Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 946

REAR AXLE  4B-21

MINOR COMPONENTS

DIFFERENTIAL ASSEMBLY

Disassembly Steps

▲

1. Ring gear

▲

2. Lock pin

▲

3. Cross pin
4. Pinion gear
5. Thrust block

6. Side gear
7. Thrust washer
8. Differential cage

4B-22  REAR AXLE

Important Operations

1. Ring Gear
Take care not to damage the ring gear or the differential case
when removing the ring gear.  Never try to wedge a tool
between the two faces.

2. Lock Pin
Drive out the pinion shaft lock pin with a long drift punch.  It
may be necessary to first remove the stakes in the lock pin with
a 5 mm drill.

3. Cross Pin

(1) Check the amount of backlash before removal.

Backlash

mm(in)

194 mm

0.03 - 0.08 (0.001 - 0.003)

220 mm

0.13 - 0.18 (0.005-0.007)

(2) Remove the cross pin with a brass drift punch, and take out

the pinion gears, side gears, thrust block and thrust

washers from the differential cage.

REAR AXLE  4B-23

LIMITED SLIP DIFFERENTIAL (LSD)

(FOR RING SIZE 194 mm)

Disassembly Steps

1. Spring pin
2. Pinion spider
3. Thrust block

▲

4. Pinion washer

▲

5. Pinion gear
6. Side gear
7. Friction disc and plate assembly

8. Side gear
9. Friction disc and plate assembly

10. Differential cage
11. Sleeve
12. Spring plate
13. Disc spring
14. Disc and plate

4B-24  REAR AXLE

Important Operations

4. Pinion washer

5. Pinion gear

(1) Clamp special tool (side gear holder) into a vice.  Set the

LSD assembly.

Holder : 5-8840-2010-0

(J-36563)

(2) Set special tools (side pinion expanders and pinion rotator)

to the LSD.

Expander : 5-8840-2011-0

(J-36564)

Rotor : 5-8840-2012-0

(J-36565)

(3) Set special tool (cage lock bar) through a ring gear fixing

hole to a vice.

Then rotate side pinion expanders with a wrench one half to

one full turn to provide backlash between the side and

pinion gears.

Bar : 5-8840-2013-0

(J-36566)

(4) With a wrench, rotate special tool (pinion rotator) to remove

the pinion gear and the pinion washer.