Page 497 of 6000

4A2A–30
DIFFERENTIAL (REAR 220mm)
3. After measuring dimensions of each of the above
sections, proceed with the adjustment in the following
manner:
Adjust the clearance to satisfy the equation below.
{(F – B) + G – H}=0.05 – 0.20 mm
Also, select the thrust washers so that the
dimensional difference between the back surfaces of
the left and right pressure rings to the thrust washers
is 0.05mm or less.
Thickness : 1.5mm (0.059 in)
1.6 mm(0.063 in)
1.7 mm(0.067 in)
NOTE: When assembling the parts, apply recommended
gear oil sufficiently to each of the parts, especially, to the
contact surfaces and sliding surfaces.
1. Install Differential cage B.
2. Install Thrust washer.
3. Install Spring disc.
When assembling the spring disc, make sure the
mounting direction is correct as shown in figure.
425RS068
Legend
(1) Friction Plate
(2) Spring Disc
(3) Friction Disc
4. Inatall Spring disc.
5. Inatall Friction plate.
6. Inatall Friction disc.
7. Inatall Friction plate.
8. Inatall Friction disc.
9. Inatall Pressure ring.
10. Inatall Side gear.
11. Inatall Pinion and pinion shaft.
12. Inatall Side gear.
13. Inatall Pressure ring.
14. Inatall Friction disc.15. Inatall Friction plate.
16. Inatall Friction disc.
17. Inatall Friction plate.
18. Inatall Spring disc.
When assembling the spring disc, make sure the
mounting direction is correct.
19. Inatall Spring disc.
20. Inatall Thrust washer.
21. Inatall Differential cage A.
22. Inatall Screw.
Matching the guide marks of the differential cages A
and B, tighten the screws evenly in the diagonal
order.
425RS055
Page 498 of 6000
DIFFERENTIAL (REAR 220mm)
4A2A–31
23. Check the operation.
Measure the starting torque using the side gear
holder.
Starting torque:
64–98Nꞏm(6.5–7.3kgꞏm/47–72Ibft)
425RW065
Legend
(1) Side Gear Holder : 5–8840–2381–0
Page 499 of 6000
4A2A–32
DIFFERENTIAL (REAR 220mm)
Main Data and Specifications
General Specifications
Rear axle
Ty p eBanjo, Semi–floating
Rear axle Size220mm(8.66in)
Gear typeHypoid
Gear ratio (to 1)4.555(6VD1,4JG2–TC)
4.777(4JG2)
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)
Capacity1.8liter(1.6 Imp qt/1.9 US qt)
Page 500 of 6000
DIFFERENTIAL (REAR 220mm)
4A2A–33
Torque Specifications
E04RW016
Page 501 of 6000
4A2A–34
DIFFERENTIAL (REAR 220mm)
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2157–0
(J–37221)
Holder; Pinion flange
5–8840–2294–0
(J–24250)
Installer; Oil seal
5–8840–0275–0
(J–37264)
Differential holding
fixture
(Use with
5–8840–0003–0)
5–8840–0003–0
(J–3289–20)
Holding fixture base
5–8840–0013–0
5–8840–0014–0
(J–22888)
Puller; Side bearing
5–8840–2196–0
(J–8107–2)
Adapter; Side bearing
plug
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2197–0
(J–22912–01)
Separator
5–8840–2164–0
(J–24256)
Installer; Outer bearing
outer race
5–8840–0007–0
(J–8092)
Driver handle
5–8840–2163–0
(J–24252)
Installer; Inner bearing
outer race
5–8840–2085–0
(J–21777–42)
Front Pilot
5–8840–0127–0
(J–23597–9)
Nut and bolt
Page 502 of 6000
DIFFERENTIAL (REAR 220mm)
4A2A–35
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2166–0
(J–23597–7)
Gauge plate
5–8840–0126–0
(J–8001)
Dial indicator
5–8840–2167–0
(J–23597–8)
Disc
5–8840–0128–0
(J–23597–1)
Arbor
9–8522–1165–0
(J–6133–01)
Installer; Pinion bearing
5–8840–2293–0
(J–39209)
Punch; End nut lock
ILLUSTRATIONTOOL NO.
TOOL NAME
5–8840–2162–0
(J–24244)
Installer; Side bearing
5–8840–2323–0
(J–39602)
Remover; Outer bearing
5–8840–2165–0
(J–37263)
Installer; Pinion oil seal
5–8840–2381–0
(J–41033)
Holder; Side gear
5–8840–0129–0
(J–23597–12)
Rear pilot
Page 503 of 6000
4A2A–36
DIFFERENTIAL (REAR 220mm)
MEMO
Page 504 of 6000

DIFFERENTIAL (REAR 244mm)
4A2B–1
DRIVELINE/AXLE
DIFFERENTIAL (REAR 244mm)
CONTENTS
Service Precaution 4A2B–1. . . . . . . . . . . . . . . . . . . . . .
General Description 4A2B–2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A2B–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing 4A2B–4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts 4A2B–4. . . . . .
Removal 4A2B–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Seal Replacement 4A2B–5. . . . . . . . . . . . . . . . . .
Installation 4A2B–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal 4A2B–6. . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts 4A2B–6. . . . .
Removal 4A2B–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–7. . . . . . . . . . . . . . . . . .
Installation 4A2B–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A2B–8. . . . . . . . . . . . . . . . . . . .
Differential Assembly and Associated Parts 4A2B–8
Removal 4A2B–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A2B–9. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View 4A2B–10. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–11. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A2B–13. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A2B–20. . . . . . . . . . . . . . .
Disassembled View 4A2B–20. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–21. . . . . . . . . . . . . . . . . .
Reassembly 4A2B–21. . . . . . . . . . . . . . . . . . . . . . . . . .
Locking Differential Assembly 4A2B–23. . . . . . . . . . . . .
Disassembled View 4A2B–23. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2B–23. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2B–25. . . . . . . . . . . . . . . . . .
Reassembly 4A2B–25. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A2B–27. . . . . . . . . . . . .
Special Tools 4A2B–29. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: IF SO EQUIPPED WITH A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE REFORMING SERVICE ON
OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally,such coatings
adversely affect the fastener torque and the joint
c l a m p i n g f o r c e , a n d m a y d a m a g e t h e f a s t e n e r. W h e n
you install fasteners, use the correct tightening
sequence and specification. Following these
instructions can help you avoid damage to parts and
systems.