~ • Place the shim on the drive pm1on, with the
~ chamfered side turned towards the pinion
head then
install the inner bearing onto the
pinion using an
installer and a press(Fig. 4C-
43).
Installer: J-6133-01
NOTE:
Do not apply pressure to the roller cage.
Apply pressure only to the inner race.
Fig.
4C-43
J-6133-01
I I I I
~::~ r--.J , I I '\...-___ J
14. Collapsible spacer
• Discard the used collapsible spacer and install
a new one.
13. Pinion gear
19.
Outer bearing
18.
Oil seal
ria\~ • Use oil seal installer to install a new oil seal that
~ has been soaked in rear axle lubricant (Fig. 4C-
I:;;:;I 44) .
t.::::::::.l Installer: J-24250
NOTE:
Take care to use a front differential oil seal, NOT
the rear differential oil seal.
J-24250
Fig. 4C-44

4C-20 FRONT DRIVING AXLE
12. Dust cover
11.
Flange
1 0. Flange nut
8 1) Apply lubricant to the pinion threads.
2) Tighten the nut to the specified torque using
1®..1 the pinion flange holder (Fig. 4C-45).
Pinion
flange holder: J-37221
~~~ Torque New bearing 177-275 (130-203)
N·m (lb·ft)
Used bearing 89-137 (65-101)
NOTE:
• Discard used flange nut and install new one.
• Do not over tighten the flange nut.
Fig. 4C-45
3) Pinion bearing preload
(a) Measure the bearing preload by using a
torque meter.
Note the
scale reading required to rotate the
flange.
I~U (b) Continue tightening flange nut until the
specified starting torque is obtained (Fig. 4C-
46).
Newbearing 0 ·7
-1
·1
Starting
torque f---------+--(:_5_.6_4_-9_._98_:_)_
N·m (lb·in)
0.4-0.5
(2.86-4.94)
Used
bearing
Fig. 4C-46
I'Q\1 Using special tool, stake the flange nut at two
~ points (Fig. 4C-47).
Punch:
J-39209
NOTE:
• When staking, be sure to turn the nut to insure
that there is no change in bearing preload.
•
Make sure of preload again as instructed in 3).
Fig. 4C-47
1.3mm or less
9. Adjust shim
r;cJ 1) Attach the side bearing to the differential
~ assembly without shims. Support the
1®.1 opposite side using a pilot to prevent bearing
damage (Fig. 4C-48).
~ 2)
CD Installer: J-24244
® Drive handle: J-8092
@ Pilot: J-81 07-2
Fig. 4C-48
Insert the differential cage assembly with
bearing outer races into the side bearing
bores
of the carrier (Fig. 4C-49).
..

~3)
I
Fig. 4C-49
Using two sets of feeler gauges, insert a feeler
stock of sufficient thickness between each
bearing outer race and the carrier to remove
all end play. Make certain the feeler stock is
pushed to the bottom
of the bearing bores.
Mount the dial indicator on the carrier so that
the indicator stem is at right
angles to a tooth
on the ring gear (Fig.
4C-50).
Dial
indicator: J-8001
Fig. 4C-50
I~FI4) Adjust feeler gauge thickness from side to
side
until ring gear backlash is in the specified
range (Fig. 4C-51).
Backlash mm (in) I 0.13 -0.18 (0.005 -0.007)
With zero end play and correct backlash
established,
remove the feeler gauge packs,
determine the thickness
of the shims required
and add
0.05 mm (0.002 in) to each shim pack
to provide side bearing
preload. Always use
new shims.
FRONT DRIVING AXLE 4C-21
/
Fig. 4C-51
1®15) Remove side bearing (Fig. 4C-52).
Remover: J-22888
Pilot: J-81 07-2
Fig. 4C-52
8. Side bearing
('Qil • Install the side bearings together
~ selected shims (Fig. 4C-53).
CD Installer: J-24244
® Drive handle: J-8092
® Pilot: J-8107-2
Fig.
4C-53
CD
with the

4C-22 FRONT DRIVING AXLE
7. Side bearing outer race
6. Differential cage assembly
5. Bearing cap
IP.il • Align the setting marks applied at disassembly
U (Fig. 4C-54).
Setting mark
Fig. 4C-54
4. Bolt (Fig. 4C-55)
• Tighten the bolt to the specified torque.
~~~ Torque N·m (lb·ft) 98 (72)
Fig. 4C-55
~·
Measure the amount of run-out of the ring gear
at its rear face (Fig. 4C-56).
mm (in)
Standard Limit
0.02
(0.001) 0.05 (0.002)
Fig. 4C-56
mil Gear Tooth Contact Pattern Check and
I.!:::..J Adjustment
r;o • Apply a thin coat of prussian blue or equivalent
ID to the faces of the 7-8 teeth of the ring gear.
Check the impression
of contact on the ring
gear teeth and make necessary adjustment
as
described in Fig. 4C-55 if the contact is
abnormal (Fig. 4C-57, Fig. 4C-58).
Fig. 4C-57
•