1997 ISUZU TFS SERIES Workshop Manual

REAR AXLE 4B-61
3) Axle Case to Inside Brake Drum Leakage
Checkpoint Trouble Cause Countermeasure
Replace the oil sealW orn or defective oil seal NGOil seal

4B-62 REAR AXLE
4. POWER NOT BEING TRANSMITTED TO THE WHEELS
(PROPELLER SHAFT OPERATION IS NORMAL)
Checkpoint Trouble Cause Countermeasure
Replace the rear axle shaftBroken rear axle shaft NG
Replace the drive pinion and
the ring gear as a setDrive pinion and ring gearBroken drive pinion and/or ring
gear
Replace the differential gears
and/or the spiderDifferential cage gearsBroken differential cage gears
and/or spider NG NG
OK OK
Rear axle shaft

REAR AXLE 4B-63
SPECIAL SERVICE TOOL
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-1
5-8840-2003-0
(J-24246)Axle shaft bearing nut
remover & installer
RAL-25-8840-2329-0Axle shaft bearing nut
remover & installer
(Heavy-Duty type)
RAL-3
5-8840-0079-0
(J-6627-A) Wheel pin remover
RAL-4
5-8522-1268-0
(J-24259)Axle shaft bearing outer
race installer (for 194mm)
5-8840-2201-0 194mm (H/D), 220mm
OTL-1
5-8840-0007-0
(J-8092) Driver handle
RAL-35
9-8522-1269-0
(J-24255)Bearing holder oil seal
installer (for 194mm)
RAL-115-8840-2202-0Bearing holder oil seal
installer (for 194mm H/D,
220mm)
RAL-6
9-8522-1271-0
(J-8609-01) Axle shaft bearing installer

4B-64 REAR AXLE
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-34
9-8522-1272-0
(J-24254)Axle case oil seal installer
(for 194mm)
RAL-41
5-8840-0275-0
(J-37264) Differential holding fixture
RAL-40
5-8840-0003-0
(J-3289-20) Holding fixture base
RAL-44
5-8840-0013-0
(J-22888) Side bearing puller
RAL-9
9-8521-1743-0
(J-8107-2)Side bearing plug adapter
(for 194mm)
RAL-10
5-8840-2196-0
(J-8107-4)Side bearing plug adapter
(for 220mm)
RAL-50
5-8840-0133-0
(J-8614-01)Pinion flange holder
(for 194mm)
RAL-51
5-8840-2157-0
(J-37211)Pinion flange holder
(for 220mm)
RAL-539-8521-5032-0 Final pinion spindle

REAR AXLE 4B-65
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-56
5-8840-0015-0
(J-22912-01) Separator (for 194mm)
RAL-57
5-8840-2197-0
(J-37452) Separator (for 220mm)
RAL-54
5-8840-2010-0
(J-36563)Side gear holder
(194mm L.S.D only)
RAL-59
5-8840-2011-0
(J-36564)Side gear expander
(194mm L.S.D only)
RAL-55
5-8840-2012-0
(J-36565)Side gear rotor
(194mm L.S.D only)
RAL-70
5-8840-2013-0
(J-36566)Diff. Cage lock bar
(194mm L.S.D only)
RAL-12
9-8522-1141-0
(J-24256)Outer bearing outer race
installer (for 194mm)
RAL-13
5-8840-2164-0
(J-37262)Outer bearing outer race
installer (for 220mm)
RAL-14
9-8522-1274-0
(J-24252)Outer bearing outer race
installer (for 194mm)

4B-66 REAR AXLE
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-15
5-8840-2163-0
(J-37261)Inner bearing outer race
installer (for 220mm)
RAL-60
5-8840-2085-0
(J-21777-42) Pilot (for 194mm, 220mm)
RAL-67
5-8840-2089-0
(J-23597-9) Bolt & nut (for 194mm)
RAL-63
5-8840-2087-0
(J-23597-7) Gauge plate (for 194mm)
RAL-66
5-8840-0127-0
(J-21777-43) Bolt & nut (for 220mm)
RAL-61
5-8840-0129-0
(J-23597-12) Pilot (for 220mm)
RAL-62
5-8840-2166-0
(J-23597-42) Gauge plate (for 220mm)
RAL-68
5-8840-0126-0
(J-8001)Dial gauge set
(for 194mm, 220mm)
RAL-65
5-8840-2088-0
(J-23597-8)Disc (2 pcs. Required)
(for 194mm)

REAR AXLE 4B-67
ITEM NO. ILLUSTRATION PART NO. PART NAME
RAL-69
5-8840-0128-0
(J-23597-1)Arbor
(for 194mm, 220mm)
RAL-64
5-8840-2167-0
(J-21777-86)Disc (2 pcs. Required)
(for 220mm)
RAL-279-8522-1165-0
(J-6133-01)Inner bearing installer
RAL-36
9-8522-1275-0
(J-24250)Pinion oil seal installer
(for 194mm)
RAL-37
5-8840-2165-0
(J-37263)Oil seal installer
(for 220mm)
RAL-29
9-8522-1164-0
(J-24244)Side bearing installer
(for 194mm)
RAL-285-8840-2162-0
(J-37257)Side bearing installer
(for 220mm)

FRONT WHEEL DRIVE 4C1-1
SECTION 4C1
FRONT WHEEL DRIVE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ...................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[ 4C1- 3
Special Parts Fixing Nuts and Bolts ............................................................................. 4C1- 4
Recommended Liquid Gasket ....................................................................................... 4C1- 7
Recommended Thread Locking Agents ....................................................................... 4C1- 7
Servicing<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[..... 4C1- 8
General Description........................................................................................................ 4C1-9
Front Drive Axle Assembly............................................................................................ 4C1-12
Removal and Installation .......................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[ 4C1-12
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-15
Inspection and Repair................................................................................................ 4C1-18
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-19
Differential ....................................................................................................................... 4C1-22
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-22
Major Components ............................................................................................... 4C1-22
Minor Components............................................................................................... 4C1-25
Inspection and Repair................................................................................................ 4C1-27
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-29
Minor Components............................................................................................... 4C1-29
Major Components ............................................................................................... 4C1-31
Front Hub and Disc (4
2 Model) .................................................................................... 4C1-41
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-41
Inspection and Repair................................................................................................ 4C1-44
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-45
Front Hub and Disc (4
4 Model) .................................................................................... 4C1-48
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-48
Inspection and Repair................................................................................................ 4C1-50
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011001100110011001100110011[ 4C1-51
Front Hub and Disc (Automatic Locking Hub) ............................................................. 4C1-54
INDEX