1997 ISUZU TFS SERIES Workshop Manual

4C1-34 FRONT WHEEL DRIVE
(3) Set the dial indicator to “0”. Place it on the mounting post of
the gaging 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.
(4) Position the plunger on the gage plate. Move the gaging
arbor slowly back and forth and locate the position at which
the dial indicator shows the greatest deflection. At this
point, once again set the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.
(5) After the ZERO setting is obtained, rotate the gaging arbor
until the dial indicator rod does not touch the gaging plate.
Record the number the dial indicator needle points to.
(6) Record the pinion depth code on the head of the drive
pinion.
The number indicates a necessary change in the pinion
mounting distance. A plus number indicates the need for a
greater mounting distance (which can be achieved by
decreasing the shim thickness). A minus number indicates
the need for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If examination
reveals pinion depth code “0”, the pinion is “nominal”.

FRONT WHEEL DRIVE 4C1-35
(7) Select the shim using the chart;
For 167 mmmm(in)Pinion
marking
+6 +4 +2 +0 -2 -4 -6
Dial indicator
reading (inches)
0.0521.39 (0.0547)
0.0531.39 (0.0547) 1.41 (0.0555)
0.054 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563)
0.055 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571)
0.056 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587)
0.057 1.39 (0.0547) 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594)
0.058 1.41 (0.0555) 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602)
0.059 1.43 (0.0563) 1.45 (0.0571) 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610)
0.060 1.47 (0.0579) 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626)
0.061 1.49 (0.0587) 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634)
0.062 1.51 (0.0594) 1.53 (0.0602) 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642)
0.063 1.55 (0.0610) 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657)
0.064 1.57 (0.0618) 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665)
0.065 1.59 (0.0626) 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673)
0.066 1.61 (0.0634) 1.63 (0.0642) 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681)
0.067 1.65 (0.0650) 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)
0.068 1.67 (0.0657) 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)
0.069 1.69 (0.0665) 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)
0.070 1.71 (0.0673) 1.73 (0.0681) 1.75 (0.0689) 1.77 (0.0697)
0.071 1.75 (0.0689) 1.77 (0.0697)
0.072 1.77 (0.0697)
For 194 mmmm(in)
Pinion
marking
+10 +8 +6 +4 +2 0 -2 -4 -6 -8 -10Dial indicator
reading (inches)
0.0812.18 (0.0858)0.0822.18 (0.0858) 2.20 (0.0866)0.0832.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882)0.0842.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890)0.0852.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898)0.0862.18 (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)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) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 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) 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) 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)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 (0.1008)0.097 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 (0.1008)0.098 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 (0.1008)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 (0.1008)0 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 (0.1008)0.001 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.002 2.46 (0.0969) 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.003 2.48 (0.0977) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.004 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.005 2.54 (0.1000) 2.56 (0.1008)0.006 2.56 (0.1008)
Note :
When ordering shims, find the part number in the Parts Catalog by using the thickness of the shims listed
in the above table.

4C1-36 FRONT WHEEL DRIVE
5. Inner Bearing
Place the shim on the drive pinion, with the chamfered side
turned towards the pinion head then install the inner bearing on
to the pinion using an installer and a press.
Installer : 9-8522-1165-0 (J-6133-01)
Note:
Do not apply pressure to the roller cage.
Apply pressure only to the inner race.
6. Collapsible Spacer
Discard the used collapsible spacer and install a new one.
9. Oil Seal
Use oil seal installer to install a new oil seal that has been
soaked in rear axle lubricant.
Installer : 5-8522-0046-0 (J-26234) (For 167 mm)
9-8522-1275-0 (J-24250) (For 194 mm)
Note :
Take care not to use a rear differential oil seal instead of
the front differential oil seal.
12.Flange Nut and Washer
For 194 mm
(1) Apply lubricant to the pinion threads.
(2) Tighten the nut to the specified torque using the pinion
flange holder.
Pinion flange holder : 5-8840-0133-0
(J-8614-01)
Torque N
m (kgfm/lbft)
176.6 - 274.7 (18 - 28/130 - 202)
Discard used flange nut and install new one.

