Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1974

4C2-16  FRONT DRIVING AXLE

DISASSEMBLY

1. Filler Plug

Remove filler plug and packing and drain oil.

2. Bolt

Loosen mounting bracket fitting bolts and remove front axle
drive shaft from front axle case.

3. Front Axle Drive Shaft (LH side)

4. Bolt

Loosen actuator ASM fitting bolts.

5. Actuator Assembly

Draw out actuator ASM.

6. Bolt

Remove housing fitting bolts.

7. Housing

8. Sleeve

9. Clutch Gear

10.Snap Ring

Remove snap ring from front axle case by using a snap ring
plier.

11.Inner Shaft

Take out inner shaft from front axle case.

12.Snap Ring

Remove snap ring from inner shaft by using a snap ring
plier.

13.Inner Shaft Bearing

Remove inner shaft bearing by using a special tool and
press.
Remover : 5-8840-2197-0 (J-37452)

NOTE:

Be careful not to damage the shaft.

FRONT DRIVING AXLE  4C2-17

14.Needle Bearing

Remove needle bearing from inner shaft by using a special
tool.
Remover

: 5-8840-0027-0 (J-26941)

Sliding hammer : 5-8840-0084-0 (J-2619-01)

NOTE:

Be careful not to damage the shaft.

15.Oil Seal

Remove oil seal from front axle case.

NOTE:

Be careful not to damage the front axle case.

INSPECTION AND REPAIR

Inspect the removed parts. If there are abnormalities such as
wear and damage, take corrective action or replace.

Visual Check

• Check and see if the inner shaft has such abnormalities

as wear and damage.

• When inspecting the inner shaft, be sure to check and

see if its splined part is twisted, worn, or cracked. If so,
replace with a new shaft. In case such an abnormality in
its gear part (a slide with sleeve), replace the shaft.

Inner Shaft Run-Out

With both end centers supported, rotate the shaft slowly and
measure deflection with a dial gauge.
Inner Shaft Run-Out (Limit)

mm (in)

0.5 (0.02)

NOTE:

Do not heat the shaft to correct its bend.

4C2-18  FRONT DRIVING AXLE

Inner Shaft Bearing

Inspect the state of inner shaft bearing. If any abnormality
such as smoothlessness is found, replace with a new inner
shaft bearing.
Insert a clutch gear and check the state of needle bearing.
If there is an abnormality such as smoothlessness, replace
the needle bearing.

Sleeve

Visual Check
Check and see that there is not wear, damage, or cracking
in the sleeve.

NOTE:

Close inspection of the groove and inner gear are required
because those are important parts.

Functional Check
Operate the sleeve with the inner shaft combined with the
clutch gear.
If smoothlessness is felt, replace the sleeve.

NOTE:

Gear oil should be applied to the contact surface of gear.

Dimensional Check
Check the width of sleeve center groove.
Sleeve Center Groove (Limit)

mm (in)

7.1 (0.28)

FRONT DRIVING AXLE  4C2-19

Clutch Gear

Visual Check
Check and see that there is not wear, damage, crack, or
any other abnormality in the clutch gear.
Functional Check
If there is an abnormality such as smoothlessness when
operated in combination with sleeve, replace the clutch
gear.

NOTE:

When inspecting, gear oil should be applied to the contact
surface of gear.

Dimensional Inspection
Make sure of the size illustrated.
Clutch Gear Out Side Diameter (Limit)

mm (in)

36.98 (1.46)

Battery

1
3

4

2

Actuator

Visual Check
Check and see that there is no damage, cracking, or other
abnormality.
Functional Check
Make sure of function with voltage (12V) applied to terminal

3

, 

4

 and set the tester to terminal 

1

, 

2

 in accordance

with the table below.

State

Port 

3

Port 

4

Port 

1

, 

2

conducting

Function

A

+

−

!

C

B

−

+

×

D

STATE B

STATE A

If there is an abnormality, replace the actuator as an
assembly.

NOTE:
• Be careful not to permit the entry of water or dust into

the ports of the actuator.