Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 952

REAR AXLE  4B-45

(6) Record the pinion depth code on the head of the drive

pinion.

The number indicates a necessary change in the pinion

mounting distance. A plus number indicates the need for a

greater mounting distance (which can be achieved by

decreasing the shim thickness). A minus number indicates

the need for a smaller mounting distance (which can be

achieved by increasing the shim thickness). If examination

reveals pinion depth code "0", the pinion is "nominal".

4B-46  REAR AXLE

(7) Select the shim using table below.

[194 mm]

mm(in)

Pinion
marking

+10

+8

+6

+4

+2

0

-2

-4

-6

-8

-10

Dial indicator
reading (inches)

0.081

2.18 (0.0858)

0.082

2.18 (0.0858)

2.20 (0.0866)

0.083

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

0.084

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

0.085

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

0.086

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

0.087

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

0.088

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

0.089

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

0.090

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

0.091

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

0.092

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

0.093

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

0.094

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

0.095

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

0.096

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.097

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.098

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.099

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.000

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.001

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.002

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.003

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.004

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.005

2.54 (0.1000)

2.56 (0.1008)

0.006

2.56 (0.1008)

[220 mm]

mm(in)

Pinion
marking

+10

+8

+6

+4

+2

0

-2

-4

-6

-8

-10

Dial indicator
reading (inches)

0.073

1.94 (0.0764)

1.96 (0.0772)

0.074

1.94 (0.0764)

1.96 (0.0772)

1.98 (0.0779)

0.075

1.94 (0.0764)

1.96 (0.0772)

1.98 (0.0779)

2.00 (0.0787)

0.076

1.94 (0.0764)

1.96 (0.0772)

1.98 (0.0779)

2.00 (0.0787)

2.02 (0.0795)

2.04 (0.0803)

0.077

1.96 (0.0772)

1.98 (0.0779)

2.00 (0.0787)

2.02 (0.0787)

2.04 (0.0803)

2.06 (0.0811)

0.078

1.94 (0.0764)

1.96 (0.0772)

1.98 (0.0779)

2.00 (0.0787)

2.02 (0.0787)

2.04 (0.0803)

2.06 (0.0811)

2.08 (0.0819)

0.079

1.94 (0.0764)

1.96 (0.0772)

1.98 (0.0779)

2.00 (0.0787)

2.02 (0.0787)

2.04 (0.0803)

2.06 (0.0811)

2.08 (0.0819)

2.10 (0.0827)

0.080

1.94 (0.0764)

1.96 (0.0772)

1.98 (0.0779)

2.00 (0.0787)

2.02 (0.0787)

2.04 (0.0803)

2.06 (0.0811)

2.08 (0.0819)

2.10 (0.0827)

2.12 (0.0835)

2.14 (0.0842)

0.081

1.96 (0.0772)

1.98 (0.0779)

2.00 (0.0787)

2.02 (0.0787)

2.04 (0.0803)

2.06 (0.0811)

2.08 (0.0819)

2.10 (0.0827)

2.12 (0.0835)

2.14 (0.0842)

2.16 (0.0850)

0.082

1.98 (0.0779)

2.00 (0.0787)

2.02 (0.0787)

2.04 (0.0803)

2.06 (0.0811)

2.08 (0.0819)

2.10 (0.0827)

2.12 (0.0835)

2.14 (0.0842)

2.16 (0.0850)

2.18 (0.0858)

0.083

2.00 (0.0787)

2.02 (0.0787)

2.04 (0.0803)

2.06 (0.0811)

2.08 (0.0819)

2.10 (0.0827)

2.12 (0.0835)

2.14 (0.0842)

2.16 (0.0850)

2.18 (0.0858)

2.20 (0.0866)

0.084

2.04 (0.0803)

2.06 (0.0811)

2.08 (0.0819)

2.10 (0.0827)

2.12 (0.0835)

2.14 (0.0842)

2.16 (0.0850)

2.18 (0.0858)

2.20 (0.0866)

2.22 (0.0874)

2.24 (0.0882)

0.085

2.06 (0.0811)

2.08 (0.0819)

2.10 (0.0827)

2.12 (0.0835)

2.14 (0.0842)

2.16 (0.0850)

2.18 (0.0858)

2.20 (0.0866)

2.22 (0.0874)

2.24 (0.0882)

2.26 (0.0890)

0.086

2.08 (0.0819)

2.10 (0.0827)

2.12 (0.0835)

