Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 962

4C1-18  FRONT WHEEL DRIVE

  INSPECTION AND REPAIR

Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspection.

•

 BJ assembly

•

 DOJ case, ball, ball guide, ball retainer

•

 Bellows

•

 Bearing

•

 Dust seal, oil seal

Visual Check

Inspect the following parts for wear, damage, or other
abnormal conditions.

FRONT WHEEL DRIVE  4C1-19

  REASSEMBLY

Reassembly Steps

1. Axle case and differential
2. DOJ case
3. Bracket
4. Oil seal
5. O-ring
6. Snap ring
7. Bearing
8. Snap ring
9. DOJ case assembly

▲

10. Bolt

11. BJ shaft

12. Dust seal

▲

13. Bellows

▲

14. Band

▲

15. Ball guide

▲

16. Ball retainer

▲

17. Snap ring

▲

18. Ball

▲

19. BJ shaft assembly

▲

20. Circlip

▲

21. Bellows

▲

22. Band

4C1-20  FRONT WHEEL DRIVE

Important Operations

10.Bolt

Bolt Torque

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

82.4 

±

 7.8 (8.4 

±

 0.8/60.8 

±

 5.8)

13.Bellows

(1) Apply a thin coat of grease to the shaft for smooth

installation.

(2) Apply specified grease to the ½ space of the bellows.

14.Band
Note the setting direction.
After installation, check that the bellows is free from distortion.

15.Ball Guide

16.Ball Retainer
Install the ball guide with the smaller diameter side ahead onto
the shaft.

17.Snap Ring
Install the snap ring securing the ball retainer to the shaft.

FRONT WHEEL DRIVE  4C1-21

18.Ball
Bring the ball guide of the cage into alignment with the
projected portion of the ring on the ball retainer, then turn the
cage ½ pitch.  Align the track on the ball retainer with the
window in the cage and install the six balls into position.

19.BJ Shaft Assembly
Apply specified grease to the half of the space of the DOJ case
(Approx. 50g (1.8 oz)).

20.Circlip
Install the circlip so that open ends are positioned away from
the ball groove.

21.Bellows

(1) Before installation, insert the appropriate amount of

specified grease into the DOJ case.

(2) Adjust the air pressure within the bellows by inserting a

screwdriver or equivalent, so that it equals atmospheric

pressure.

22.Band
After installation, check that the bellows is free from distortion.