Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 966

 

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Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 966

 

 

4C1-34  FRONT WHEEL DRIVE

(3) Set the dial indicator to “0”.  Place it on the mounting post of

the gaging arbor with the contact button touching the

indicator pad.  Force the dial indicator downward until the

needle has made a half turn clockwise.  Tighten down the

dial indicator in this position.

(4) Position the plunger on the gage plate.  Move the gaging

arbor slowly back and forth and locate the position at which

the dial indicator shows the greatest deflection.  At this

point, once again set the dial indicator to “0”.

Repeat the procedure to verify the “0” setting.

(5) After the ZERO setting is obtained, rotate the gaging arbor

until the dial indicator rod does not touch the gaging plate.

Record the number the dial indicator needle points to.

(6) Record the pinion depth code on the head of the drive

pinion.

The number indicates a necessary change in the pinion

mounting distance.  A plus number indicates the need for a

greater mounting distance (which can be achieved by

decreasing the shim thickness).  A minus number indicates

the need for a smaller mounting distance (which can be

achieved by increasing the shim thickness).  If examination

reveals pinion depth code “0”, the pinion is “nominal”.

FRONT WHEEL DRIVE  4C1-35

(7) Select the shim using the chart;

For 167 mm

mm(in)

Pinion
marking

+6

+4

+2

+0

-2

-4

-6

Dial indicator
reading (inches)

0.052

1.39 (0.0547)

0.053

1.39 (0.0547)

1.41 (0.0555)

0.054

1.39 (0.0547)

1.41 (0.0555)

1.43 (0.0563)

0.055

1.39 (0.0547)

1.41 (0.0555)

1.43 (0.0563)

1.45 (0.0571)

0.056

1.39 (0.0547)

1.41 (0.0555)

1.43 (0.0563)

1.45 (0.0571)

1.47 (0.0579)

1.49 (0.0587)

0.057

1.39 (0.0547)

1.41 (0.0555)

1.43 (0.0563)

1.45 (0.0571)

1.47 (0.0579)

1.49 (0.0587)

1.51 (0.0594)

0.058

1.41 (0.0555)

1.43 (0.0563)

1.45 (0.0571)

1.47 (0.0579)

1.49 (0.0587)

1.51 (0.0594)

1.53 (0.0602)

0.059

1.43 (0.0563)

1.45 (0.0571)

1.47 (0.0579)

1.49 (0.0587)

1.51 (0.0594)

1.53 (0.0602)

1.55 (0.0610)

0.060

1.47 (0.0579)

1.49 (0.0587)

1.51 (0.0594)

1.53 (0.0602)

1.55 (0.0610)

1.57 (0.0618)

1.59 (0.0626)

0.061

1.49 (0.0587)

1.51 (0.0594)

1.53 (0.0602)

1.55 (0.0610)

1.57 (0.0618)

1.59 (0.0626)

1.61 (0.0634)

0.062

1.51 (0.0594)

1.53 (0.0602)

1.55 (0.0610)

1.57 (0.0618)

1.59 (0.0626)

1.61 (0.0634)

1.63 (0.0642)

0.063

1.55 (0.0610)

1.57 (0.0618)

1.59 (0.0626)

1.61 (0.0634)

1.63 (0.0642)

1.65 (0.0650)

1.67 (0.0657)

0.064

1.57 (0.0618)

1.59 (0.0626)

1.61 (0.0634)

1.63 (0.0642)

1.65 (0.0650)

1.67 (0.0657)

1.69 (0.0665)

0.065

1.59 (0.0626)

1.61 (0.0634)

1.63 (0.0642)

1.65 (0.0650)

1.67 (0.0657)

1.69 (0.0665)

1.71 (0.0673)

0.066

1.61 (0.0634)

1.63 (0.0642)

1.65 (0.0650)

1.67 (0.0657)

1.69 (0.0665)

1.71 (0.0673)

1.73 (0.0681)

0.067

1.65 (0.0650)

1.67 (0.0657)

1.69 (0.0665)

1.71 (0.0673)

1.73 (0.0681)

1.75 (0.0689)

1.77 (0.0697)

