1997 ISUZU TFS SERIES Workshop Manual

4C1-58 FRONT WHEEL DRIVE
Outside Diameter of the Drive Clutch
Assembly
mm(in)
Standard Limit
64.75 (2.55) 64.55 (2.54)

FRONT WHEEL DRIVE 4C1-59
REASSEMBLY
Reassembly Steps
1. Wheel pin
2. Bolt
3. Inner bearing and outer race
4. Outer bearing and outer race
5. Oil seal
6. Hub and disc assembly
7. Hub nut
8. Lock washer
9. Inner cam
10. Drive clutch assembly
11. Snap ring and shim
12. Housing assembly
13. Hub cap
14. Washer and bolt

4C1-60 FRONT WHEEL DRIVE
Important Operations
1. Wheel Pin
(1) Place the hub on a wood workbench or a block of wood
approx. 6” by 6” to protect the wheel stud ends and threads.
(2) Insert a wheel stud using a hammer.
Be sure the wheel stud is started squarely and seats
completely.
2. Bolt
Align scribe marks and attach the hub to the disc.
Torque N
m (kgfm/lbft)
103
5 (10.5 1/75.9 7.2)
3. Inner Bearing and Outer Race
Outer race ; inner bearing
Install the outer race by driving it into the hub.
Installer : 5-880-2119-0
(J-36829)
Grip : 5-8840-0007-0
(J-8092)
4. Outer Bearing and Outer Race
Outer race ; outer bearing
Install the outer race by driving it into the hub.
Installer : 5-8840-0054-0
(J-29015)
Grip : 5-8840-0007-0
(J-8092)
5. Oil Seal
Place the inner bearing onto the outer race in the hub and
install a new oil seal and retaining ring.
Apply Besco L-2 or equivalent to the lip portion.
Installer : 5-8840-2120-0
(J-36830)
Grip : 5-8840-0007-0
(J-8092)

FRONT WHEEL DRIVE 4C1-61
6. Hub and Disc Assembly
(1) Apply grease in the hub.
(2) Apply Besco L-2 or equivalent to the outer and inner
bearing.
g(oz)
Hub 35 (1.23)
Outer bearing 10 (0.35)
Inner bearing 15 (0.53)
7. Hub Nut
Turn the place where there is a chamfer in the tapped hole to
the outer side, and attach the nut.
Wrench : 5-8840-2117-0
(J-36827)
Preload Adjustment
Tighten the hub nut at 29.4 N
m (3 kgfm / 21.716 lbft), then
loosen the nut to the full.
Tighten the hub nut at the value given below, using a spring
scale on the wheel pin.
Bearing Preload kg(lb)
New bearing and New oil seal 2 -2.5 (4.4 - 5.5)
Used bearing and New oil seal 1.2 - 1.8 (2.6 - 4.0)
If the measured bearing preload is outside the specifications,
adjust it by loosening or tightening the bearing nut.
8. Lock Washer
Turn the side with larger diameter of the tapered bore to the
vehicle outer side, and attach the washer.
If the bolt holes in the lock plate are not aligned with the
corresponding holes in the nut, reverse the lock plate.
If the bolt holes are still out of alignment, turn in the nut just
enough to obtain alignment,. Screw is to be fastened tightly so
its head may come lower than the surface of the washer.

4C1-62 FRONT WHEEL DRIVE
9. Inner Cam
(1) Before installation, shift the transfer lever to “2H” position.
(2) Clean the flange surface of the hub, the thread holes, the
surface of the lock washer and the spline portion of the axle
shaft.
(3) Install the inner cam by aligning the key way of the inner
cam with the groove of the knuckle.
Hit the inner cam lightly with plastic hammer or equivalent
and make sure the inner cam is in contact with the lock
washer.
If it is difficult to install the inner cam, use the tool (installer)
and a plastic hammer or the equivalent.
Install the special tool.
Use the plastic hammer to lightly tap around the special tool “A”
surface as shown in the illustration.
Installer : 58840-2137-0 (J-38194)
Note: Do not strike the inner cam gear teeth with the plastic
hammer.
Shim Selection
(1) Lower vehicle from hoist.
(2) Support lower link with floor jack, placing axle in normal
horizontal position.

FRONT WHEEL DRIVE 4C1-63
(3) Install special tool 5-8840-2126-0 to axle shaft by 5-8840-
2125-0 until it comes into contact with the lock washer.
(4) Using feeler gauge, measure clearance “t” between the
special tool and the snap ring groove of the axle shaft.
(5) If clearance “t” is larger than snap ring groove, shims must
be installed select shims so that clearance “t” is 0 to 0.1 mm
(0 to 0.0039 in).
Thickness shims; 0.2, 0.3, 0.5, 1.0 mm
(6) Remove special tool 5-8840-2126-0, leaving the inner cam
in position.
10.Drive Clutch Assembly
Apply multipurpose grease or hub bearing grease to the
following portions.
(1) Axle shaft splines

4C1-64 FRONT WHEEL DRIVE
“A” groove and “B” portion
g(oz)
“A” Groove 7 (0.25)
“B” portion 3 (0.11)
“C” circumference and “D” portion
g(oz)
“C” circumference 8 (0.29)
“D” portion 4 (0.15)
(2) Align the cut part of the drive clutch assembly with the
protudent part of inner cam.
(3) Engage the cam teeth of the drive clutch assembly to that of
the inner cam by turning the axle shaft.
11.Snap Ring and Shims
(1) Install shims (selected above) to axle by hand.
Note :
Always use a new snap ring.
(2) Install special tool 5-8840-2125-0 (B) to axle.
(3) Install snap ring to tool.
(4) Install tool driver 5-8840-2125-0 (A).
(5) Pull out the axle shaft fully by pulling the tool 5-8840-2125-0
(B) and install snap ring to axle by pushing on tool driver 5-
8840-2125-0 (A).
(6) Remove tool from axle.
Snap ring installer : 5-8840-2125-0
(J-36835)

FRONT WHEEL DRIVE 4C1-65
Caution
After installation of the shims and the snap ring, check the
fitting condition of the snap ring.
12.Housing Assembly
(1) Apply Loctite 515 or the equivalent to the flange surface of
the housing assembly.
(2) Make sure that the housing assembly turns smoothly.
If it turns smoothly, the spacer selected above is correct.
(3) Bolt tightening torque :
Torque N
m (kgfm/lbft)
58.9
5 (6 0.5/43.4 3.6)