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Home >> Isuzu >> 1994 >> Trooper S, Standard >> Repair and Diagnosis >> Drivelines & Axles >> Differentials & Drive Axles >> Differential & Axle Shafts - 4WD Front >> Overhaul >> Front Differential >> Reassembly, Installation & Adjustment

Reassembly, Installation & Adjustment

  1. Install thrust washers, side gears, and pinion gears into differential cage. Install pinion shaft without lock pin.
  2. Using dial indicator, measure pinion and side gear backlash while holding side gear. See Figure . If backlash is not .001-.003" (.03-.08 mm), adjust by selecting side gear thrust washers of different thickness.
  3. Thrust washers are available in thicknesses from .039-.043" (1.0-1.10 mm), in increments of .002" (.05 mm). Ensure both sides are equally shimmed. Once backlash is correct, install pinion shaft lock pin.
  4. Stake lock pin hole to prevent movement. Install ring gear onto differential cage. Ensure alignment marks on differential cage and ring gear are aligned. Apply Loctite 271 to NEW ring gear bolt threads and install bolts.
  5. Tighten bolts to specification in diagonal pattern. See TORQUE SPECIFICATIONS  . Temporarily install side bearings without shims. Support opposite end of differential cage to prevent bearing damage.
  6. Install pinion bearing races and pinion bearings. Rotate bearings to ensure they are seated properly. Install Pilot (J-21777-42), Preload Stud (J-23597-9), and Gauge Plate (J-23597-7). Tighten preload stud nut to 17 ft. lbs. (23 N.m) for new bearings, or 97 INCH lbs. (11 N.m) for used bearings. See Fig 1 .
    Fig 1: Installing Pinion Depth Gauging Set
    G60929Courtesy of ISUZU MOTOR CO.
  7. Clean side bearing bores. Assemble Discs (J-23597-8) and Arbor (J-23597-1). Install assembly into side bearing bores. Install and tighten bearing caps to 72 ft. lbs. (98 N.m). Set dial indicator to zero. Install dial indicator onto arbor post. Position stem on top surface of gauge plate.
  8. Move dial indicator downward on arbor stud until needle rotates 1/2 turn clockwise. Tighten dial indicator at that position. Rotate arbor back and forth until dial indicator indicates maximum deflection. Set dial indicator to zero.
  9. Repeat procedure to ensure proper setting. Rotate arbor until dial indicator stem does not contact gauge plate. Record dial indicator reading. This reading is nominal pinion shim thickness.
  10. Note number marked on gear end of drive pinion. Mark may be a zero, plus (+), or minus (-) number. If mark is zero, pinion is nominal. Combine dial indicator reading and pinion marking to determine proper drive pinion shim thickness to be used. See Fig 2 .
    Fig 2: Determining Front Drive Pinion Shim Thickness
    G74023Courtesy of ISUZU MOTOR CO.
  11. Remove bearing caps and pinion depth gauging set. Install selected shim pack, with chamfered side toward gear side of pinion. Press rear pinion bearing onto drive pinion. Lubricate bearing.
  12. Install drive pinion and NEW collapsible spacer into carrier. Install front pinion bearing. Lubricate pinion oil seal lip with rear axle lubricant. Install oil seal.
  13. Install flange onto drive pinion. Lubricate pinion threads. Install NEW pinion nut and washer. Tighten pinion nut to specification. See PINION PRELOAD SPECIFICATION  . Rotate pinion to seat bearings.
  14. Using INCH lb. torque wrench, measure drive pinion starting torque. If starting torque is not as specified in PINION PRELOAD SPECIFICATION  , adjust pinion nut until preload torque is within specification. DO NOT  exceed maximum torque specification.
    PINION PRELOAD SPECIFICATION

    Application Nut Torque Ft. Lbs. (N.m) (1) Starting Torque INCH Lbs. (N.m)
    New Bearing 130-203 (177-275) 6.2-9.7 (.7-1.1)
    Used Bearing 66-101 (89-137) 3.5-4.4 (.4-.5)
    (1)
    Staring torque is initial force required to rotate pinion, measured at flange.
    NOTE: DO NOT  loosen pinion nut to decrease preload. If preload is exceeded, a NEW collapsible spacer must be installed and nut retightened until proper preload is attained.
  15. Install differential assembly and side bearing races into axle housing. Insert feeler gauge of sufficient thickness between each bearing race and axle housing to remove all end play. Ensure each feeler gauge extends to bottom of bearing bores. Lock drive pinion in place.
  16. Using a dial indicator, measure ring gear backlash. If backlash is not .005-.007" (.13-.18 mm), select feeler gauge thickness on each side to adjust backlash. With zero end play and correct backlash, remove feeler gauges.
  17. To determine required thicknesses of shim packs, add .002" (.05 mm) to each feeler gauge thickness. Always use NEW shims. Remove differential assembly. Remove side bearings. Install NEW shim packs. Install side bearings onto differential assembly.
  18. Install differential assembly and bearing races into axle housing. Install bearing caps in original locations. Tighten bolts to specification. See TORQUE SPECIFICATIONS  .
  19. Measure ring gear runout. If runout exceeds .002" (.05 mm), correct by cleaning or replacing parts. Check gear tooth contact. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION.
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