1997 ISUZU TFS SERIES torque

4B-60 REAR AXLE
2) Axle Case Leakage
Checkpoint Trouble Cause Countermeasure
Tighten the drain plug and/or
replace the gasket(s)Loose drain plug and/or
defective gasket(s) NG
Reapply the liquid gasket
Tighten the bolts to the
specified torque
Clean the air breather
Liquid gasket seal bad
Loose bolts
Air breatherClogged air breather
Differential carrier
Replace the axle caseAxle caseCracked axle case
NG NG NG NG
OK OK
OK
Oil filler and drain plug

FRONT WHEEL DRIVE 4C1-7
RECOMMENDED LIQUID GASKET
Type Brand Name Manufacture Remarks
RTV*
Silicon BaseThreeBond 1207B
ThreeBond 1207C
ThreeBond 1215Three Bond
Three Bond
Three BondFor Engine Repairs
For Axle Case
Repairs, T/M
Water Base ThreeBond 1141E Three Bond For Engine Repairs
SolventThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402Three bond
Isuzu
Isuzu
IsuzuFor Engine Repairs
AnerobicLOCTITE 515
LOCTITE 518Loctite
LoctiteAll
* RTV : Room Temperature Vulcanizer
Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacture's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying
the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater
than 0.25 mm (0.01 in). Poor adhesion will result.
RECOMMENDED THREAD LOCKING AGENTS
LOCTITE Type LOCTITE Color Application Steps
LOCTITE 242 Blue1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.
LOCTITE 262 Red2. Apply LOCTITE to the bolts.
LOCTITE 270 Green
LOCTITE 271 Red3. Tighten the bolts to the specified torque.
4. Wait at least on hour before continuing the installation procedure.

4C1-14 FRONT WHEEL DRIVE
Important Operations - Installation
5. Front Drive Axle Assembly
Place the front axle assembly in position under the vehicle
using a lifting jack.
3. Nut
Front Axle Mounting Nut Torque N
m (kgfm/lbft)
152.1
14.7 (15.5 1.5/112.1 10.8)
2. Propeller Shaft
Align the setting marks applied the removal.
Bolt Torque N
m (kgfm/lbft)
167 mm 35.3
2.9 (3.6 0.3/26.0 2.2)
194 mm 62.8 3.9 (6.4 0.4/46.3 2.9)

4C1-20 FRONT WHEEL DRIVE
Important Operations
10.Bolt
Bolt Torque N
m (kgfm/lbft)
82.4
7.8 (8.4 0.8/60.8 5.8)
13.Bellows
(1) Apply a thin coat of grease to the shaft for smooth
installation.
(2) Apply specified grease to the ½ space of the bellows.
14.Band
Note the setting direction.
After installation, check that the bellows is free from distortion.
15.Ball Guide
16.Ball Retainer
Install the ball guide with the smaller diameter side ahead onto
the shaft.
17.Snap Ring
Install the snap ring securing the ball retainer to the shaft.

FRONT WHEEL DRIVE 4C1-27
INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspection.
Ring gear, pinion gear
Bearing
Side gear, pinion gear, cross pin
Differential cage, carrier
Thrust washer
Oil seal
Visual Check
Inspect the following parts for wear, damage, or other
abnormal conditions.
Ring Gear Replacement
(1) The ring gear should always be replaced with the drive
pinion as a set.
(2) W hen installing the ring gear, apply LOCTITE 271 or
equivalent to the threaded hole and bolt.
(3) Tighten the fixing bolts in a diagonal sequence as
illustrated.
(4) Discard used bolts and install new ones.
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)
For 167 mm
Note that all bolts have a left hand thread.
Clearance Between the Differential Pinion
and the Cross Pin
mm(in)
Standard Limit
167 mm 0.06 - 0.12 (0.002 - 0.005) 0.2 (0.008)
194 mm 0.05 - 0.10 (0.002 - 0.004) 0.2 (0.008)

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.

FRONT WHEEL DRIVE 4C1-33
Tighten the nut to the specified torque.
N
m (kgfm/lbft)
New bearing 2.26 (23/20)
Used bearing0.98 - 1.18
(10 - 12/8.7 - 10.4)
(2) Clean the side bearing bores. Install the dial indicator with
the discs and Arbor. Install and tighten the bearing caps to
the specified torque.
Torque N
m (kgfm/lbft)
167 mm 68.7
9.8 (7.0 1.0/50.6 7.2)
194 mm 98.1 9.8 (10.0 1.0/72.3 7.2)
For 167 mm
1Dial indicator : 5-8840-0126-0
(J-8001)
2Disc (2 pcs.) : 5-8840-2086-0
(J-23597-4)
3Arbor : 5-8840-0128-0
(J-23597-1)
4Gage plate : 5-8840-2090-0
(J-23597-26)
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)

4C1-36 FRONT WHEEL DRIVE
5. Inner Bearing
Place the shim on the drive pinion, with the chamfered side
turned towards the pinion head then install the inner bearing on
to the pinion using an installer and a press.
Installer : 9-8522-1165-0 (J-6133-01)
Note:
Do not apply pressure to the roller cage.
Apply pressure only to the inner race.
6. Collapsible Spacer
Discard the used collapsible spacer and install a new one.
9. Oil Seal
Use oil seal installer to install a new oil seal that has been
soaked in rear axle lubricant.
Installer : 5-8522-0046-0 (J-26234) (For 167 mm)
9-8522-1275-0 (J-24250) (For 194 mm)
Note :
Take care not to use a rear differential oil seal instead of
the front differential oil seal.
12.Flange Nut and Washer
For 194 mm
(1) Apply lubricant to the pinion threads.
(2) Tighten the nut to the specified torque using the pinion
flange holder.
Pinion flange holder : 5-8840-0133-0
(J-8614-01)
Torque N
m (kgfm/lbft)
176.6 - 274.7 (18 - 28/130 - 202)
Discard used flange nut and install new one.