1997 ISUZU TFS SERIES back gear

4B-48 REAR AXLE
(3) Pinion bearing preload.
(a) Measure the bearing preload by using a torque wrench.
Note the scale reading required to rotate the flange.
(b) Continue tightening until the specified starting torque is
obtained.
Pinion Bearing Preload Starting Torque N
m (kgfm/lbft)
194 mm 64 - 113 (6.5 - 11.5/47 - 72)
220 mm 69 - 127 (7 - 13/51 - 94)
11.Backlash and Pre-load Adjusting Shim
(1) Attach the side bearing to the differential assembly without
shims. Support the opposite side using a pilot to prevent
bearing damage.
1Installer : 9-8522-1164-0 (194 mm)
(J-24244)
: 5-8840-2162-0 (220 mm)
(J-37257)
2Drive handle : 5-8840-0007-0
(J-8092)
3Pilot : 9-8521-1743-0
(J-8107-2)
(2) Position the differential cage assembly with the bearing
outer races to 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 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.
Dial indicator : 5-8840-0126-0
(J-8001)

REAR AXLE 4B-49
(4) Adjust the feeler gauge thickness from side to side until the
ring gear backlash is in the specified range.
Backlash mm(in)
194 mm 0.13 - 0.18 (0.005 - 0.007)
220 mm 0.15 - 0.20 (0.006 - 0.008)
With zero end play and correct backlash established, remove
feeler gauge packs, determine the thickness of 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)
Adapter : 9-8521-1743-0 (194 mm)
(J-8107-2)
: 5-8840-2196-0 (220 mm)
(J-8107-4)
12.Side Bearing
Install side bearings together with selected shims.
1Installer : 9-8522-1164-0 (194 mm)
(J-24244)
: 5-8840-2162-0 (220 mm)
(J-37257)
2Drive handle : 5-8840-0007-0 (J-8092)
3Pilot : 9-8521-1743-0 (J-8107-2)
15.Bearing Cap
Align the setting marks applied at the time of disassembly.

REAR AXLE 4B-53
1. ABNORMAL REAR AXLE NOISE
1) Noise when the Engine is Driving the Vehicle
Checkpoint Trouble Cause Countermeasure
Replenish the gear oilInsufficient gear oil NG
Differential side bearingAdjust the differential side
bearing preload
Replace the drive pinion
bearings
Adjust the drive pinion bearing
preload
Replace the gear oil
Loose differential side
bearings
W orn drive pinion bearings
Loose drive pinion bearings
W rong or poor grade gear oil
Drive pinion to ring gear
backlash
Drive pinion end play
Adjust the backlashToo much or too little backlash
Continued on the next pageOK OK
NG NG NG NG NG
OK
OK
Rear axle gear oil
Replace the differential side
bearingsW orn differential side bearings NG

4B-54 REAR AXLE
Checkpoint Trouble Cause Countermeasure
Replace the drive pinion and
the ring gear as a setExcessive ring gear run-out
Replace the drive pinion and
the ring gear as a setDrive pinion and/or ring gear
damage
NG NGDrive pinion and ring gear Continued from the previous page
Replace the drive pinion and
the ring gear as a setW orn drive pinion and ring
gear NG
2) Noise when the Vehicle is Coasting
Checkpoint Trouble Cause Countermeasure
Replace the ring gear and the
pinion as a setRing gear damaged
Adjust the backlashInsufficient backlash
OK
Ring gearNG NG
Drive pinion and ring gear
backlash

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.

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)

4C1-84 FRONT WHEEL DRIVE
4. NOISES IN FRONT AXLE
Checkpoint Trouble Cause Countermeasure
Replenish the gear oilInsufficient gear oil NG
Replace the wheel bearing
Replace the pinion shaft
bearing
Replace the ring gear pinion
gear or side gear
Replace the gear oil
W heel bearingWorn
Pinion shaft bearingWorn
W orn or chipped
W rong or poor grade gear oil
Ring gear, pinion gear or side
gear
Adjust the backlashDrive pinion to ring gear
backlashToo much or too little backlash
NG NG NG NG NG
OK OK
OK
OK
Oil level
Tighten or replaceDifferential bearingLoose or worn NG OK