1998 ISUZU TROOPER Service Repair Manual

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Page 521 of 3573

ISUZU TROOPER 1998 Service Repair Manual 4A2B±18DIFFERENTIAL (REAR 244mm)
4. Adjust feeler gauge thickness from side to side
until ring gear backlash is in the specified range.
Backlash: 0.13± 0.2mm (0.005± 0.008in)
425RS032With zero end

Page 522 of 3573

ISUZU TROOPER 1998 Service Repair Manual DIFFERENTIAL (REAR 244mm)
4A2B±19
16. Tighten the bolt to the specified torque.
Torque:108N´m (11.0kg´m/80 lb ft)
425RS036
Gear Tooth Contact Pattern Check and Adjustment
1. Apply a thin coat of Pr

Page 523 of 3573

ISUZU TROOPER 1998 Service Repair Manual 4A2B±20DIFFERENTIAL (REAR 244mm)
Differential Cage Assembly
Disassembled View
415RW010
Legend
(1) Thrust Washer (for Pinion Gear)
(2) Pinion Mate Gear
(3) Thrust Washer(for Side Gear)
(4) Side Gear(5

Page 524 of 3573

ISUZU TROOPER 1998 Service Repair Manual DIFFERENTIAL (REAR 244mm)
4A2B±21
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin using a small drift.
425RS042
4. Remove the differential shaft by using a hard metal
rod and a ha

Page 525 of 3573

ISUZU TROOPER 1998 Service Repair Manual 4A2B±22DIFFERENTIAL (REAR 244mm)
2. Install the pinion mate gear with thrust washer by
engaging it with the side gears while turning both
pinion mate gears simultaneously in the same
direction.
425RS

Page 526 of 3573

ISUZU TROOPER 1998 Service Repair Manual 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)

Page 527 of 3573

ISUZU TROOPER 1998 Service Repair Manual 4A2B±24DIFFERENTIAL (REAR 244mm)
4. Remove Differential shaft (2) using hammer and
punch.
Place shop towel behind case to prevent differential
shaft from dropping out of case.
425RW005
5. Assemble cl

Page 528 of 3573

ISUZU TROOPER 1998 Service Repair Manual 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

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

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