SECTION 4A1 - DIFFERENTIAL (FRONT)
Service Precaution
Front Drive Axle
Diagnosis
Pinion Shaft Oil Seal
Pinion Shaft Oil Seal and
Associated Parts
Removal
Inspection and Repair
Installation
Front Drive Axle Assembly
Front Drive Axle Assembly and
Associated Parts
Removal
Installation
Differential Assembly
Disassembled View
Disassembly
Reassembly
Differential Cage Assembly
Disassembled View
Disassembly
Inspection and Repair
Reassembly
Main Data and Specifications
Special Tools
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM(SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE REFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFOMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED , do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threade d fasteners or
fastener joint interfaces. Generally,such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specification. Following
these instructions can help you avoid damage to
parts and systems.
Techline
Front Drive Axle
Diagnosis
Condition Possible cause Correction
Oil Leak At Front Axle W orn or defective oil seal. Replace the oil seal.
Front axle housing cracked. Repair or replace.
Oil Leak At Pinion Shaft Too much gear oil. Correct the oil level.
Oil seal worn or defective. Repla ce the oil seal.
Pinion flange loose or damaged. Tighten or replace.
Noises In Front Axle Drive Shaft
Joint Broken or worn drive shaft joints and
bellows (BJ and DOJ). Replace the drive shaft joints and
bellows.
“Clank" When Accelerating From
“Coast" Loose drive shaft joint to output
shaft bolts. Tighten.
Damaged inner drive shaft joint. Replace.
Shudder or Vibration During
Acceleration Excessive drive shaft joint angle. Repair.
W orn or damaged drive shaft joints. Replace.
Sticking spider assembly (inner
drive shaft joint). Lubricate or replace.
Sticking joint assembly (outer drive
shaft joint). Lubricate or replace.
Vibration At Highwa y Speeds Out of balance or out of round tires. Balance or replace.
Front end out of alignme nt. Align.
Noises in Front Axle Insufficient gear oil. Replenish the gear oil.
Wrong or poor grade gear oil. Replace the gear oil.
Drive pinion to ring gear backlash
incorrect. Adjust the backlash.
W orn or chipped ring gear, pinion
gear or side gear. Replace the ring gear , pinion gear or
side gear.
Pinion shaft bearing worn. Replace the pinion shaft bearing.
Wheel bearing worn. Replace the wheel bearing.
Diff erential bearing loose or worn. Tighten or replace.
Wanders and Pulls Wheel bearing preload too tight. Adjust the wheel bearing preload.
Incorrect front alignment. Adjust the front alignment.
Steering unit loose or worn. Tighten or replace.
Tire worn or improperly inflated. Adjust the inflation or replace.
F ront or rear suspension parts loose
or broken. Tighten or replace.
Front Wheel Shimmy Wheel bearing worn or improperly
adjusted. Adjust or replace.
Incorrect front alignment. Adjust the front alignment.
W orn ball joint or bush. Replace the ball joint or bush.
Steering unit loose or worn. Tighten or replace.
Tire worn or improperly inflated. Replace or adjust the inflation.
Shock absorber worn. Replace the shock absorber.
Pinion Shaft Oil Seal
Pinion Shaft Oil Seal and Associated Parts
415RX004
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Removal
1. Raise the vehicle and support it at the frame.
The hoist must remain under the front axle housing.
2. Drain the front axle oil by loosening the drain
plug(1).
412RS001
(1) Flange Nut
(2) Flange
(3) Oil Seal
(4) Outer Bearing
(5) C ol la ps ible Space r
3.Remove the front propeller shaft. Refer to Front
Propeller Shaft in this section.
4.Remove flange nut by using pinion flange holder 5–
8840–2157–0.
415RW028
5.Remove flange.
6.Remove oil seal.
7.Remove outer bearing by using remover 5–8840–
2323–0.
415RW048
8.Remove collapsible spacer.
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the following parts.
1.Seal surface of the pinion.
2.Cage bore for burns.
Installation
1.Install collapsible spacer. Discard the used
collapsible spacer and install a new one.
2.Install outer bearing.
NOTE: Do not drive in, but just temporarily set in the
outer bearing by hand, which should be indirectly
pressed in finally by tightening the flange nut.
3.Install oil seal, use oil seal installer 9–8522–1275–0
to install a new oil seal that has grease on seal lip.
415RW021
4.Install flange.
5.Install flange nut, refer to Differential Assembly
Overhaul for flange nut reassembly in this section.
