1997 ISUZU TFS SERIES Workshop Manual

REAR AXLE 4B-21
MINOR COMPONENTS
DIFFERENTIAL ASSEMBLY
Disassembly Steps
1. Ring gear
2. Lock pin
3. Cross pin
4. Pinion gear
5. Thrust block6. Side gear
7. Thrust washer
8. Differential cage

4B-22 REAR AXLE
Important Operations
1. Ring Gear
Take care not to damage the ring gear or the differential case
when removing the ring gear. Never try to wedge a tool
between the two faces.
2. Lock Pin
Drive out the pinion shaft lock pin with a long drift punch. It
may be necessary to first remove the stakes in the lock pin with
a 5 mm drill.
3. Cross Pin
(1) Check the amount of backlash before removal.
Backlash mm(in)
194 mm 0.03 - 0.08 (0.001 - 0.003)
220 mm 0.13 - 0.18 (0.005-0.007)
(2) Remove the cross pin with a brass drift punch, and take out
the pinion gears, side gears, thrust block and thrust
washers from the differential cage.

REAR AXLE 4B-23
LIMITED SLIP DIFFERENTIAL (LSD)
(FOR RING SIZE 194 mm)
Disassembly Steps
1. Spring pin
2. Pinion spider
3. Thrust block
4. Pinion washer
5. Pinion gear
6. Side gear
7. Friction disc and plate assembly8. Side gear
9. Friction disc and plate assembly
10. Differential cage
11. Sleeve
12. Spring plate
13. Disc spring
14. Disc and plate

4B-24 REAR AXLE
Important Operations
4. Pinion washer
5. Pinion gear
(1) Clamp special tool (side gear holder) into a vice. Set the
LSD assembly.
Holder : 5-8840-2010-0
(J-36563)
(2) Set special tools (side pinion expanders and pinion rotator)
to the LSD.
Expander : 5-8840-2011-0
(J-36564)
Rotor : 5-8840-2012-0
(J-36565)
(3) Set special tool (cage lock bar) through a ring gear fixing
hole to a vice.
Then rotate side pinion expanders with a wrench one half to
one full turn to provide backlash between the side and
pinion gears.
Bar : 5-8840-2013-0
(J-36566)
(4) W ith a wrench, rotate special tool (pinion rotator) to remove
the pinion gear and the pinion washer.

REAR AXLE 4B-25
(FOR RING SIZE 220 mm)
Disassembly Steps
1. Bolt
2. Differential cage cover
3. Thrust washer
4. Bellve disc
5. Bellve disc
6. Friction plate
7. Friction disc
8. Friction plate
9. Friction disc
10. Pressure ring
11. Side gear
12. Thrust block13. Pinion gear and pinion spider
14. Side gear
15. Pressure ring
16. Friction disc
17. Friction plate
18. Friction disc
19. Friction plate
20. Bellve disc
21. Bellve disc
22. Thrust washer
23. Thrust washer

4B-26 REAR AXLE
Important Operations
Prepare a side gear holder (An axle shaft must be used) as
shown in the left figure, clamp it with a stock vice, and set a
differential.
1. Bolt
Apply a setting mark to the differential cage cover and
differential cage a remove the bolt using the press.
W hen the differential cage is pressed down with the press,
loosen the four bolts fixing the differential cage evenly and
remove them, and then disconnect the differential cage.

REAR AXLE 4B-27
INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspection.
Gear
Bearing
Differential box
Drive pinion
Visual Check
Inspect the following parts for wear, damage or other abnormal
conditions.
Clearance between pinion gear and cross pin:
194 mm and 220 mm mm(in)
Standard Limit
0.06 - 0.12
(0.002 - 0.005)0.2 (0.008)
Clearance between side gear and differential cage.
mm(in)
Standard Limit
194 mm0.03 - 0.10
(0.001 - 0.004)0.15 (0.006)
220 mm0.05 - 0.11
(0.002 - 0.004)0.15 (0.006)
Play in splines between the side gear and axle shafts.
mm(in)
Standard Limit
194 mm 0.08 - 0.36 (0.003 - 0.014)
220 mm 0.08 - 0.38 (0.003 - 0.015)0.5 (0.02)

4B-28 REAR AXLE
Differential cage
Check the ring gear the side gear fitting faces and the cross pin
hole for scores or roughness. Correct as necessary. Slight
scores or roughness may be corrected with an oil stone or fine
sand paper.

Friction disc and plate assembly.
Check the parts for damage or other abnormal conditions.
Check the friction plate for distortion.
Limit mm(in) 0.07 (0.0027)
Check the friction plate for wear.
Limit (A - B) mm(in) 0.1 (0.0039)
Note : A = Non-sliding face thickness
B = Sliding face thickness
Check the friction disc for distortion.
Limit mm(in) 0.07 (0.0027)