Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 973

4C1-62  FRONT WHEEL DRIVE

9. Inner Cam

(1) Before installation, shift the transfer lever to “2H” position.

(2) Clean the flange surface of the hub, the thread holes, the

surface of the lock washer and the spline portion of the axle

shaft.

(3) Install the inner cam by aligning the key way of the inner

cam with the groove of the knuckle.

Hit the inner cam lightly with plastic hammer or equivalent

and make sure the inner cam is in contact with the lock

washer.

If it is difficult to install the inner cam, use the tool (installer)
and a plastic hammer or the equivalent.
Install the special tool.
Use the plastic hammer to lightly tap around the special tool “A”
surface as shown in the illustration.
Installer : 58840-2137-0 (J-38194)
Note: Do not strike the inner cam gear teeth with the plastic

hammer.

Shim Selection

(1) Lower vehicle from hoist.

(2) Support lower link with floor jack, placing axle in normal

horizontal position.

FRONT WHEEL DRIVE  4C1-63

(3) Install special tool 5-8840-2126-0 to axle shaft by 5-8840-

2125-0 until it comes into contact with the lock washer.

(4) Using feeler gauge, measure clearance “t” between the

special tool and the snap ring groove of the axle shaft.

(5) If clearance “t” is larger than snap ring groove, shims must

be installed select shims so that clearance “t” is 0 to 0.1 mm

(0 to 0.0039 in).

Thickness shims; 0.2, 0.3, 0.5, 1.0 mm

(6) Remove special tool 5-8840-2126-0, leaving the inner cam

in position.

10.Drive Clutch Assembly
Apply multipurpose grease or hub bearing grease to the
following portions.
(1) Axle shaft splines

4C1-64  FRONT WHEEL DRIVE

•

 “A” groove and “B” portion

g(oz)

“A” Groove

7 (0.25)

“B” portion

3 (0.11)

•

 “C” circumference and “D” portion

g(oz)

“C” circumference

8 (0.29)

“D” portion

4 (0.15)

(2) Align the cut part of the drive clutch assembly with the

protudent part of inner cam.

(3) Engage the cam teeth of the drive clutch assembly to that of

the inner cam by turning the axle shaft.

11.Snap Ring and Shims

(1) Install shims (selected above) to axle by hand.

Note :
Always use a new snap ring.

(2) Install special tool 5-8840-2125-0 (B) to axle.

(3) Install snap ring to tool.

(4) Install tool driver 5-8840-2125-0 (A).

(5) Pull out the axle shaft fully by pulling the tool 5-8840-2125-0

(B) and install snap ring to axle by pushing on tool driver 5-

8840-2125-0 (A).

(6) Remove tool from axle.
Snap ring installer : 5-8840-2125-0

(J-36835)

FRONT WHEEL DRIVE  4C1-65

Caution

After installation of the shims and the snap ring, check the
fitting condition of the snap ring.

12.Housing Assembly

(1) Apply Loctite 515 or the equivalent to the flange surface of

the housing assembly.

(2) Make sure that the housing assembly turns smoothly.

If it turns smoothly, the spacer selected above is correct.

(3) Bolt tightening torque :

Torque

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

58.9 

±

 5 (6 

±

 0.5/43.4 

±

 3.6)