1997 ISUZU TFS SERIES Workshop Manual

4C1-26 FRONT WHEEL DRIVE
Important Operations
3. Lock Pin
Break staking on the lock pin using a 5 mm (0.20 in.) diameter
drill.
4. Cross Pin
Remove the cross pin using a soft metal rod and a hammer.

FRONT WHEEL DRIVE 4C1-27
INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspection.
Ring gear, pinion gear
Bearing
Side gear, pinion gear, cross pin
Differential cage, carrier
Thrust washer
Oil seal
Visual Check
Inspect the following parts for wear, damage, or other
abnormal conditions.
Ring Gear Replacement
(1) The ring gear should always be replaced with the drive
pinion as a set.
(2) W hen installing the ring gear, apply LOCTITE 271 or
equivalent to the threaded hole and bolt.
(3) Tighten the fixing bolts in a diagonal sequence as
illustrated.
(4) Discard used bolts and install new ones.
Bolt Torque N
m (kgfm/lbft)
167 mm 78.5
9.8 (8 1/57.9 7.2)
194 mm 107.9 9.8 (11 1/79.6 7.2)
For 167 mm
Note that all bolts have a left hand thread.
Clearance Between the Differential Pinion
and the Cross Pin
mm(in)
Standard Limit
167 mm 0.06 - 0.12 (0.002 - 0.005) 0.2 (0.008)
194 mm 0.05 - 0.10 (0.002 - 0.004) 0.2 (0.008)

4C1-28 FRONT WHEEL DRIVE
Clearance Between the Side Gear and the
Differential Box
mm(in)
Standard Limit
167 mm 0.03 - 0.11 (0.001 - 0.004) 0.15 (0.006)
194 mm 0.03 - 0.10 (0.001 - 0.004) 0.15 (0.006)
Play in Splines Between the Side Gear
and the Axle Shaft
mm(in)
Standard Limit
167 mm 0.11 - 0.38 (0.004 - 0.015) 0.30 (0.012)
194 mm 0.07 - 0.36 (0.003 - 0.014) 0.25 (0.010)

FRONT WHEEL DRIVE 4C1-29
REASSEMBLY
MINOR COMPONENTS
Reassembly Steps
1. Differential cage
2. Thrust washer
3. Side gear
4. Pinion gear
5. Cross pin
6. Lock pin
7. Ring gear
8. Bolt
Important Operations
4. Pinion Gear
Install the pinion gear by engaging it with the side gears while
turning both pinion gears simultaneously in the same direction.

4C1-30 FRONT WHEEL DRIVE
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.
(2) Adjust the backlash between the side gear and the pinion
gear.
mm(in)
Backlash 0.03 - 0.08 (0.001 - 0.003)
Thickness of thrust washers available
mm(in)
167 mm 1.05, 1.15, 1.25 (0.041, 0.043, 0.049)
194 mm 1.00, 1.05, 1.10 (0.039, 0.041, 0.043)
6. Lock Pin
After lock pin installation, stake the cage to prevent discharge
of the lock pin.
7. Ring Gear
When installing the ring gear, apply LOCTITE 271 or equivalent
to the threaded hole and bolt.
8. Bolt
Tighten the bolts in diagonal sequence as illustrated.
Bolt Torque N
m (kgfm/lbft)
167 mm 78.5
9.8 (8 1/57.9 7.2)
194 mm 107.9 9.8 (11 1/79.6 7.2)
Note :
Discard used bolts and install new ones.
For 167 mm
Note that all bolts have a left hand thread.

FRONT WHEEL DRIVE 4C1-31
MAJOR COMPONENTS
Reassembly Steps
1. Diff. carrier
2. Outer bearing outer race
3. Inner bearing outer race
4. Adjust shim
5. Inner bearing
6. Collapsible spacer
7. Pinion gear
8. Outer bearing
9. Oil seal
10. Dust cover11. Flange
12. Flange nut and washer
13. Adjust shim
14. Side bearing
15. Bearing outer race
16. Diff. cage assembly
17. Bearing cap
18. Bolt
19. Axle case
20. Differential assembly
21. Bolt

4C1-32 FRONT WHEEL DRIVE
Important Operations
2. Outer Bearing Outer Race
Installer : 5-8522-0048-0 (167 mm)
(J-29038)
9-8522-1141-0 (194 mm)
(J-24256)
Grip : 5-8840-0007-0
(J-8092)
3. Inner Bearing Outer Race
Installer : 5-8522-0049-0 (167 mm)
(J-29039)
9-8522-1274-0 (194 mm)
Grip : 5-8840-0007-0
(J-8092)
4. Adjust Shim
Adjustment of drive pinion mounting distance
(1) Apply gear oil to the inner and outer drive pinion bearing.
Clean the pinion setting gage set.
Then install the gage set together with the inner and outer
bearings.
For 167 mm
1Pilot : 5-8840-2092-0
(J-23597-28)
2Nut and bolt : 5-8840-0127-0
(J-21777-43)
3Rear pilot : 5-8840-02091-0
(J-23597-27)
4Gage plate : 5-8840-2090-0
(J-23597-26)
For 194 mm
1Pilot : 5-8840-2085-0
(J-21777-42)
2Nut and bolt : 5-8840-2089-0
(J-23597-9)
4Gage plate : 5-8840-2087-0
(J-23597-7)

FRONT WHEEL DRIVE 4C1-33
Tighten the nut to the specified torque.
N
m (kgfm/lbft)
New bearing 2.26 (23/20)
Used bearing0.98 - 1.18
(10 - 12/8.7 - 10.4)
(2) 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 N
m (kgfm/lbft)
167 mm 68.7
9.8 (7.0 1.0/50.6 7.2)
194 mm 98.1 9.8 (10.0 1.0/72.3 7.2)
For 167 mm
1Dial indicator : 5-8840-0126-0
(J-8001)
2Disc (2 pcs.) : 5-8840-2086-0
(J-23597-4)
3Arbor : 5-8840-0128-0
(J-23597-1)
4Gage plate : 5-8840-2090-0
(J-23597-26)
For 194 mm
1Dial indicator : 5-8840-0126-0
(J-8001)
2Disc (2 pcs.) : 5-8840-2088-0
(J-23597-8)
3Arbor : 5-8840-0128-0
(J-23597-1)
4Gage plate : 5-8840-2087-0
(J-23597-7)