Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Instruction - page 89

4A2–14

DIFFERNTIAL (REAR)

Inspecting the Axle Before
Disassembly

1. Remove the axle cover from the rear axle and drain

the axle lubricant into a suitable container.

2. Check ring gear backlash. Refer to

Backlash

Adjustment in this section. This information can be
used to determine the cause of the axle problem. It
will also help when setting up the shim packs for
locating and preloading the differential cage.

3. Check case for metal chips and shavings. Determine

where these chips and shavings come from, such as
a broken gear or bearing cage.

D

If possible, determine the cause of the axle problem
before disassembly.

Disassembly

1. Remove axle shafts.

D

Refer to

axle shaft replacement in this section.

2. Remove ABS sensor.
3. Remove bearing caps and bolts.

D

Mark the caps and the housing as left and right.

CAUTION: Bearing caps are machined with the
housing and must be assembled in the same
position as removed. Note the matched letter
stamped on the caps and carrier. When assembled,
the letters on the caps must agree in both the
hosizontal and vertical position with the letters on
the carrier.

420RW003

4. Remove Differential case.

D

Pry the case from the axle housing at the differential
“window”.

420RW010

5. Remove side bearing outer races and shims.

D

Mark the races and shims as left and right, and
place them with the bearing cups.

6. Remove differential side bearings using remover

J–42379 and plug J–39830.

D

Select insert ; 303174 and collet halves ; 44801 in
remover kit J–42379.

415RW003

7. Remove ring gear bolts.

D

Ring gear bolts use right handed threads.

CAUTION: DO not pry the ring gear from the case.
This will damage the ring and the differential case.

DIFFERENTIAL (REAR)

4A2–15

8. Remove ring gear from the differential.

D

Drive the ring gear off with a brass drift if necessary.

D

Check drive pinion bearing preload.

425RW018

D

Check the pinion assembly for looseness by
moving it back and forth. (Looseness indicates
excessive bearing wear.)

9. Remove pinion flange nut and washer.

D

Use flange holder J–8614–01 to hold the pinion
flange.

10. Remove pinion flange.

D

Use flange holder J–8614–01 to remove the pinion
flange.

415RS018

11. Remove pinion from the axle housing.

D

Thread the pinion nut halfway onto the pinion.

D

Drive the pinion out of the housing with a hammer
and a soft drift.

D

Remove the nut and then remove the pinion.

12. Remove collapsible spacer(1).

415RW011

13. Remove outer seal, outer oil slinger and outer pinion

bearing.

14. Remove inner bearing, inner oil slinger and shim from

the pinion.

D

Press the bearing off the pinion using remover
J–42379.

415RW004

D

Select insert ; 303174 and collet halves ; 44801 in
remover kit J–42379.

D

Remove the shim.

15. Remove bearing cups and baffle plate from the axle

housing using a hammer and a punch.

D

Work the cups out of the housing evenly, moving the
punch back and forth between one side of the cup
and the other.

D

The baffle plate will be destroyed and should be
replaced with a new one.

4A2–16

DIFFERNTIAL (REAR)

16. Remove exciter ring.

D

Remove the exciter ring from the differential using a
mallet or a brass hammer if it is required.

NOTE: Discard the exciter ring after removal.

425RS097

Cleaning

Do not steam clean drive parts which have ground and
polished surfaces such as gears, bearings, and shafts.
These parts should be cleaned in a suitable solvent. All
parts should be disassembled before cleaning.
Parts should be thoroughly dried immediately after
cleaning. Use soft, clean, lintless rags. Parts may be dried
with cimpressed air. Do not allow the bearings to spin
while drying them with compressed air.

Inspection and Repair

It is very important to carefully and thoroughly inspect all
drive unit parts before reassembly.
Thorough inspection of the drive parts for wear or stress
and subsequent replacement of worn parts will eliminate
costly drive component repair after reassembly.

Axle Housing

D

The carrier bore for nicks or burrs that would prevent
the outer diameter of the pinion seal from sealing,
Remove any burrs that are found.

D

The bearing cap bores for nicks or burrs.
Remove any burrs that are found.

D

The housing for cracks. Replace the housing if any
cracks are found.

D

The housing for foreign material such as metal chips,
dirt, or rust.

Pinion and Ring Gear

D

Pinion and ring gear teeth for cracking, chipping,
scoring, or excessive wear.

D

Pinion splines for wear.

D

Pinion flange splines for wear.

D

The sealing surface of the pinion flange for nicks,
burrs, or rough tool marks which would cause
damage to the seal’s inside diameter and result in an
oil leak.

D

Replace all worn or broken parts.

D

Ring and pinion gears are matched sets and are both
replaced anytime a replacement of either is
necessary.

Bearings

D

Bearings visually and by feel.

D

The bearings should feel smooth when oiled and
rotated while applying as much hand pressure as
possible.
The large end of the bearing rollers for wear.
This is where tapered roller bearing wear is most
evident.

D

Bearing cups for wear, cracks, brinelling and scoring.

D

Bearing and cups are only replaced as sets.

D

If the rear axle was operated for an extended period of
time with very loose bearings, the ring gear and drive
pinion will also require replacement.

D

Low mileage bearings may have minute scratches
and pits on the rollers and the bearing cups from the
initial pre-load. Do not replace a bearing for this
reason.

D

Bearing cups for cracks or chips.

Shims

D

Shims for cracks and chips. Damaged shims should
be replaced with an equally sized service shim.

Reassembly

1. Install pinion bearing races and baffle plate using

outer bearing race installer J–8611–01 / inner bearing
race installer J–42836 and drive handle J–8592.

NOTE: Baffle plate must be installed, when install the
inner pinion bearing race.

425RW019

DIFFERENTIAL (REAR)

4A2–17

425RW020

2. Clean all the gauge parts.
3. Lubricate the outer and inner bearings with axle

lubricant.

4. Place the bearings into the pinion bearing races.
5. Place the inner oil slinger onto the inner pinion

bearing.

NOTE: The inner oil slinger must be placed between
gauge plate and inner pinion bearing when measuring the
pinion depth.

6. Install gauge plate J–39837–2, inner J–42827 stud

and nut J–21777–43 and outer pilot J–42824 to the
pinion bore.

420RW005

7. Hold the stud stationary at the flats of the stud (and).

Tighten the stud nut
Torque: 2.2 N·m (1.6 lb ft)

8. Rotate the gauge plate and bearings several

complete revolutions to seat the bearings.

9. Tighten the stud nut until a torque of 1.6 to 2.2 N·m

(1.2 to 1.6 lb ft.) is required to keep the gauge plate in
rotation.

10. Assemble discs J–39837–1, arbor J–23597–1 and

dial indicator J–8001 to the side bearing bores.

NOTE: The bearing bores must be clean and burr-free.

420RW005

11. Install the side bearing caps and tighten the bolts to

the specified torque.

Torque: 108 N·m (80 lb ft)

12. Rotate the gauge plate until the gauging area is

parallel with the discs.

13. Position the arbor assembly in the carrier so that the

plunger is centered on the gauge area of the gauge
plate.

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