0.068

1.67 (0.0657)

1.69 (0.0665)

1.71 (0.0673)

1.73 (0.0681)

1.75 (0.0689)

1.77 (0.0697)

0.069

1.69 (0.0665)

1.71 (0.0673)

1.73 (0.0681)

1.75 (0.0689)

1.77 (0.0697)

0.070

1.71 (0.0673)

1.73 (0.0681)

1.75 (0.0689)

1.77 (0.0697)

0.071

1.75 (0.0689)

1.77 (0.0697)

0.072

1.77 (0.0697)

For 194 mm

mm(in)

Pinion
marking

+10

+8

+6

+4

+2

0

-2

-4

-6

-8

-10

Dial indicator
reading (inches)

0.081

2.18 (0.0858)

0.082

2.18 (0.0858)

2.20 (0.0866)

0.083

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

0.084

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

0.085

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

0.086

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

0.087

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

0.088

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

0.089

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

0.090

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

0.091

2.18 (0.0858)

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

0.092

2.20 (0.0866)

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

0.093

2.24 (0.0882)

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

0.094

2.26 (0.0890)

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

0.095

2.28 (0.0898)

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

0.096

2.32 (0.0914)

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.097

2.34 (0.0921)

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.098

2.36 (0.0929)

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.099

2.38 (0.0937)

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0

2.42 (0.0953)

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.001

2.44 (0.0961)

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.002

2.46 (0.0969)

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.003

2.48 (0.0977)

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.004

2.52 (0.0992)

2.54 (0.1000)

2.56 (0.1008)

0.005

2.54 (0.1000)

2.56 (0.1008)

0.006

2.56 (0.1008)

Note :
When ordering shims, find the part number in the Parts Catalog by using the thickness of the shims listed
in the above table.

4C1-36  FRONT WHEEL DRIVE

5. Inner Bearing
Place the shim on the drive pinion, with the chamfered side
turned towards the pinion head then install the inner bearing on
to the pinion using an installer and a press.
Installer : 9-8522-1165-0 (J-6133-01)
Note:
Do not apply pressure to the roller cage.
Apply pressure only to the inner race.

6. Collapsible Spacer
Discard the used collapsible spacer and install a new one.

9. Oil Seal
Use oil seal installer to install a new oil seal that has been
soaked in rear axle lubricant.
Installer : 5-8522-0046-0 (J-26234) (For 167 mm)

9-8522-1275-0 (J-24250) (For 194 mm)

Note :
Take care not to use a rear differential oil seal instead of
the front differential oil seal.

12.Flange Nut and Washer

For 194 mm

(1) Apply lubricant to the pinion threads.

(2) Tighten the nut to the specified torque using the pinion

flange holder.

Pinion flange holder : 5-8840-0133-0

(J-8614-01)

Torque

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

176.6 - 274.7 (18 - 28/130 - 202)

Discard used flange nut and install new one.

FRONT WHEEL DRIVE  4C1-37

(3) Pinion bearing preload

(a) Measure the bearing preload by using a torque meter.  Note

the scale reading required to rotate the flange.

(b) continue tightening until the specified starting torque is

obtained.

Starting Torque

N

⋅

m (kgf

⋅

cm/lb

⋅

in)

0.63 - 1.13 (6.5 - 11.5/5.7 - 9.9)

For 167 mm
(1) Apply lubricant to the pinion threads.

(2) Tighten the nut to the specified torque using the pinion

flange holder.

Pinion flange holder : 5-8840-0133-0 (J-8614-01)
Torque

N

⋅

m (kgf

⋅

m/lb

⋅

ft)

117 - 127 (12 - 13/87 - 94)

Discard used flange nut and install new one.

(3) Continue tightening until the specified starting torque is

obtained.

Starting Torque

N

⋅

m (kgf

⋅

cm/lb

⋅

in)

0.59 - 1.0 (6 - 11/5.2 - 9.5)

13.Adjust Shim

(1) Attach the side bearing to the differential assembly without

shims.  Support the opposite side using a pilot to prevent

bearing damage.

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)

 

 

 

 

 

 

 

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