1998 ISUZU TROOPER Rear axle

DIFFERENTIAL (REAR 244mm)
4A2B±9
Installation
1. Clean the contact surfaces of the axle and differential
carrier. As shown in the drawing, apply Three Bond
TB1215 or equivalent then install differential
assembly.
425RS006
2. Install bolt and nut. Tighten the differential carrier
mounting bolts and nuts to the specified torque.
Torque:Nuts 44N´m (4.5kg´m/33 lb ft)
Bolts 64N´m (6.5kg´m/47 lb ft)
3. Install axle shaft assembly. Be sure not to damage
the oil seal by axle shaft.
4. Install nut, refer to Axle Shaft in this section.
5. Install parking brake cable, refer to Parking Brakes in
Brake section.
NOTE: After completing the assembling work, fill the
prescribed gear oil to the filler hole.
Lubricant capacity: 3.0 liter (2.6 Imp qt/3.2
US qt)
6. Tighten the oil filler plug to the specified torque.
Torque: 78N´m (8.0kg´m/58 lb ft)

DIFFERENTIAL (REAR 244mm)
4A2B±23
Locking Differential Assembly
Disassembled View
425RW027
Legend
(1) Thrust Washer±Differential Pinion Mate Gear
(2) Pinion Mate Gear
(3) Dished Spacer
(4) Disc
(5) Plate
(6) Ring Gear(7) Differential Plate Retainer
(8) Lock Pin
(9) Differential Case
(10) Ring Gear Bolts
(11) Differential Shaft
(12) Differential Side Gear
Disassembly
1. Remove ring gear.
2. Place one of the axle shafts, which was removed from
the assembly, into a vise. Tighten shaft in vise firmly.
The spline end of the shaft is not to exceed 3 inches
(76.2 mm) above the top of the vise.
Position the differential on the shaft with the ring gear
side down.
3. Remove Lock pin (1) from differential shaft using a
punch.

DIFFERENTIAL (REAR 244mm)
4A2B±25
11. Remove top side gear and clutch pack.
NOTE:

Keep the stack of plates and discs intact and in
exactly the same position while they are being
removed.
12. Remove case from holder. Turn case with flange or
ring gear side up to allow side gear and clutch pack to
be removed from case.
13. Remove differential plate retainer from both clutch
packs to allow separation of the plates and discs.
NOTE:

Keep the discs and plates in the same order as they
were removed.
425RW009
Legend
(1) Differential Plate
(2) Differential Disc
(3) Dished Spacer
(4) Side Gear
Inspection and Repair
Cleaning

All parts with solvent.
Visual Inspection

Clean all parts with solvent.

Plates and Discs. If any one disc or plate in either
stack shows evidence of excessive wear or scoring,
the complete stack is to be replaced on both sides.

Side Gears and Pinion Mate Gears. The gear teeth of
these parts should be checked for extreme wear and
possible cracks. The external teeth of the side gear,
which retain the concentric groove discs, should also
be checked for wear or cracks.

If replacement of one gear is required due to wear,
etc., then both side gears, pinion mate gears, and
thrust washers are to be replaced.
Differential Shaft. If excessive wear is evident, the
differential shaft should be replaced.

Differential Plate Retainers. If wear is evident on any
one of the differential plate retainers, all four retainers
must be replaced.

Differential Case. If scoring, wear or metal pickup is
evident on the machined surfaces, replacement of
the case is necessary.
Reassembly
1. Lubricate thrust face of side gears, plates and discs
with the proper limited slip rear axle lubricant.
2. Assemble plates and discs in exactly in the same
position as they were removed, regardless of whether
they are new or original.
3. Install differential plate retainer to ears of plates.
NOTE:

Make sure both retainers are completely seated on
ears of plates.
4. Install clutch pack and side gear into bottom side gear
bore. Make sure clutch pack stays assembled to side
gear splines, and that retainers are completely seated
into pockets of case.
NOTE:

To prevent clutch pack from falling out of case, hold
clutch pack in place by hand while repositioning case
on bench.
5. Install other side gear and clutch pack. Make sure
clutch pack stays assembled to side gear splines, and
retainers are completely seated into pockets of case.
6. Hold clutch pack in position and assemble special tool
5±8840±2586±0, screw cap (2), cap (1) and forcing
screw (3). Tighten forcing screw into bottom cap to
hold both clutch packs in position.
7. With tools assembled to case, position case on shaft
by aligning splines of side gear with those of shaft.
Tighten forcing screw to compress clutch packs in
order to provide clearance for pinion mate gears.
425RW064

