1997 ISUZU TFS SERIES differential

4C1-40 FRONT WHEEL DRIVE
20.Differential Assembly
(1) Clean the faces of the front axle case and differential
carrier.
Apply the recommended liquid gasket or its equivalent to
the sealing side of the axle case and the carrier.
(2) Attach the differential case and the carrier assembly to the
front axle case and tighten the nuts and bolts. The axle
case bolt is used for drainage.
Torque N
m (kgfm/lbft)
25.5
5 (2.6 0.5/18.8 3.6)
(3) Install the axle shaft assemblies as instructed earlier in this
section under “Axle Shaft Replacement”.
(4) Fill the axle case with hypoid gear lubricant, to just below
the filler hole.
Lubricant capacity liter (US/UK gal)
167 mm 1.0 (0.26/0.22)
194 mm 1.4 (0.37/0.31)

4C1-74 FRONT WHEEL DRIVE
FRONT PROPELLER SHAFT
REMOVAL AND INSTALLATION
Since the propeller shaft assembly is carefully
balanced, a setting mark should be applied to
the flange before removal to indicate correct
position.Install the parts by aligning the setting marks
made at removal.
Removal Steps
1. Nut ; differential side
2. Bolt ; transfer side
3. Propeller shaft assembly ; rear side
4. Propeller shaft assembly ; front side
Installation Steps
4. Propeller shaft assembly ; front side
3. Propeller shaft assembly ; rear side
2. Bolt ; transfer side
1. Nut ; differential side
Important Operation - Installation
3. Propeller Shaft Assembly ; Rear Side
Align the indexing marks (about 3 mm dia. punched mark) on
the propeller shaft end and the splined yoke.

FRONT WHEEL DRIVE 4C1-75
2. Bolt ; Transfer Side
Torque N
m (kgfm/lbft)
Bolt size M10 62.8 3.9 (6.4 0.4/46.3 2.9)
1. Bolt ; Differential Side
Torque N
m (kgfm/lbft)
Bolt size M8 35.3 2.9 (3.6 0.3 / 26 2.2)

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

FRONT WHEEL DRIVE 4C1-87
7. AUTOMATIC LOCKING FREE WHEEL HUB
(1) DOES NOT LOCK OR LOCKS ONLY ON ONE SIDE
Note :
1. Stop the vehicle
2. Shift the transfer lever to 4H or 4L
3. Now start driving the vehicle and the
hubs will lock automatically.
4. Once the hubs are locked, they will
remain locked, even if the transfer lever
is shifted from 4L or 4H into 2H, as long
as the vehicle travels in a same
direction.
Checkpoint Trouble Cause Countermeasure
ReplaceStill will not lock NGTry locking procedure once
more
(2) DOES NOT FREEWHEEL OR FREEWHEELS ONLY TO ONE SIDE
Note :
Freewheel operation
1. Stop the vehicle
2. Shift the transfer lever to 2H
3. Back up the vehicle for three or four feet;
this will disengage the front differential.
Checkpoint Trouble Cause Countermeasure
ReplaceStill will not freewheel
Driver the vehicle for five
minutes and then try the
freewheel procedure again
Still will not freewheel NGTry freewheel procedure once
more