1997 ISUZU TFS SERIES torque

REAR AXLE 4B-41
8. Ring Gear
Discard used bolts and install new ones.
When installing the ring gear, apply the LOCTITE 271 or
equivalent to the threaded holes and bolts after applying.
Ring Gear Bolt Torque N
m (kgfm/lbft)
107.9
9.8 (11 1/79.5 7.2)

REAR AXLE 4B-43
Important Operations
1. Outer Bearing Outer Race
Installer : 9-8522-1141-0 (194 mm)
(J-24256)
5-8840-2164-0 (220 mm)
(J-8092)
Grip : 5-8840-0007-0
(J-8092)
2. Inner Bearing Outer Race
Installer : 9-8522-1274-0 (194 mm)
(J-24252)
5-8840-2163-0 (220 mm)
(J-37261)
Grip : 5-8840-0007-0
(J-8092)
3. Pinion Depth Adjusting ; Shim
Adjustment of drive pinion mounting distance.
(1) Apply gear oil to the drive pinion bearing, inner and outer.
Clean all of the pinion setting gage sets.
Then install the gage set together with the inner and outer
bearings.
For 194 mm
1Pilot : 5-8840-2085-0 (J-21777-42)
2Stud and nut : 5-8840-2089-0 (J-23597-9)
4Gage plate : 5-8840-2087-0 (J-23597-7)
For 220 mm
1Front pilot : 5-8840-2085-0 (J-21777-42)
2Stud and nut : 5-8840-0127-0 (J-21777-43)
3Rear pilot : 5-8840-0129-0 (J-23597-12)
4Gage plate : 5-8840-2166-0 (J-23597-42)
Tighten the nut to the specified torque.
194 mm and 220 mm kg
cm(lb.in)
23 (20)

4B-44 REAR AXLE
(2) Clean the side bearing bores. Install a dial indicator with
discs and arbor. Then install and tighten the bearing caps
to the specified torque.
Torque N
m (kgfm/lbft)
194 mm 98.1
9.8 (10 1/72 7.2)
220 mm 107.9 9.8 (11 1/79.6 7.2)
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)
For 220 mm
1Dial indicator : 5-8840-0126-0 (J-8001)
2Disc (2 pcs.) : 5-8840-2167-0 (J-21777-86)
3Arbor : 5-8840-0128-0 (J-23597-1)
4Gage plate : 5-8840-2166-0 (J-23597-42)
(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.

REAR AXLE 4B-47
4. Inner Bearing
Place the shim on the drive pinion with the chamfered side
turned toward the pinion head, then attach the inner bearing to
the pinion using an installer and a press.
Installer : 9-8522-1165-0
(J-6133-01)
NOTE :
Do not press on the roller cage.
Press only on the inner race.
5. Collapsible Spacer
Discard the used collapsible spacer and install a new one.
8. Oil Seal
Use the oil seal installer to install a new oil seal that has been
soaked in rear axle lubricant.
Installer : 9-8522-1275-0 (194 mm)
(J-24250)
: 5-8840-2165-0 (220 mm)
(J-37263)
10.Flange Nut and Washer
(1) Apply lubricant to pinion threads.
(2) Tighten the nut to the specified torque using the pinion
flange holder.
Pinion flange holder : 5-8840-0133-0 (194 mm)
(J-8614-01)
5-8840-2157-0 (220 mm)
(J-37221)
Flange Nut Torque N
m (kgfm/lbft)
194 mm 176.6 - 274.7 (18 - 28/130 - 202)
220 mm 245.3 - 294.3 (25 - 30/181 - 217)
Discard used flange nuts and install new ones.

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)

4B-50 REAR AXLE
16.Bolt
Cap Bolt Torque N
m (kgfm/lbft)
194 mm 98.1
9.8 (10 1/72 7.2)
220 mm 107.9 9.8 (11 1/79.5 7.2)
Measure the amount of run-out of the ring gear at its rear face.
Run-Out mm(in)
Standard Limit
194 mm
220 mm0.02 (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
7 - 8 teeth of the ring gear. Check the impression of contact
obtained on the ring gear teeth and make necessary
adjustment as described below if the contact is abnormal.

REAR AXLE 4B-51
17.Differential Assembly
(1) Clean the faces of the rear axle case and differential carrier
and apply the recommended liquid gasket or its equivalent.
(2) Mount the differential case and the carrier assembly to the
rear axle case and tighten the nuts and bolts.
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)
Nut 44 14.7 (4.5 1.5/32.5 10.8)
Bolt 68.5 5 (6.5 0.5/47 3.6)220 mm 194 mm
(3) Install the axle shaft assemblies as instructed earlier in this
section under "Axle Shaft Reassembly".
(4) Fill the axle case with hypoid gear lubricant to just below the
filler hole.
Lubricant Capacity liter (US/UK gal.)
194 mm 1.5 (0.4/0.33)
220 mm 1.8 (0.48/0.4)
Check owners manual for correct type and viscosity of gear
lubricant required.

REAR AXLE 4B-59
3. OIL LEAKAGE
1) Differential Carrier Leakage
Checkpoint Trouble Cause Countermeasure
Correct the oil levelToo much gear oil NG
Reapply the liquid gasket
and/or tighten the lock nut to
the specified torque
Reapply the liquid gasket
Tighten the bolts to the
specified torque
Replace the oil seal
Ring gear thrust boltLoose lock nut and/or liquid
Liquid gasket seal bed
Loose bolts
Oil sealW orn or defective oil seal
Differential carrier
Clean the air breatherAir breatherClogged air breather
NG NG NG NG NG
OK OK OK
OK
Gear oil level