1997 ISUZU TFS SERIES Workshop Manual

REAR AXLE 4B-29
Check the friction disc for wear.
Limit (A - B) 0.1 (0.0039)
Note : A = Non-sliding face thickness
B = Sliding face thickness
Slide gear and sleeve
Check the parts for damage or other abnormal conditions.
Pinion shaft and pinion gear
Check the parts for damage or other abnormal conditions.

Pressure Ring
Check the parts for damage or other abnormal conditions.
1Sliding part for a pinion
2Sliding part for a disc
3Sliding part for a gear
4V-shape groove for the pinion spider
5Fitting protrusion for a case
6Fitting part for the inner surface of a case
7Sliding part for a side gear or a case

4B-30 REAR AXLE
Friction Disc and Plate Assembly
Check the parts for damage or other abnormal conditions.
1Sliding part
2Protrusion
Check the friction plate for distortion.
Limit mm(in) 0.08 (0.0031)
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) 0.08 (0.0031)
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

REAR AXLE 4B-31
Check the Thrust Washer mm(in)
Limit 1.3 (0.051)

4B-32 REAR AXLE
REASSEMBLY
MINOR COMPONENTS
LIMITED SLIP DIFFERENTIAL (LSD)

Reassembly Steps
1. Friction disc and plate
2. Disc spring
3. Spring plate
4. Sleeve
5. Differential cage
6. Friction disc and plate assembly
7. Side gear8. Friction disc and plate assembly
9. Side gear
10. Pinion gear
11. Pinion washer
12. Thrust block
13. Pinion shaft
14. Spring pin

REAR AXLE 4B-33
Important Operations
1. Friction disc and plate
Measure the thickness of disc and plate pack (A). mm(in)
Thickness (A) 7
0.1 (0.27 0.004)
If the thickness (A) is beyond the limits, adjust with a friction
disc of selected thickness.
Thickness of friction discs available mm(in)
1.4 (0.055), 1.5 (0.059)
Apply molybdenum disuffide grease to the friction discs and
plates.
3. Spring plate
Install the spring plate with dished side turned side turned to
the differential cage side.
10.Pinion gear
11.Pinion washer
(1) Clamp special tool (side gear holder) into a vise. Set the
LSD assembly.
Holder : 5-8840-2010-0
(J-36563)
(2) Set special tools (side pinion expanders and side pinion
rotator) to the LSD.
Expander : 5-8840-2011-0
(J-36564)
Rotator : 5-8840-2012-0
(J-36565)

4B-34 REAR AXLE
(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 proper clearance to install the pinion
gears.
Bar : 5-8840-2013-0
(J-36566)
(4) Attach the pinion gears and washers in the proper order to
the left and right hand side of the differential cage.
(5) W ith a wrench, turn special tool (pinion rotator) to align the
pinion gear and washer holes with the pinion shaft holes on
the differential cage.
Confirmation of operation
Using the side gear holder, measure the starting of the side
gear.
Starting Torque N
m (kgfm/lbft)
Standard 147-225 (15 - 23/108 - 166)
Side gear holder : 5-8840-2010-0
(J-36563)
Side gear rotor : 5-8840-2012-0
(J-36565)

REAR AXLE 4B-35

Reassembly Steps
1. Differential cage
2. Thrust washer
3. Bellve disc
4. Bellve disc
5. Friction plate
6. Friction disc
7. Friction plate
8. Friction disc
9. Pressure ring
10. Side gear
11. Pinion gear and pinion spider
12. Thrust block13. Side gear
14. Pressure ring
15. Friction disc
16. Friction plate
17. Friction disc
18. Friction plate
19. Bellve disc
20. Bellve disc
21. Thrust washer
22. Differential cage cover
23. Bolt

4B-36 REAR AXLE
Adjustment of Clearance between
Friction Disc and Plate
1) Measuring depth of differential case
mm(in)
Standard (A-B) 80.58 (3.17)
(C) 10.58 (0.41)
2) Measuring overall length of pressure ring, friction disc and
plate assembly
Assembly pinion shaft with pressure ring, then friction
disc and plate.
Measure length between plates at both ends over V-
shape groove. (D)
3) After A, B, C and D dimensions are measured, perform
adjustment with the following procedure.
Measure disc spring :
1.75 mm (0.69 in)
2 pcs (E)
Measure thickness of plate spring
Standard dimension :
1.75 mm (0.069 in)
2 pcs (F)
4) Select a friction disc or plate so that ((A-B+C) - (D+E+F) =
0.06 to 0.20 mm (0.002 to 0.008 in.) and also the difference
in total dimension of friction disc and plate, plate spring and
disc spring (left/right side) does not exceed 0.05 mm (0.002
in.).
Thickness : 1.75, 1.85 mm
Adjusting Backlash of Side Gear in Axial
Direction
1) Measuring depth of differential case
mm(in.)
Standard (F-B) 82.03 (3.23)
(G) 12.03 (0.47)