NO TE: Discard the used nut and install a new one.
Front Drive Axle Assembly
Front Drive Axle Assembly and Associated Parts
412RX010
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(1) Propel le r Sha ft
(2) Mounting Nut
(3) Front Axle Case Assembly and Front Drive
Shaft Assembly
(4) Washer
(5) Mounting Bolt
(6) Tie–rod End; Power Steering Unit
(7) Knuckle and Back Plate
(8) Hub and Disc Assembly
(9) Suspension Crossmember
Removal
1.Jack up the vehicle and support it using jack stand.
2.Remove the tire and wheel.
3.Remove the stone guard.
4.Remove the brake caliper fixing bolt and hang the
caliper. Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front Wheel Speed Sensor in Brake
section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7.Remove the propeller shaft, refer to Front Propeller
Shaft in this section.
8.Loosen the height control arm of the torsion bar,
then remove the torsion bar from lower control arm.
refer to Torsion Bar in Suspension section.
9.Remove the suspension crossmember.
10.Remove the lower nut (1) of the stabilizer link.
11.Remove the lower bolt and nut (2) of the shock
absorber.
412RW057
12.Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering Section.
13.Disconnect the hose of the shift on the fly, at the
hose clip portion (1).
14.Disconnect the shift switch connector (2).
412RW058
15.Remove the bolts and nuts of the lower control arm
(Frame side), then disconnect the lower control arm
from frame.
16.Disconnect between the right side upper control arm
and the knuckle, then remove the knuckle with lower
control arm.
CAUTION: When removing the knuckle, be careful
not to damage the oil seal inside of the knuc kle.
410RW008
17.Support the differential case by the jack.
18.Remove the front axle mounting bolts and nuts,
lower the jack slowly. Remove the left side drive
shaft end from the knuckle, then lower the axle
assembly from the vehicle.
CAUTION:
1.During the work, be sure that the axle assembly
is supported securly.
2.Be careful not to damage the bellows of the
power steering unit by interference.
3.Be careful not to damage the hose bracket of the
shift on the fly by interference.
Installation
1.Support the differential case by the jack.
2.Jack up the front drive axle assembly, install the left
side drive shaft to the knuckle, then install the mount
bolts and nuts.
CAUTION:
1.Be careful not to damage the bellows of the
power steering unit by interference.
2.Be careful not to damage the hose bracket of the
shift on the fly by interference.
3.When installing the drive shaft to the knuckle,
be careful not to damage the oil seal inside of
the knuckle.
3.Tighten the mounting bolts and nuts to the specified
torque.
Torque:168N·m (17.2kg·m/124 lbft)
412RX011
4.Install the right side knuckle with lower control arm
to the upper control arm.
Refer to Knuckle in Suspension section.
CAUTION: When insert the drive shaft to the
knuckle, be careful not to damage the oil seal inside
of the knuckle.
5.Align the bolt hole of the lower control arm, install
the bolts and nuts.
NOTE: Adjust the buffer clearance before tighten the
bolts and nuts of the lower control arm.
6.Install the hose of the shift on the fly (1).
7.Install the shift switch connector (2) of the shift on
the fly.
412RW058
8.Install the tie-rod end of the power steering unit to
the knuckle, tighten the nut to the specified torque.
Torque:118N·m (12.0kg·m/87 lbft)
9.Install lower bolts and nuts of the shock absorber,
tighten it to the specified torque.
Torque:93N·m (9.5kg·m/69 lbft)
10.Install lower nuts of the stabilizer link, tighten it to
the specified torque.
11.Install the suspension crossmember.
12.Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the
bear i ng preload.
Refer to Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake
system.
16. Install the brake caliper. Tighten the bolt of the
caliper bracket to the specified torque.
Torque:50N·m (5.1kg·m/37 lbft)
17. Install the stone guard.
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Steering section.
20. Tighten the bolts and nuts of the lower control arm
to the specified torque.
Refer to Lower Control Arm in Suspension section.
Differential Assembly
Disassembled View
415RX003
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(1) Differential Assembly
(2) Flange Nut
(3) Flange
(4) Dust Cover
(5) Oil Seal
(6) Outer Bearing
(7) Outer Bearing Outer Race
(8) Differential Carrier
(9) Bearing Cap
(10) Bolt
(11) Inner Bearing Outer Race
(12) Collapsible Spacer
(13) P inion Gear
(14) Inner Bearing
(15) A djust Shim
(16) Diff Cage Assembly
(17) Side Bearing Outer Race
(18) Side Bearing
(19) A djust Shim
(20) Bolt
(21) Axle Case
Disassembly
1. Remove differential carrier fixing bolt.
2. Remove differential assembly.
3. Using holding fixture 5–8840–0275–0 and holding
fixture base 5–8840–0003–0, fix the differential
asse mbly to the b ench.
