Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 1140

4A2–28

DIFFERENTIAL (REAR)

Limited Slip Differential Assembly

Disassembled View

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Disassembly

1. Place the holder J–39824 into a vise.

 Position the differential on the holder with the ring
gear side down. 

2. Remove Lock pin (1) from differential shaft using a

punch.

3. Remove Differential shaft (2) using hammer and

punch.
Place shop towel behind case to prevent differential
shaft from dropping out of case.

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 Legend  

(1) Thrust Washer–Differential Pinion Mate Gear
(2) Pinion Mate Gear
(3) Dished Spacer
(4) Disc
(5) Plate

(6) Differential Plate Retainer
(7) Lock Pin
(8) Differential Case
(9) Ring Gear Bolts

(10) Differential Shaft

(11) Differential Side Gear

DIFFERENTIAL (REAR)

4A2–29

4. Assemble clutch pack unloading tool .

a. Install cap J–34174–1 to the bottom differential

side gear.

b. Install threaded screw cap J–34174–2 to top

differential side gear.   Thread forcing screws J–
22342–15 into threaded screw cap until it
becomes centered   into the bottom cap.

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c.

Tighten forcing screw until tight enough to
collapse dished spacers and allow looseness
between side and pinion mate gears.

5. Both pinion mate gear thrust washers using a shim

stock (1) of 0.51 mm (0.020 in.) or equivalent tool to
push out washers. 

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6. Relieve tension of dished spacers by loosening

forcing screw.

NOTE:

•  You may have to adjust the forcing screw slightly to

allow the case to rotate. 

7. Assemble LSD service adapter J–39834 onto long

drive handle J-8592.  Insert it into differential shaft
hole of case. Pull on handle and rotate case until
pinion mate gears can be removed.

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8. Remove pinion mate gears.

9. Hold side gear top clutch pack (1) with one hand

and remove positraction unloading tools.

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10. Remove top side gear and clutch pack.

NOTE:

• Keep the stack of plates and discs intact and in

exactly the same position while they are being
removed.

11. Remove case from holder.  Turn case with flange or

ring gear side up to allow side gear and clutch pack
to be removed from case.

12. Remove differential plate retainer from both clutch

packs to allow separation of the plates and discs.

4A2–30

DIFFERENTIAL (REAR)

NOTE:

• Keep the discs and plates in the same order as they

were removed.

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Inspection and Repair

Cleaning

• All parts with solvent.

Visual Inspection

• Clean all parts with solvent.

• Plates and Discs. If any one disc or plate in either

stack shows evidence of   excessive wear or scoring,
the complete stack is to be replaced on both sides. 

• Side Gears and Pinion Mate Gears. The gear teeth of

these parts should be checked for extreme wear and
possible cracks. The external teeth of the side gear,
which retain the concentric groove discs, should also
be checked for wear or cracks. 

• If replacement of one gear is required due to wear,

etc., then both side gears, pinion mate gears, and
thrust washers are to be replaced. 

• Differential Shaft. If excessive wear is evident, the

differential shaft should be replaced. 

• Differential Plate Retainers. If wear is evident on any

one of the differential plate retainers, all  four
retainers must be replaced. 

• Differential Case. If scoring, wear or metal pickup is

evident on the machined surfaces, replacement of
the case is necessary. 

Reassembly

1. Lubricate thrust face of side gears, plates and discs

with the proper limited slip rear axle lubricant.

2. Assemble plates and discs in exactly in the same

position as they were removed, regardless of
whether they are new or original.

3. Install differential plate retainer to ears of plates. 

NOTE:

• Make sure both retainers are Completely seated on

ears of plates.

4. Install clutch pack and side gear into bottom side

gear bore. Make sure clutch pack   stays assembled
to side gear splines, and that retainers are
completely seated into pockets of case. 

NOTE:

• To prevent clutch pack from falling out of case, hold

clutch pack in place by hand while repositioning case
on bench.

5. Install other side gear and clutch pack. Make sure

clutch pack stays assembled to side gear splines,
and retainers are completely seated into pockets of
case.

6. Hold clutch pack in position and assemble screw

cap J–34174–2, cap J–34174–1 and forcing screw
J–22342–15. Tighten forcing  screw into bottom cap
to hold both clutch packs in position.

7. With tools assembled to case, position case on

holder J–39824 by aligning splines of side gear with
those of shaft. Tighten forcing screw to compress
clutch packs in order to provide clearance for pinion
mate gears.

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8. Install pinion mate gears.

• Place the pinion mate gears into the differential

180 degrees apart.

 Legend     

(1) Differential Plate
(2) Differential Disc
(3) Dished Spacer
(4) Side Gear

DIFFERENTIAL (REAR)

4A2–31

9. While holding gears in place, insert LSD service

adapter J–39834  with long drive handle   J–8592 in
differential shaft hole of case. Pull on long drive
handle J–8592 and rotate case, allowing   gears to
turn. Make sure that holes in pinion mate gears
align with holes in case.

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• It may be necessary to adjust tension on forcing

screw to rotate case.

10. Tighten forcing screw to compress the clutch packs,

to allow installation of spherical thrust washers.

11. Lubricate spherical thrust washers (2), and

assemble into case (1). Use a small screw   driver to
push washers into place. Remove tools. 

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12. Position differential shaft in case and drive in with

hammer. Be sure lock pin   hole of differential shaft
(5)  is properly aligned to allow installation of lock
pin (3).   Be sure that thrust washers and differential
pinion mate gears are aligned with the differential
case (4). Install new lock pin to proper depth using a
punch.

Stake metal of case over pin in two places, 180
degrees apart.

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