2004 ISUZU TF SERIES torque

4B-16 REAR AXLE

8.
Certainly install new snap ring, use snap ring pliers.
When transform or damage, replace new one.



RTW34BMH000101
Legend


1.
Snap ring

2.
Crevice
3.
Sensor rotor (with ABS)

Spacer (without ABS)


9.
Insert a shim of sufficient thickness between snap
ring and end of sensor rotor (or spacer).


Standard
0 
0.2 mm (0 
0.008 in)


Crevice is measured using thickness gauge, and
when crevice exceeds 0.2 (mm), it adjusts so that
is may become 0.2 (mm) or less using shim.


Shim Pats No.
Thickness

1 9-41519110-
0.18 mm (0.0071 in)

2 8-97130387-

0.50 mm (0.0197 in)


Crevice
No. of shim
Total

Mm (in)
1 2
mm (in)

1.0(0.0394) 
2
1.00(0.0394)

0.9(0.0354)
2
1
0.86(0.0339)

0.8(0.0315)
1
1
0.68(0.0268)

0.7(0.0276)
1
1
0.68(0.0268)

0.6(0.0236)

1
0.50(0.0197)

0.5(0.0197)

1
0.50(0.0197)

0.4(0.0158)
2 
0.36(0.0142)
0.3(0.0118)
1 
0.18(0.0071)
0.2(0.0079)
1 
0.18(0.0071)

10. Install axle shaft assembly in rear axle case
assembly.
Note:
When inserting an axle shaft, it inserts so that an
oil seal may not be damaged.
11. Install and tighten bearing holder fixing nut to the
specified torque.

Torque : 84 N
m (8.6 kg
m/62 lb
ft)
12. Install wheel cylinder and tighten the bolt to the
specified torque.

Torque : 9 N
m (0.9 kg
m/78 lb
ft)
13. Install parking brake outer cable in back plate and
inner cable in parking brake lever.

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.

4B-22 REAR AXLE

Reassembly
1.
Install outer bearing outer race by using installer 5-
8840-2164-0 and grip 5-8840-0007-0.

425L100002
2.
Install inner bearing outer race by using installer 5-
8840-2163-0 and grip 5-8840-0007-0.

425L100003



3.
Adjust the drive pinion mounting distance as
follows:
a.
Apply gear oil to the inner and outer drive
pinion bearing. Clean the pinion setting
gauge set. Then install the gauge set
together with the inner and outer bearings.
Install gauge plate 5-8840-2166-0 (3), inner
pilot 5-8840-0129-0 (2), stud and nut 5-8840-
0127-0 (4) and outer pilot 5-8840-2085-0 (1)
through inner and outer bearings.
b.
Tighten the nut to the specified torque.

Torque: 2.3 N
m (0.23 kg
m/20 lb in)



425RW030

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-26 REAR AXLE

4. Place the shim on the drive pinion, then install the
inner bearing onto the pinion by using installer 9-
8522-1165-0 and a press.
Note:
Do not apply pressure to the roller cage. Apply
NOTE: pressure only to the inner race.
425L100008

5. Install collapsible spacer. Discard the used
collapsible spacer and install a new one.
6. Install drive pinion shaft assembly.
7. Install outer bearing and oil seal.
8. Use oil seal installer 5-8840-2165-0 to install a
new oil seal that has grease on seal lip.

415RW029

9. Install flange assembly.
10. Install flange nut.
a. Apply lubricant to the pinion threads.
b. Using the pinion flange holder 5-8840-0133-0,
tighten the nut only enough to remove the shaft
end play.
Note :
Discard used flange nut and install new one.
415RW040

c. Adjust pinion bearing preload.


Measure the bearing preload by using a torque
meter and note the scale reading required to
rotate the flange.


Continue tightening flange nut until the specified
starting torque is obtained.
Starting torque :
0.7-1.3 N
m (0.07-0.13 kg
m/6-11 lb
ft)

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-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