2004 ISUZU TF SERIES differential

4B-18 REAR AXLE

17.
Install brake pipe and ABS sensor and tighten it to
the specified torque.

Torque :

ABS Sensor
8 N
m (0.8 kg
m/69 lb
ft)

Brake Pipe
16 N
m (1.6 kg
m/12 lb
ft)
420R30003

18.
Bleed brake pipe at the wheel cylinder. (Refer to
the section “Power-assisted Brake System”)
19.
Install brake drum.


Install propeller shaft. (Refer to Section “Rear
Propeller Shaft”.)


Refill differential oil.


Install wheel and tire.


Lower vehicle.

REAR AXLE 4B-19

Differential Assembly
Disassemble View
Legend


1.
Bolt

2.
Bearing Cap

3.
Differential Cage Assembly

4.
Side Bearing Outer Race

5.
Side Bearing

6.
Adjust Shim

7.
Flange Nut

8.
Flange Assembly

9.
Drive Pinion Shaft Assembly
415RY 00005


10.
Collapsible Spacer

11.
Inner Bearing

12.
Adjust Shim

13.
Oil Seal

14.
Outer Bearing

15.
Inner Bearing Outer Race

16.
Outer Bearing Outer Race

17.
Differential Carrier

4B-20 REAR AXLE

Disassembly
1.
Using holding fixture 5-8840-0275-0 and holding
fixture base 5-8840-0003-0, fix the differential
assembly to the bench.
425L100007

2.
Apply a setting mark to the side bearing cap and
the differential carrier then remove bearing cap.



425RS009

3.
Remove differential cage assembly.
4.
Remove side bearing outer race. After removal,
keep the right and left hand side bearing
assemblies separate to maintain inner and outer
race combinations.
5.
Remove side bearing by using remover 5-8840-
0013-0, 5-8840-0014-0 and adapter 5-8840-2196-
0.

415L100001

6.
Note the thickness and position of the shims then
remove adjust shim.
7.
Remove the flange nut by using pinion flange
holder 5-8840-0133-0 after raising up its staked
parts completely.
415RW040

REAR AXLE 4B-27

Note :





Do not overtighten or loosen and then
retighten the nut.





Pinion nut torque will be in the range of 245-
294 N
 m (25-30 kg
 m/181-217 lb
 ft).
425RW018
d. Using punch 5-8840-2293-0, stake the flange
nut at two points.
Note :
When staking, be sure to turn the nut to ensure
that there is no change in bearing preload. Make
sure NOTE: of preload again as instructed in c.

RTW34BSH000201

11. Adjust ring gear backlash.
a.
Attach the side bearing to the differential
assembly without shims by using installer 5-
8840-2162-0 and grip 5-8840-0007-0.

425L100010
b. Insert the differential cage assembly with
bearing outer races into the side bearing bores
of the carrier.

REAR AXLE 4B-29

12. Install the side bearings together with the selected
shims by using installer 5-8840-2162-0, drive
handle 5-8840-0007-0.

425L100010
13. Install side bearing outer race.
14. Install differential cage assembly.
15. Align the setting marks (1) applied at disassembly
then install the bearing cap.




425RS035



16. Tighten the bolt to the specified torque.
Torque :
108 N
m (11 kg
m/80 lb
ft)

4B-32 REAR AXLE

Differential Cage Assembly
Disassembled View

425R300005
Legend

1. Bolt
2. Ring Gear
3. Lock Pin
4. Cross Pin
5. Pinion Gear
6. Side Gear
7. Thrust Washer (for Side Gear)
8. Differential Cage

REAR AXLE 4B-33

Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Drive out lock pin using a long drift Punch.
425RS042

4. Check the amount of backlash between pinion
gear on side gear before removal of cross pin.
Backlash :
0.13-0.18 mm (0.005–0.007 in)
5. Remove the cross pin by using a brass drift
punch and hammer.





425RS043

6. Take out pinion gear, side gear and thrust
washer.
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
conditions are found through inspection.
Check the following parts:


Ring gear, pinion gear


Bearing


Side gear, pinion gear, cross pin


Differential cage, carrier


Thrust washer


Oil seal
Clearance between pinion gear and cross pin:
mm(in)

Standard Limit
0.06 - 0.12
(0.002 - 0.005) 0.2 (0.008)

425L100012

Clearance between side gear and differential cage.
mm(in)

Standard Limit
0.05 - 0.11
(0.002 - 0.004) 0.15 (0.006)

4B-34 REAR AXLE

425R300010

Play in splines between the side gear and axle shafts.
mm(in)

Standard Limit
0.08 - 0.38
(0.003 - 0.015) 0.5 (0.02)

425L100014
Differential cage
Check the ring gear the side gear fitting faces and the
cross pin hole for scores or roughness. Correct as
necessary. Slight scores or roughness may be
corrected with an oil stone or fine sand paper.
425R300006

Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard use bolts and install new ones.
3.
Apply LOCTITE 271 on bolt from the end of thread
to the middle of straight portion.
4. Tighten the fixing bolts in a diagonal sequence as
illustrated.
Torque : 108 Nm (11 kgm/80 lbft)



425RW033