Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 941

REAR AXLE  4B-1

SECTION 4B

REAR AXLE

TABLE OF CONTENTS

PAGE

Main Data and Specifications ......................................................................................... 4B- 2

Special Parts Fixing Nut and Bolt .................................................................................. 4B- 3

Recommended Liquid Gasket ........................................................................................ 4B- 5

Recommended Thread Locking Agents ........................................................................ 4B- 5

Rear Axle Assembly ........................................................................................................ 4B- 6

General Description .................................................................................................... 4B- 6

Servicing........................................................................................................................... 4B- 7

Axle Shaft ......................................................................................................................... 4B- 8

Disassembly ................................................................................................................ 4B- 8

Inspection and Repair................................................................................................. 4B-11

Reassembly ................................................................................................................. 4B-12

Differential ........................................................................................................................ 4B-16

Removal and Installation ............................................................................................ 4B-16

Disassembly ................................................................................................................ 4B-18

Major Components................................................................................................ 4B-18

Minor Components................................................................................................ 4B-21

Limited Slip Differential (LSD).............................................................................. 4B-23

Inspection and Repair................................................................................................. 4B-27

Reassembly ................................................................................................................. 4B-32

Minor Components................................................................................................ 4B-32

Limited Slip Differential ........................................................................................ 4B-32

Major Components................................................................................................ 4B-42

Troubleshooting.......................................................................................................... 4B-52

INDEX

4B-2  REAR AXLE

MAIN DATA AND SPECIFICATIONS

REAR AXLE

Ring gear size

mm(in)

194 (7.94)

220 (8.66)

Rear axle type

Banjo, semi-floating

Rear axle capacity

N (kg/lb)

16475 (1680/3700)

Rear axle case

Axle tube section

Outside diameter

mm(in)

75 (2.95)

Thickness

mm(in)

4.5 (0.118)

Final drive type

Single speed

Final gear type

Hypoid

Final gear ratio HEC2.0L engine 

(4

×

2)

-

4.555 or 4.777

(4

×

2)

4.555

4.777

HEC2.2L engine

(4

×

4)

4.555

4.777

Drive pinion bearing preload

kg-cm(lb.in)

Starting torque (At drive pinion flange nut)

6.5-11.5 (5.6-10)

7-13 (6.1-11.3)

Preload adjusting method

Collapsible

Final gear backlash

mm(in)

0.13-0.18 (0.005-0.007)

0.15-0.20 (0.006-0.008)

Differential carrier assembly

Weight (Dry)

N (kg/lb)

208 (21.2/46.7)

284 (29.0/63.9)

Amount of hub grease

g(OZ)

80 (2.8)

(one wheel)

Lubrication

Specified gear oil (APL grade)

GL-5

Oil capacity

lit (US/UK gal)

1.5 (0.4/0.33)

1.8 (0.48/0.4)

REAR AXLE  4B-3

  SPECIAL PARTS FIXING NUT AND BOLT

REAR AXLE AND DIFFERENTIAL
194 mm

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

73.6

±

5 (7.5

±

0.5 / 54.2

±

3.6)

176.6-274.7 (18-28 / 130-202)

98

±

9.8 (10

±

1 / 72

±

7.2)

107.9

±

9.8 (11

±

1 / 79.5

±

7.2)

78.5

±

14.7 (8

±

1.5 / 58

±

11)

24.5

±

5 (2.5

±

0.5 / 18

±

3.6)

37.3

±

3.9 (3.8

±

0.4 / 27

±

2.9)

78.5

±

14.7 (8

±

1.5 / 58

±

11)

260

±

29.4 (26.5

±

3 / 191.6

±

21.7)

4B-4  REAR AXLE

220 mm

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

107.9

±

9.8 (11

±

1/79.5

±

7.2)

107.9

±

9.8 (11

±

1/79.5

±

7.2)

245.3-294.3 (25-30/181-217)

73.6

±

5 (7.5

±

0.5/54.2

±

3.6)

78.5

±

14.7 (8

±

1.5/58

±

11)

44

±

14.7 (4.5

±

1.5/32.5

±

10.8)

78.5

±

14.7 (8

±

1.5/58

±

11)

260

±

29.4 (26.5

±

3/191.6

±

21.7)

63.8     (6.5     / 47     )

+7.2
- 3.6

+1.0
- 0.5

+9.8
- 5