Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 1138

4A2–20

DIFFERENTIAL (REAR)

18. Select the shim using the chart;

Dial Indicator 
Reading 
(inches)

Marking (inches)

+3

+2

+1

0

-1

-2

-3

0.027

      

0.030

0.028

     

0.030

0.031

0.029

    

0.030

0.031

0.032

0.030

   

0.030

0.031

0.032

0.033

0.031

  

0.030

0.031

0.032

0.033

0.034

0.032

 0.030

0.031

0.032

0.033

0.034

0.035

0.033

0.030

0.031

0.032

0.033

0.034

0.035

0.036

0.034

0.031

0.032

0.033

0.034

0.035

0.036

0.037

0.035

0.032

0.033

0.034

0.035

0.036

0.037

0.038

0.036

0.033

0.034

0.035

0.036

0.037

0.038

0.039

0.037

0.034

0.035

0.036

0.037

0.038

0.039

0.040

0.038

0.035

0.036

0.037

0.038

0.039

0.040

0.041

0.039

0.036

0.037

0.038

0.039

0.040

0.041

0.042

0.040

0.037

0.038

0.039

0.040

0.041

0.042

0.043

0.041

0.038

0.039

0.040

0.041

0.042

0.043

0.044

0.042

0.039

0.040

0.041

0.042

0.043

0.044

0.045

0.043

0.040

0.041

0.042

0.043

0.044

0.045

0.046

0.044

0.041

0.042

0.043

0.044

0.045

0.046

0.047

0.045

0.042

0.043

0.044

0.045

0.046

0.047

0.048

0.046

0.043

0.044

0.045

0.046

0.047

0.048

0.049

0.047

0.044

0.045

0.046

0.047

0.048

0.049

0.050

0.048

0.045

0.046

0.047

0.048

0.049

0.050

0.051

0.049

0.046

0.047

0.048

0.049

0.050

0.051

0.052

0.050

0.047

0.048

0.049

0.050

0.051

0.052

0.053

0.051

0.048

0.049

0.050

0.051

0.052

0.053

 

0.052

0.049

0.050

0.051

0.052

0.053

  

0.053

0.050

0.051

0.052

0.053

   

0.054

0.051

0.052

0.053

    

0.055

0.052

0.053

     

0.056

0.053

      

DIFFERENTIAL (REAR)

4A2–21

19. Remove bearing caps and depth gauging tools.

20. Install the correct pinion shim and inner oil slinger

onto pinion.

NOTE:  Do not install pinion gear into housing at this
time.

21. If the exciter ring was removed,   install the new

exciter ring onto the differential case by pressing
using the ring gear as a pilot.

425RS047

22. Install ring gear(1) to the differential case(2)

425RW021

23. Install new ring gear bolts.

• Tighten the ring gear bolts alternately in stages,

gradually pulling the ring gear onto the differential
case.

Tighten the ring gear bolts in sequence

Torque: 108 N·m (80lb ft)

NOTE:  Discard used bolts and install new ones.

415RS016

Side Bearing Preload Adjustment

1. The side bearing preload adjustment must be made

before installing the pinion.

2. The side bearing preload is adjusted by changing

the thickness of both the left and right shims equally.
This maintain the original backlash.

3. Install master side bearings J–39836 onto the case.

Remove all nicks, burrs, dirt etc., from the hubs to
allow the master bearings to rotate freely.

425RW026

4A2–22

DIFFERENTIAL (REAR)

4. Assemble the differential case into the housing (less

pinion).   Install bearing caps and finger tight bolts.
Mount a dial indicator with a magnetic base to the
housing and indicate on the flange or head of screw.
Force the differential assembly as far as possible in
the dirction towards the indicator.
With force still applied, set indicator at zero(0).

NOTE:  Dial indicator set should be capable of a
minimum travel of 5.08 mm (0.2 in).

425RS107

5. Force the differetial assembly as far as it will go in

the opposite direction. Repeat these steps until the
same reading is obtained.

6. RECORD THE READING OF THE INDICATOR.

This amount, in shims, will be included in the final
assembly shim stack to establish side bearing
preload and ring gear and pinion backlash.

7. After marking sure the readings are correct, remove

the indicator and differetial assembly from the
housing.

Pinion Installation

• The bearing cups should have been installed in

Pinion Depth Adjustment in this section.

1. Place the shim(1) and inner oil slinger(2) on the

pinion gear,   then install the pinion inner bearing(3)
using installer J–42828.

425RW023

• Drive the bearing until the bearing cone seats on

the pinion shims.

2. Install a new collapsible spacer.

• Lubracate the pinion bearings with axle lublicant.

3. Install pinion to the axle housing.

4. Install outer pinion bearing onto the pinion.

• Hold the pinion forward from inside the case

while driving the bearing onto the pinion.

5. Install oil seal slinger.

6. Install pinion oil seal using installer J–37263.

7. Install the pinion flange to the pinion by tapping it

with a rawhide hammer until a few threads show
through the pinion flange.

8. Install pinion washer and a new nut  while holding

the pinion flange with flange holder J–8614–01.

• Tighten the nut until the pinion end play is just

taken up. Rotate the pinion while tightening the
nut to seat the bearings.

Torque:217-678 N·m (160-500 lb ft)

Once there is no end play in the pinion, the
preload torque should be checked.

DIFFERENTIAL (REAR)

4A2–23

• Remove flange holder J–8614–01. Using an

inch-pound torque wrench,   check the pinion
preload by rotating the pinion with the wrench.

425RW018

Preload should be at 1.0 to 1.6N·m (8 to 14inlbs.)
on new bearings, or 0.46 to 0.69N·m (4 to
6 in lbs.) for used bearings.

• If the preload torque is below the preloads given

above, continue torquing the nut in small
increments.   Check the preload after each
tightening.   Each tightening increases the
bearing preload by several pounds.   If the
bearing preload is exceeded, the pinion will have
to be removed, and a new collapsible spacer
installed.

• Once a preload of 1.0 to 1.4N·m (8 to 12inlbs.)

has been obtained, rotate the pinion several
times to assure that the bearings have seated.
Recheck the preload, and adjust if necessary.

Determination of Backlash & Preload
Shims

1. Install master side bearings onto the case.

2. Install differential assembly into the carrier.

3. Install the bearing cap and finger tight bolts.

4. Set up the dial indicator.

5. Force the differential assembly away from the pinion

gear until it is completely seated against the cross
bore face of the carrier.

6. With force still applied to the differential case, place

the tip of dial indicator on a machined surface of the
differential case, if available, or on the head of a ring
gear screw, and set the indicator at zero(0).

7. Force the ring gear to mesh with the pinion gear.

Rock the ring gear slightly to make sure the gear
teeth are meshed.   Repeat this procedure several
times until the same reading is obtained each time.
Be sure the indicator reads zero(0) each time the

ring gear is forced back into contact with the cross
bore face.   This reading will be the necessary
amount of shims to be placed between the
differential case and side bearing cone on the ring
gear side.

8. The remaining amount of shims, which is the

difference between the overall found in step 6 of
Side Bearing Pre-load Adjustment and step(7)
above, should be placed on the other side of the
differential case,   plus additional 0.38 mm (0.015in)
for obtaining preload and backlash.

9. Place the required amount of shims on each hub as

determined in the previous steps and assemble side
bearing cone by using installer J–21784 and handle
J–8592. 

425RW022

10. Total torque to rotate — Increase of pinion torque to

rotate due to differential case assembly shall not
exceed 3.4N·m (30 in lbs.) divided by the gear ratio.