Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 967

4C1-38  FRONT WHEEL DRIVE

(2) Insert the differential cage assembly with bearing outer

races into 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 plat.  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 : 5884-0126-0

(J-8001)

(4) Adjust feeler gauge thickness from side to side until ring

gear backlash is in the specified range.

Backlash

mm(in)

0.13 - 0.18 (0.005 - 0.007)

With zero end play and correct backlash established,

remove the feeler gauge packs, determine the thickness of

the shims required and add 0.05 mm (0.002 in) to each

shim pack to provide side bearing preload.  Always use new

shims.

(5) Remove side bearing

Remover : 5-8840-0013-0

(J-22888)

Pilot

: 5-8521-0019-0 (167 mm)

9-8521-1743-0 (194 mm)
(J-8107-2)

14.Side Bearing
Install the side bearings together with the selected shims.

For 167 mm

1

Installer

: 5-8840-0138-0 (J-29036)

2

Drive handle : 5-8840-0007-0 (J-8092)

3

Pilot : 5-8521-0019-0

For 194 mm

1

Installer

: 9-8521-1164-0 (J-24244)

2

Drive handle : 5-8840-0007-0 (J-8092)

3

Pilot

: 9-8521-1743-0 (J-8107-2)

FRONT WHEEL DRIVE  4C1-39

17.Bearing Cap
Align the setting marks applied at disassembly.

18.Bolt

Bolt Torque

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

167 mm

68.7 

±

 9.8 (7.0 

±

 1.0/50.6 

±

 7.2)

194 mm

98.1 

±

 9.8 (10.0 

±

 1.0/72.3 

±

 7.2)

Measure the amount of run-out of the ring gear at its rear face.

mm(in)

Standard

Limit

0.02 (0.001)

0.05 (0.002)

Gear Tooth Contact Pattern Check and Adjustment
Apply a thin coat of prussian blue or equivalent to the faces of
the 7 - 8 teeth of the ring gear.  Check the impression of
contact on the ring gear teeth and make necessary adjustment
as described below if the contact is abnormal.

4C1-40  FRONT WHEEL DRIVE

20.Differential Assembly

(1) Clean the faces of the front axle case and differential

carrier.

Apply the recommended liquid gasket or its equivalent to

the sealing side of the axle case and the carrier.

(2) Attach the differential case and the carrier assembly to the

front axle case and tighten the nuts and bolts.  The axle

case bolt is used for drainage.

Torque

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

25.5 

±

 5 (2.6 

±

 0.5/18.8 

±

 3.6)

(3) Install the axle shaft assemblies as instructed earlier in this

section under “Axle Shaft Replacement”.

(4) Fill the axle case with hypoid gear lubricant, to just below

the filler hole.

Lubricant capacity

liter (US/UK gal)

167 mm

1.0 (0.26/0.22)

194 mm

1.4 (0.37/0.31)

FRONT WHEEL DRIVE  4C1-41

FRONT HUB AND DISC (4

×

2 model)

  DISASSEMBLY

Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure.

Disassembly Steps

1. Bolt

▲

2. Brake caliper

▲

3. Hub cap
4. Split pin
5. Nut retainer
6. Hub nut
7. Lock washer

8. Outer bearing

▲

9. Hub and disc assembly

10. Oil seal
11. Inner bearing and outer race

▲

12. Bolt

▲

13. Wheel pin