425RW046
4. Remove bearing cap bolt.
5. Apply a setting mark to the side bearing cap and the
differential carrier then remove bearing cap.
425RS009
6. Remove dif ferential cage asse mbly.
7. Remove side bearing outer race, after removal,
keep the right and left hand side bearing assemblies
separate to maintain inner and outer race
combinations.
8. Remove side bearing, using remover 5–8840–
0013–0, 5–88 40–0014–0 and ada pter 9–852 1–
1743–0.
415RW023
9. Remove adjust shim, note the thickness and
pos ition of the shims removed.
10. Remove the fla nge nut using holding w renc h 5–
8840–2157–0 after raising up its staked parts
completely.
425RW057
11. Remove flange.
12. Remove dust cover.
13. Remove the drive pinion assembly using a soft
metal rod and a hammer.
425RS012
14. Remove collapsible spacer.
15. Remove the inner bearing using remover 5–8840–
0015–0 and a press.
415RW033
16. Remove adjust shim.
17. Remove oil seal.
18. Remove oute r bearing.
19. Remove the inner bearing outer race (1) and the
outer bearing outer race (2) by using a brass bar
and a hammer.
425RS014
425RS015
Reassembly
1. Using installer 9–8522–1141–0 and grip 5–8840–
0007–0, ins tal l oute r bea r ing outer race.
415RW018
2. Using installer 9–8522–1274–0 and grip 5–8840–
0007–0, install Inner bearing outer race.
415RW017
3. Install adjust shim and adjust drive pinion mounting
distance:
1. Apply gear oil to the inner and outer drive pinion
bearing.
Clean the pinion setting gauge set.
Then install the gauge set together with the
inner and oute r bearings.
2. Tighten the nut to the specified torque.
Torque:2.3N·m (0.2kg·m/20lbin)
415RS009
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3. Clean the side bearing bores. Install the dial
indicator with the discs and arbor. Install and
tighten the bearing caps to the specified torque.
Torque:98N·m (10kg·m/72lbft)
415RS010
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(1) Pilot : 5–8840–2085–0
(2) Nut and Bolt: 5–8840–2089–0
(3) Gauge Plate : 5–8840–2087–0
(1) Dial Indi c ator: 5–8840–0 126 –0
(2) Disc (2 pcs.): 5–8840–2088–0
(3) Arbor: 5–8840–0128–0
(4) Gauge Plate: 5–8840–2087–0
4. Set the dial indicator to “0". Place it on the
mounting post of the gauging 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.
425RS020
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5. Position the plunger on the gauge plate. Move
the gauging arbor slowly back and forth and
locate the position at which the dial indicator
shows the greatest defection. At this point, once
again set the dial indicator to “0".
Repeat the procedure to verify the “0" setting.
425RS021
6. After the ZERO setting is obtained, rotate the
gauging arbor until the dial indicator rod does
not touch the gauging plate .
Record the number the dial indicator needle
points to.
425RS022
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7. Record the pinion depth code on the head of the
dri ve 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 f or a smaller mounting distance (which
can be achie ved by increasing the shim
thickness). If examination reveals pinion depth
code “0", the pinion is “nominal".
425RS023
(1) Dial Indicator
(2) Ganging Arbor
(3) Plunger
(4) Gauge Plate
(1) Example=Dial indicator reading of 0.085
8. Select the shim using chart;
NOTE: When ordering shims, find the part number in
the parts catalog by using the thickness of shims listed
in the ablve table.
Pinion
marking +10 +8 +6 +4 +2 0 –2 –4 –6 –8 –10
Dial
indi cator
reading
(Inches) mm
(Inches) mm
(Inches) mm
(Inches) mm
(Inches) mm
(Inches) mm
(Inches) mm
(Inches) mm
(Inches) mm
(Inches) mm
(Inches) mm
(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) 2.23
(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)
02.42
(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)
4. Place the shim on the drive pinion. Install the inner
bearing onto the pinion using an installer 9–8522–
1165–0 and a press.
NOTE: Do not apply pressure to the roller cage and
apply pressure only to the inner race.
