Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 964

4C1-26  FRONT WHEEL DRIVE

Important Operations

3. Lock Pin
Break staking on the lock pin using a 5 mm (0.20 in.) diameter
drill.

4. Cross Pin
Remove the cross pin using a soft metal rod and a hammer.

FRONT WHEEL DRIVE  4C1-27

  INSPECTION AND REPAIR

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

•

 Ring gear, pinion gear

•

 Bearing

•

 Side gear, pinion gear, cross pin

•

 Differential cage, carrier

•

 Thrust washer

•

 Oil seal

Visual Check

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

Ring Gear Replacement

(1) The ring gear should always be replaced with the drive

pinion as a set.

(2) When installing the ring gear, apply LOCTITE 271 or

equivalent to the threaded hole and bolt.

(3) Tighten the fixing bolts in a diagonal sequence as

illustrated.

(4) Discard used bolts and install new ones.

Bolt Torque

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

167 mm

78.5 

±

 9.8 (8 

±

 1/57.9 

±

 7.2)

194 mm

107.9 

±

 9.8 (11 

±

 1/79.6 

±

 7.2)

For 167 mm

Note that all bolts have a left hand thread.

Clearance Between the Differential Pinion

and the Cross Pin

mm(in)

Standard

Limit

167 mm

0.06 - 0.12 (0.002 - 0.005)

0.2 (0.008)

194 mm

0.05 - 0.10 (0.002 - 0.004)

0.2 (0.008)

4C1-28  FRONT WHEEL DRIVE

Clearance Between the Side Gear and the

Differential Box

mm(in)

Standard

Limit

167 mm

0.03 - 0.11 (0.001 - 0.004)

0.15 (0.006)

194 mm

0.03 - 0.10 (0.001 - 0.004)

0.15 (0.006)

Play in Splines Between the Side Gear
and the Axle Shaft

mm(in)

Standard

Limit

167 mm

0.11 - 0.38 (0.004 - 0.015)

0.30 (0.012)

194 mm

0.07 - 0.36 (0.003 - 0.014)

0.25 (0.010)

FRONT WHEEL DRIVE  4C1-29

  REASSEMBLY

MINOR COMPONENTS

Reassembly Steps

1. Differential cage
2. Thrust washer
3. Side gear

▲

4. Pinion gear

▲

5. Cross pin

▲

6. Lock pin

▲

7. Ring gear

▲

8. Bolt

Important Operations

4. Pinion Gear
Install the pinion gear by engaging it with the side gears while
turning both pinion gears simultaneously in the same direction.