2.14 (0.0842)

2.16 (0.0850)

2.18 (0.0858)

2.20 (0.0866)

2.22 (0.0874)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

0.087

2.12 (0.0835)

2.14 (0.0842)

2.16 (0.0850)

2.18 (0.0858)

2.20 (0.0866)

2.22 (0.0874)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.30 (0.0906)

2.32 (0.0913)

0.088

2.14 (0.0842)

2.16 (0.0850)

2.18 (0.0858)

2.20 (0.0866)

2.22 (0.0874)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.30 (0.0906)

2.32 (0.0913)

2.34 (0.0921)

0.089

2.16 (0.0850)

2.18 (0.0858)

2.20 (0.0866)

2.22 (0.0874)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.30 (0.0906)

2.32 (0.0913)

2.34 (0.0921)

2.36 (0.0929)

0.090

2.18 (0.0858)

2.20 (0.0866)

2.22 (0.0874)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.30 (0.0906)

2.32 (0.0913)

2.34 (0.0921)

2.36 (0.0929)

0.091

2.22 (0.0874)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.30 (0.0906)

2.32 (0.0913)

2.34 (0.0921)

2.36 (0.0929)

0.092

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.30 (0.0906)

2.32 (0.0913)

2.34 (0.0921)

2.36 (0.0929)

0.093

2.26 (0.0890)

2.28 (0.0898)

2.30 (0.0906)

2.32 (0.0913)

2.34 (0.0921)

2.36 (0.0929)

0.094

2.28 (0.0898)

2.30 (0.0906)

2.32 (0.0913)

2.34 (0.0921)

2.36 (0.0929)

0.095

2.32 (0.0913)

2.34 (0.0921)

2.36 (0.0929)

0.096

2.34 (0.0921)

2.36 (0.0929)

0.097

2.36 (0.0929)

Note :
When ordering shims, find the part number in the Parts Catalog by using the thickness of the shims listed
in the above table.

REAR AXLE  4B-47

4. Inner Bearing
Place the shim on the drive pinion with the chamfered side
turned toward the pinion head, then attach the inner bearing to
the pinion using an installer and a press.
Installer : 9-8522-1165-0

(J-6133-01)

NOTE :
Do not press on the roller cage.
Press only on the inner race.

5. Collapsible Spacer
Discard the used collapsible spacer and install a new one.

8. Oil Seal
Use the oil seal installer to install a new oil seal that has been
soaked in rear axle lubricant.
Installer : 9-8522-1275-0 (194 mm)

(J-24250)

: 5-8840-2165-0 (220 mm)

(J-37263)

10.Flange Nut and Washer

(1) Apply lubricant to pinion threads.

(2) Tighten the nut to the specified torque using the pinion

flange holder.

Pinion flange holder : 5-8840-0133-0 (194 mm)

(J-8614-01)
5-8840-2157-0 (220 mm)
(J-37221)

Flange Nut Torque

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

194 mm

176.6 - 274.7 (18 - 28/130 - 202)

220 mm

245.3 - 294.3 (25 - 30/181 - 217)

Discard used flange nuts and install new ones.

4B-48  REAR AXLE

(3) Pinion bearing preload.

(a) Measure the bearing preload by using a torque wrench.

Note the scale reading required to rotate the flange.

(b) Continue tightening until the specified starting torque is

obtained.

Pinion Bearing Preload Starting Torque

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

194 mm

64 - 113 (6.5 - 11.5/47 - 72)

220 mm

69 - 127 (7 - 13/51 - 94)

11.Backlash and Pre-load Adjusting Shim

(1) Attach the side bearing to the differential assembly without

shims.  Support the opposite side using a pilot to prevent

bearing damage.

1

Installer

: 9-8522-1164-0 (194 mm)

(J-24244)

: 5-8840-2162-0 (220 mm)

(J-37257)

2

Drive handle : 5-8840-0007-0

(J-8092)

3

Pilot

: 9-8521-1743-0

(J-8107-2)

(2) Position the differential cage assembly with the bearing

outer races to the side bearing bores of the carrier.

(3) Using two sets of feeler gauges, insert a feeler stock of

sufficient thickness between each bearing outer race and

the carrier to remove all end play.  Make certain the feeler

stock is pushed to the bottom of the bearing bores.

Mount the dial indicator on the carrier so that the indicator

stem is at right angles to a tooth on the ring gear.

Dial indicator : 5-8840-0126-0

(J-8001)