425RW067
5. Discard the used coll apsible spacer and install a
new one.
6. Install pinion gear.
7. Install outer bearing.
8. Use oil seal installer 9–8522–1275–0 to install a
new oil seal that has been soaked in front axle
lubricant.
NO TE: Take care to use a front differential oil seal, NO T
the rear differential oil seal.
415RW024
9. Install duct cover.
10. Install flange.
11. Install flange nut.
1. Apply lubricant to the pinion threads.
2. Tighten the nu t to the specif ied to rque using the
pinion flange holder 5–8840–2157–0.
Torque:177-275 N·m(18-28kg·m/130-203lbft)
NO TE: Discard used flange nut and install new one and
do not over tighten the flange nut.
425RW057
3. Adjust 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 flange nut until the
specified starting torque is obtained.
Starting torque:
New bearing:0.7–1.1N·m(6.5–11.5kg·cm/5.6–
10lbin)
Used bearing:0.4–0.5N·m(3.3–5.7kg·cm/2.9–
5.0lbin)
425RS027
4. Using punch 5–8840–2293–0, stake the flange
nut at two points.
NOTE: When staking, be sure to turn the nut to insure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3)
415RW019
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12. Install adjust shim.
1. Attach the side bearing to the differential
assembly without shims. Support the opposite
side using a pilot to prevent bearing damage.
425RS029
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2. Insert the differential cage assembly with
bearing outer races into the side bearing bores
of the carri er.
425RS030
(1) 1.3mm or less
(1) Dr i ve handle:5–8 840 –000 7–0
(2) Installer:9–8522–1164–0
(3) Pilot:9–8521–1743–0
3. Using two sets of feeler gauges, insert a feeler
stock of sufficient thickness between each
bearing outer race and the carrier to remove all
end play. Make certain the feeler stock is pushed
to the bottom of the bearing bores.
Mount the dial indicator 5–8840–0126–0 on the
carrier so that the indicator stem is at right
angles to a tooth on the ring gear.
425RS031
4. Adjust feeler gauge thickness from side to side
until ring gear backlash is in the specified range.
Backlash:0.13–0.18mm(0.005 –0.007in)
425RS032
With zero end play and correct backlash
established, remove the feeler gauge packs,
determine the thickness of the shims required
and add 0.05 mm (0.002 in) to each shim pack
to provide side bearing preload. Alwa ys use new
shims.
5. Use bearing remover 5–8840–0013–0, 5–8840–
0014–0 and pilot 9–8521–1743–0 to remove
side bearing.
415RW020
13. Install the side bearings together with the selected
shims.
425RS029
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(1) Dr i ve Handle:5–88 40– 000 7–0
(2) Installer: 9–8522–1164–0
(3) Pilot: 9–8521–1743–0
14. Install side bearing outer race.
15. Install differential cage assembly.
16. Install bearing cap then align the setting marks(1)
applied at disassembly.
425RS035
17. Tighten the cap bolt to the specified torque.
Torque:98N·m (10kg·m/72lbft)
425RS036
1. Measure the amount of run-out of the ring gear
at its rear face.
Standard: 0.02 mm (0.001 in)
Limit: 0.05 mm (0.002 in)
425RS037
Gear Tooth Contact Pattern Check and
Adjustment
1. Apply a thin coat of prussian blue or equivalent
to the faces of the 7–8 teeth of the ring gear.
Check the impression of contact on the ring
gear teeth and make necessary adjustment as
described in illustration if the contact is
abnormal.
425RS038
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425RS039
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)
18. Install differential assembly.
1. Clean the faces of the front axle case and
differential carr ier.
Apply Three Bond TB1215 or equivalent to the
sealing side of the axle case and the carrier.
2. Attach the differential case and the carrier
assembly to the front axle case and tighten the
nuts and bolts.
Torque:25N·m(2.5kg·m/19lbft)
415RS014
3. Fill the axle case with hypoid gear lubricant, to
just below the filler hole.
Lubricant capacity:1.4liter(1.2 Imp qt/1.5 USqt)
Differential Cage Assembly
Disassembled View
415RS015
Legend
EndOFCallout
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin, break staking on the lock pin,
using a 5mm (0.20 in) diameter drill.
425RS042
(1) Pinion Gear
(2) Thrust Washer
(3) Side Gear
(4) Cross Pin
(5) Ring Gear
(6) Bolt
(7) Differential Cage
(8) Lock Pin
4. Remove the cross pin, using a soft metal rod and a
hammer.