DIFFERENTIAL (REAR 244mm)
4A2B±27
Main Data and Specifications
General Specifications
Rear axle
TypeBanjo, Semi±floating
Rear axle Size244 mm (9.61 in)
Gear typeHypoid
Gear ratio (to 1)4.100(6VE1 with A/T)
4.300(6VE1 with M/T,4JX1)
Differential typeTwo pinion
Lubricant GradeGL±5: (Standard differential)
GL±5, LSD: (Limited slip differential)
Locking Differential Lubricant80W90 GL±5
(USE Limited Slip Differential Gear Lubricant or Friction
Modifier Organic Additive)
Capacity3.0 liter (2.6 Imp qt/3.2 US qt)

DIFFERENTIAL (REAR 244mm)
4A2B±29
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±2294±0
(J±39210)
Installer; Axle shaft inner
seal
5±8840±0133±0
(J±8614±01)
Pinion flange holder
5±8840±2165±0
(J±37263)
Installer; Pinion oil seal
5±8840±2029±0
(J±42832)
Holding fixture
5±8840±0003±0
(J±3289±20)
Holding fixture base
5±8840±2587±0
(J±42379)
Remover; Bearing
ILLUSTRATIONTOOL NO.
TOOL NAME
5±8840±2576±0
(J±8107±3)
Adapter; Side bearing
plug
5±8840±0008±0
(J±8611±01)
Installer; Outer bearing
outer race
5±8840±0007±0
(J±8092)
Grip
5±8840±2571±0
(J±42831)
Installer; Inner bearing
outer race
5±8840±2575±0
(J±42824)
Pilot;Outer
5±8840±0127±0
(J±21777±43)
Nut & Stud

4B1±8
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Normal Operation
The motor actuator mounted on transfer rear case is
driven by signal from 4WD switch on instrument panel.
After complete the connecting transfer front output gear
to, or disconnecting it from, front propeller shaft, conditionof the transfer position switch changes. The vacuum
solenoid valve (VSV) is driven by the signal from transfer
position switch and the vacuum actuator connects front
wheels to, or disconnect them from, front axles.
Time Chart of Shifting Under Normal Condition
F04RW002

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±24
No.NAMECONTENTS
1VIGPower supply (IG)
2N.CNot used
34WD OUT4WD signal output
4SOL (+)Electromagnetic solenoid
5ADC (+)Axle disconnect output
6LIGHTING SWLighting SW input
7BRAKEBrake SW input
84H SW4H SW input
94L SW4L SW input
10AXEL SWAXEL SW input
11ABS INOperation signal input
12TOD SWTOD SW input
13DIAGSelf-diagnosis input
14D-G MAPD-G MAP recognition input (Only V6 engine)
15Ref.Vehicle speed sensor supply
16N.CNot used
17US/JAPDestination recognition input
18COM (±)Vehicle speed sensor GND
19S-GNDSensor GND
20P-GNDPower GND
21TPSThrottle position sensor
22TECH 2TECH 2 output
23Rer. SigRear vehicle speed sensor input
24Frt. SigFront vehicle speed sensor input
25IND.a4WD disply signal a
26IND.b4WD display signal b
27IND.c4WD display signal c
28IND.AUTOAUTO display output
29IND RrRear display output
30CHECKTOD warning lamp

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±30
Diagnostic Trouble Codes
CodeItemDiagnosisCheck flow No.
12Start codeNormalÐ
13RefShorted GND6
14Front speed sensorInput abnormality (open, sig or com)2
15RefShorted VB6
16Front speed sensorInput abnormality3
21TPSShorted or disconnected wiring, abnormality in
input7
23ECUCPU abnormality1
24Rear speed sensorInput abnormality (open, sig or com)5
25CHECK lampShorted14
26EMC (+)Shorted GND10
27Rear speed sensorInput abnormality4
28ADC (+) & AXLE SWOutput abnormality11
31EMC (+)Shorted or disconnected coil/wiring9
32ADC (+)Shorted or disconnected coil/wiring12
33ADC (+)Shorted GND13
34D-G MAPInput abnormality8
35CHECK lampShorted or disconnected wiring14
36ECUCPU abnormality1
37ECUCPU abnormality1
38ECUCPU abnormality1
TPS : Throttle Position Sensor
EMC : Electromagnetic coil
ADC : Shift on the fly (Axle Dis Connect)
D-G MAP : Discrimination engine type