2004 ISUZU TF SERIES lock

PROPELLER SHAFT 4A-25
401RS027
Propeller Shaft Run





out
Support the ends of the propeller shaft on V-blocks (2) and
check for run

out by holding the probe of a dial indicator (1) in
contact with the center part of the shaft. If the amount of run

out is beyond the standard value for assembly, correct with a
bench press or replace the shaft with a new propeller shaf
t
assembly.
Standard: 0.3 mm (0.012 in)
Limit: 0.5 mm (0.02 in)


401RS009
Play in Splines in Normal Direction of Rotation
Check the amount of play between the sleeve yoke (1) and the
propeller shaft spline (2) in the direction of rotation, using a
pointed feeler gauge.
Standard: 0.073




0.156 mm (0.003




0.006 in)
Limit: 0.3 mm (0.012 in)


401RS010
Play in Universal Joint
Limit: Less than 0.1 mm (0.004 in)


401RS011
Reassembly
1. Install spider to flange yoke. Be sure to install the spider by
aligning the setting marks made during disassembly.
2. Apply a molybdenum

disulfide grease or a multi

purpose
type grease NLGI No. 2 to inside of the bearing cap.
Grease Amount: Approx. 1.2 g (0.042 oz)

REAR AXLE 4B-1

SECTION 4B
REAR AXLE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4B- 3
Torque Specifications....................................................................................................................4B- 4
Recommended Liquid Gasket .......................................................................................... 4B- 6
Recommended Thread Locking Agents .......................................................................... 4B- 6
Rear Axle Assembly .......................................................................................................... 4B- 7
General Description ...................................................................................................... 4B- 7
Servicing............................................................................................................................. 4B- 8
Rear Axle ............................................................................................................................ 4B- 9
Disassembly .................................................................................................................. 4B- 10
Inspection and Repair................................................................................................... 4B- 13
Reassembly ................................................................................................................... 4B- 14
Differential Assembly.....................................................................................................................4B- 19
Disassembly .................................................................................................................. 4B- 20
Reassembly ................................................................................................................... 4B- 22
Differential Cage Assembly..........................................................................................................4B- 32
Disassembly .................................................................................................................. 4B- 33
Inspection and Repair...............................................................................................................4B- 33
Reassembly.................................................................................................................................4B- 35
Limited Slip Differential (LSD) .......................................................................................... 4B- 36
Disassembly................................................................................................................................4B- 37
Inspection and Repair................................................................................................... 4B- 38
Reassembly ................................................................................................................... 4B- 40
Troubleshooting ............................................................................................................ 4B- 43
Special Service Tool..................................................................................................................4B- 54

4B-2 REAR AXLE

Service Precaution
WARNING:

THIS VEHICLE HAS 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, REFE
R
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 prope
r
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 o
r
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 clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specification.
Following these instructions can help you avoid
damage to parts and systems.

4B-6 REAR AXLE

RECOMMENDED LIQUID GASKET

Type Brand Name Manufacture Remarks

RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
Water Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer
Note :
1. It is very important that the liquid gaskets listed
above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid
gasket.
Follow the manufacture's instructions at all
times.

3. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon
contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518
between two metal surfaces having a clearance
of greater than 0.25 mm (0.01 in). Poor
adhesion will result.



RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.

The surfaces must be perfectly dry.

LOCTITE 262

Red 2. Apply LOCTITE to the bolts.


LOCTITE 270

Green

LOCTITE 271

Red
3. Tighten the bolts to the specified torque.
4. Wait at least one hour before continuing the installation procedure.

REAR AXLE 4B-11

305R30000
Legend


1.
Tension Pin

2.
Shoe Clamp Spring

3.
Return Spring

4.
Shoe Assembly with Parking Brake Lever

5.
Shoe Assembly with Adjuster Lever

6.
Spring

7.
Parking Brake Cable


8.
Adjuster

9.
Parking Brake Lever

10.
Adjuster Spring

11.
Adjuster Lever

12.
Wheel Cylinder

13.
Back plate


4.
Remove tension pin and shoe clamp spring.
5.
Remove return spring.
6.
Remove shoe assembly with parking brake lever.
7. Remove shoe assembly with adjuster lever and
spring.
8.
Remove parking brake inner cable from parking
brake lever.
9.
Use offset box wrench to compress locking lugs
on the cable, then remove parking brake outer
cable from back plate.

311RS012

REAR AXLE 4B-23

c.
Clean the side bearing bores. Place discs and
dial indicator on to arbor, and place tool into
position in side bearing bores. Install and
tighten the bearing caps to the specified
torque.

Torque :

108 N
m (11 kg
m/80 lb in)
425RW031
Legend


1.
Dial Indicator : 5-8840-0126-0

2.
Gauge Plate : 5-8840-2166-0

3.
Disc (2 pcs.) : 5-8840-2167-0

4.
Arbor : 5-8840-0128-0

Note :
The scale on the dial indicator (5-8840-0126-0) is
inch unit.

d.
Set the dial indicator 5-8840-0126-0 to “0".
Place it on the mounting post of the gauging
arbor with the contact button touching the
indicator pad. Force the dial indicator
downward until the needle has made a half
turn clockwise. Tighten down the dial
indicator in this position.






425RS020
Legend

1.
Dial Indicator

2.
Gauging Arbor

3.
Plunger

4.
Gauge Plate

e.
Position the plunger on the gauge plate. Move
the gauging arbor slowly back and forth and
locate the position at which the dial indicator
shows the greatest deflection. At this point,
once again set the dial indicator to “0".
Repeat the procedure to verify the “0"
setting.


425RS021

f.
After the ZERO setting is obtained, rotate the
gauging arbor until the dial indicator rod does
not touch the gauging plate. Record the
number the dial indicator needle points to.

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)