425RS043
5. Remove pinion gear.
6. Remove side gear.
7. Remove thrust washer.
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the following parts.
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard used bolts and install new ones.
3. When installing the ring gear , apply LOCTITE 271 or
equivalent to all the threaded area and half of the
unthreaded area of the bolt.
4. Discard used bolts and install new ones..
Torque:108N·m(11.0Kg·m/80lbft)
415RS016
Clearance between the differential pinion
and the cross pin measurement:
Standard: 0.06 - 0.12 mm (0.002 - 0.005 in)
Limit: 0.2 mm (0.008 in)
425RS045
Clearance between the side gear and the
differential box:
Standard: 0.03 - 0.10 mm (0.001 - 0.004 in)
Limit: 0.15 mm (0.006 in)
425RS046
Legend
EndOFCallout
Play in splines between the side gear and
the axl e sh aft :
Standard: 0.08 - 0.36 mm (0.003 - 0.014 in)
Limit: 0.5 mm (0.02 in)
425RS047
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear with thrust washer by
engaging it with the side gears while turning both
pinion gears simultaneously in the same direction.
425RS048
4. Install cross pin.
1. Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
425RS049
(1) Side Gear
(2) Differential Box
2. Adjust the backlash between the side gear and
the pinion gear.
Backlash: 0.03 - 0.08 mm (0.001 - 0.003 in)
Thickness of thrust washers available:
1.00mm, 1.05mm, 1.10mm(0.039in, 0.041in,
0.043in)
425RS050
5. Install lock pin. After lock pin installation, stake the
cage to secure the lock pin.
425RS051
Legend
EndOFCallout
6. Clean the ring gear threaded holes to remove the
locking agent. When installing the ring gear, apply
LOCTITE 271 or equiv alent to all the threaded area
and half of the unthreaded area of the bolt.
7. Tighten the bolts in diagonal sequence as
illustrated.
Torque:108N·m(11.0kg·m/80lbft)
NO TE: Discard used bolts and install new ones.
415RS016
(1) Staked Portion
(2) Lock Pin
Main Data and Specifications
General Specifications
Axle tube Type It consists of the duct, a cast iron housing and the axle
tube.
Gear type Hypoid
Gear ratio (to 1) 4.100 (6VD1 with A/T)
4.300 (6VD1 with M/T)
4.777 (X22SE with M/T)
Diff erential type Two pinion
Oil capacity liter (US qt) 1.4 (1.5) (Differential)
0.12 (0.13) (Actuator Housing: Shift on the fly)
Type of lubricant GL–5 (75W–90)
Axle shaft type Constant velocity joint (Birfield joint type and double offset
joint)
Hub locking Type Rigid
Torque Specifications
E04RX008
E04RX014
Special Tools
ILLUSTRATION TOOL NO.
TOOL NAME
5–8840–2157–0
(J–37221)
Holder; Pinion flange
9–8522–1275–0
(J–24250)
Installer; Oil seal
5–8840–0275–0
(J–37264)
Differential holding fixture
(Use with 5–8840–0003–
0 base)
5–8840–0003–0
(J–3289–20)
Holding fixture base
5–8840–0013–0
5–8840–0014–0
(J–22888)
Puller; Side bearing
9–8521–1743–0
(J–8107–2)
Adapter; Side bearing
plug
5–8840–0015–0
(J–22912–01)
Separator
9–8522–1141–0
(J–24256)
Installer; Outer bearing
outer race
5–8840–0007–0
(J–8092)
Driver handle
9–8522–1274–0
(J–24252)
Installer; Inner bearing
outer race
ILLUSTRATION TOOL NO.
TOOL NAME
5–8840–2085–0
(J–21777–42)
Pilot
5–8840–2089–0
(J–23597–9)
Nut and bolt
5–8840–2087–0
(J–23597–7)
Gauge plate
5–8840–0126–0
(J–8001)
Dial indicator
5–8840–2088–0
(J–23597–8)
Disc
5–8840–0128–0
(J–23597–1)
Arbor
ILLUSTRATION TOOL NO.
TOOL NAME
9–8522–1165–0
(J–6133–01)
Installer; Pinion bearing
5–8840–2293–0
(J–39209)
Punch; End nut lock
9–8522–1164–0
(J–24244)
Installer; Side bearing
5–8840–2323–0
(J–39602)
Remover; Outer bearing
ILLUSTRATION TOOL NO.
TOOL NAME