1997 ISUZU TFS SERIES Workshop Manual

REAR AXLE 4B-13
Important Operations
2. Bearing Outer Race
Installer : 5-8522-1268-0
(194 mm standard suspension)
(J-24259)
: 5-8840-2201-0
(194 mm heavy-duty suspension and 220 mm)
Grip : 5-8840-0007-0 (J-8092)
3. Oil Seal ; Bearing Holder
Installer : 9-8522-1269-0
(194 mm standard suspension)
(J-24255)
: 5-8840-2202-0(194 mm H/D, 220 mm)
5. Bearing
Apply a generous amount of grease to the bearing inner race.
g(oz)
Approx. 30 (1)
6. Axle Shaft Assembly
7. Bearing Nut and Lock Washer
(1) Insert four through-bolts into the back plate.
(2) Install bearing holder to the back plate.
(3) Install the above parts onto the axle shaft.
(4) Install bearing over axle shaft and press it into bearing
holder.
Axle shaft bearing Installer : 9-8522-1271-0 (J-8609-01)

4B-14 REAR AXLE
(5) Install the bearing nut into position by using a vise and the
special tool.
Installer : 5-8840-2003-0
(J-24246)
Torque N
m (kgfm/lbft)
260
5 (26.5 0.5/192 3.6)
(6) Position the chisel perpendicular to the center of the lock
nut groove.
Stake the lock nut.
8. Oil Seal ; Axle Case
Oil seal installer : 9-8522-1272-0 (J-24254)
(1) Apply measured amount of good quality grease to the inner
face of the rear axle case.
g(oz)
Type of greaseW heel bearing grease or
Multipurpose type grease
Amount of grease required 80 (2.8)
9. Shim
Install the axle shaft assembly to the axle case with a 2 mm
(0.08 in) thick shim fit into position between the bearing holder
and axle case flange. Install and tighten the bolts evenly in
progression.
Torque N
m (kgm/lbft)
74
5 (7.5 0.5/54 3.6)

REAR AXLE 4B-15
Install the axle shaft assembly on the opposite side and push it
in until it fits against the differential thrust block. Then,
measure the clearance (t) between the bearing holder and the
axle case flange and determine the thickness of the shim to be
installed by the following formula :
Measured clearance (t) + 0.3 mm (0.012 in) = thickness of
shim to be installed.
mm(in)
thickness of shims available
1.0, 0.5, 0.13, 0.076, 0.05
(0.036, 0.026, 0.005, 0.003, 0.002)
10.Bolt and Nut
Torque N
m (kgfm/lbft)
74
5 (7.5 0.5 / 54 3.6)
Connect the brake lines to wheel cylinder.
Connect the parking brake rear cable.
Brake air bleeding, refer to servicing to Section 5 brake.
Note :
To install the axle shaft assembly, follow the reassembly
procedure outline under the "BRAKE".
12.Wheel and Tire
Tighten the wheel nut in numerical order.
Torque N
m (kgfm/lbft)
117.7
9.8 (12 1/86.8 7.2)

4B-16 REAR AXLE
DIFFERENTIAL
REMOVAL AND INSTALLATION
Removal Steps
1. Propeller shaft
2. Axle shaft
3. Differential assembly
Installation Steps
3. Differential assembly
2. Axle shaft
1. Propeller shaft
To remove the axle shaft assembly,
follow the disassembly procedure outline
in this Section “Axle shaft”
Important Operation - Removal
2. Axle Shaft
Disengage the axle shafts from the carrier assembly and
partially withdraw the shafts from the axle tube.
It is not necessary to completely remove the axle shafts.
Move them only enough to allow the differential to be removed.
To remove the axle shaft assembly, follow the disassembly
procedure outline in this Section "Axle shaft".

REAR AXLE 4B-17
Important Operations - Installation
3. Differential Assembly
(194 mm)
Torque N
m (kgfm/lbft)
NUT 37.3
3.9 (3.8 0.4/27 2.9)
BOLT 24.5 5 (2.5 0.5/18 3.6)
(220 mm)
Torque N
m (kgfm/lbft)
NUT 44
14.7 (4.5 1.5/32.5 10.8)
BOLT 63.8 5 (6.5 0.5/47 3.6)
Apply the recommended liquid gasket or its equivalent to the
sealing side of the axle case and the carrier.
To install the axle shaft assembly, follow
the reassembly procedure outline in the
“Rear axle shaft” section.
2. Axle Shaft
Torque N
m (kgfm/lbft)
73.6
5 (7.5 0.5/54.2 3.6)
1. Propeller Shaft
Torque N
m (kgfm/lbft)
194 mm 35.3
2.9 (3.6 0.3/26 2.2)
220 mm 62.8 3.9 (6.4 0.4/46.3 2.9)

4B-18 REAR AXLE
DISASSEMBLY
MAJOR COMPONENTS
Disassembly Steps
1. Side bearing cap
2. Side bearing outer race
3. Differential cage assembly and ring gear
4. Side bearing
5. Backlash and side bearing preload
adjusting shim
6. Flange nut and washer
7. Flange assembly
8. Drive pinion shaft assembly
9. Inner bearing
10. Pinion depth adjusting shim
11. Drive pinion shaft
12. Collapsible spacer
13. Oil seal
14. Outer bearing
15. Inner bearing outer race
16. Outer bearing outer race

REAR AXLE 4B-19
Important Operations
Before disassembling, make a pattern check using the method
described later in this section under "Gear Tooth Contact
Pattern Check and Adjustments". This check will help
determine what service should be performaed on the
differential components.
On some bench operations, it may be advantageous to use a
holding fixture and a holding fixture base.
Tool 5-8840-0275-0 (J-37264) and 5-8840-0003-0 (J-3289-20)
are available tools that work well for this purpose.
1. Bearing Cap
Apply an alignment mark to the side bearing cap and
differential carrier.
2. Side Bearing Outer Race
After removal, keep the right and left side bearing assemblies
separate to maintain inner and outer race combinations.
4. Side Bearing
5. Backlash and Side Bearing Preload Adjusting Shim
Remover : 5-8840-0013-0 (J-22888)
Adapter : 9-8521-1743-0 (J-8107-2) (194 mm)
5-8840-2196-0 (J-8107-4) (220 mm)
Carefully record the thickness of each side bearing and each
shim pack. Keep them separated and in order for later
reassembly.
6. Flange nut and washer (194 mm)
Holder : 5-8840-0133-0
(J-8614-01)

4B-20 REAR AXLE
Flange Nut and Washer (220 mm)
Holder : 5-8840-2157-0
(J-37221)
8. Drive Pinion Shaft Assembly
Hold a soft metal rod against the end of the drive pinion. Drive
out the pinion from the carrier by tapping the hammer against
the metal rod.
Installer : 9-8521-5032-0
9. Inner Bearing
Remove the pinion bearing using a separator and a press.
Separator : 5-8840-0015-0 (194 mm)
(J-22912-01)
: 5-8840-2197-0 (220 mm)
(J-37452)
Inner bearing outer
race15.Inner Bearing Outer Race
16.Outer Bearing Outer Race
Remove the inner bearing outer race and the outer bearing
outer race by using a brass bar and a hammer.
Other bearing outer
race