FRONT WHEEL DRIVE 4C1-37
(3) Pinion bearing preload
(a) Measure the bearing preload by using a torque meter. Note
the scale reading required to rotate the flange.
(b) continue tightening until the specified starting torque is
obtained.
Starting Torque N
m (kgfcm/lbin)
0.63 - 1.13 (6.5 - 11.5/5.7 - 9.9)
For 167 mm
(1) Apply lubricant to the pinion threads.
(2) Tighten the nut to the specified torque using the pinion
flange holder.
Pinion flange holder : 5-8840-0133-0 (J-8614-01)
Torque N
m (kgfm/lbft)
117 - 127 (12 - 13/87 - 94)
Discard used flange nut and install new one.
(3) Continue tightening until the specified starting torque is
obtained.
Starting Torque N
m (kgfcm/lbin)
0.59 - 1.0 (6 - 11/5.2 - 9.5)
13.Adjust Shim
(1) Attach the side bearing to the differential assembly without
shims. Support the opposite side using a pilot to prevent
bearing damage.
For 167 mm
1Installer : 5-8840-0138-0
(J-29036)
2Drive handle : 5-8840-0007-0
(J-8092)
3Pilot : 5-8521-0019-0
For 194 mm
1Installer : 9-8521-1164-0
(J-24244)
2Drive handle : 5-8840-0007-0
(J-8092)
3Pilot : 9-8521-1743-0
(J-8107-2)

4C1-38 FRONT WHEEL DRIVE
(2) Insert the differential cage assembly with bearing outer
races into the side bearing bores of the carrier.
(3) 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 plat. 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.
Dial indicator : 5884-0126-0
(J-8001)
(4) Adjust feeler gauge thickness from side to side until ring
gear backlash is in the specified range.
Backlash mm(in)
0.13 - 0.18 (0.005 - 0.007)
W ith 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.
(5) Remove side bearing
Remover : 5-8840-0013-0
(J-22888)
Pilot : 5-8521-0019-0 (167 mm)
9-8521-1743-0 (194 mm)
(J-8107-2)
14.Side Bearing
Install the side bearings together with the selected shims.
For 167 mm
1Installer : 5-8840-0138-0 (J-29036)
2Drive handle : 5-8840-0007-0 (J-8092)
3Pilot : 5-8521-0019-0
For 194 mm
1Installer : 9-8521-1164-0 (J-24244)
2Drive handle : 5-8840-0007-0 (J-8092)
3Pilot : 9-8521-1743-0 (J-8107-2)

FRONT WHEEL DRIVE 4C1-39
17.Bearing Cap
Align the setting marks applied at disassembly.
18.Bolt
Bolt 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)
Measure the amount of run-out of the ring gear at its rear face.
mm(in)
Standard Limit
0.02 (0.001) 0.05 (0.002)
Gear Tooth Contact Pattern Check and Adjustment
Apply a thin coat of prussian blue or equivalent 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 below if the contact is abnormal.

4C1-40 FRONT WHEEL DRIVE
20.Differential Assembly
(1) Clean the faces of the front axle case and differential
carrier.
Apply the recommended liquid gasket or its equivalent to
the sealing side of the axle case and the carrier.
(2) Attach the differential case and the carrier assembly to the
front axle case and tighten the nuts and bolts. The axle
case bolt is used for drainage.
Torque N
m (kgfm/lbft)
25.5
5 (2.6 0.5/18.8 3.6)
(3) Install the axle shaft assemblies as instructed earlier in this
section under “Axle Shaft Replacement”.
(4) Fill the axle case with hypoid gear lubricant, to just below
the filler hole.
Lubricant capacity liter (US/UK gal)
167 mm 1.0 (0.26/0.22)
194 mm 1.4 (0.37/0.31)

FRONT WHEEL DRIVE 4C1-41
FRONT HUB AND DISC (42 model)
DISASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure.
Disassembly Steps
1. Bolt
2. Brake caliper
3. Hub cap
4. Split pin
5. Nut retainer
6. Hub nut
7. Lock washer8. Outer bearing
9. Hub and disc assembly
10. Oil seal
11. Inner bearing and outer race
12. Bolt
13. Wheel pin