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Home >> Isuzu Truck >> 1996 >> Trooper V6-3165cc 3.2L SOHC (6VD1) >> Repair and Diagnosis >> Transmission and Drivetrain >> Drive Axles, Bearings and Joints >> Axle Shaft Assembly >> Service and Repair >> Front

Front

Original Equipment Service Manuals for this model show the CV shafts on the front axle being removed after the Front Axle Assembly itself has been removed. It may be possible to remove the front CV shafts without removing the entire Front Axle Assembly, however OE Service Manuals do not show such a procedure. The following is the procedure given in the OE Service Manual.

Front Drive Axle Assembly
Removal






- Jack up the vehicle and support it using jack stands.
- Remove the tire and wheel.
- Remove the drain bolt to drain differential oil.






NOTE:During the work, be sure that the differential case is supported by the jack.

- Remove the brake caliper fixing bolt and hang the caliper.
- Remove the antilock brake system speed sensor. (If equipped with antilock brake system)
1. Remove hub assembly (Disc, back plate and knuckle)
- Remove the locking hub.
- Disconnect the knuckle and the suspension arm.
2. Steering link and arm assembly.
3. Suspension crossmember
4. Propeller shaft
5. Protector
6. Breather Hose
- Remove the hose clips.
- Disconnect breather hoses from front drive axle tube and disconnect housing.
7. Vacuum Hose
- Disconnect vacuum hose from actuator.






7a. Shift switch connector.
8. VSV Assembly
- Be sure not to remove hose and connector from VSV assembly.






9. Mounting bolt and nut
10. Washer and spacer






11. Bolt
- Remove the mounting bracket fixing bolt.






12. Front axle case assembly and front drive shaft assembly (LH side)
- Lower the vehicle and disconnect the RH front drive shaft assembly, and then remove the front axle case assembly and front drive shaft assembly (LH).
13. Front drive shaft assembly (RH)
Installation
13. Front drive shaft assembly (RH)
- Lay the assembly on the lower arm.
12. Front axle case assembly and front drive shaft assembly (LH)
- Place the axle case on the lack, connect to the front drive shaft assembly (RH) before installing to the vehicle.
11. Bolt
- Tighten the mounting bracket fixing bolt to the specified torque.
- Torque N.m (lb.ft) 116 (85)






10. Washer and spacer
9. Mounting bolt and nut. Tighten the mounting bolt and nut to the specified torque.
- Torque N.m (lb.ft) 152 (112)
8. VSV Assembly
- Tighten nuts to specified torque.
- Torque N.m (lb.in) 8 (69)
7a. Shift switch connector
- Install the shift switch connector. Be careful not to allow dust into connector.
7. Vacuum Hose
- Install the actuator side of hose being careful not to allow dust in hose.
6. Breather Hose
5. Protector
- Tighten bolts to specified torque.
- Torque N.m (lb.ft) 26 (20)
4. Propeller shaft
3. Suspension crossmember
2. Steering link and arm assembly
1. Hub assembly (Disc, back plate and knuckle)

Disassembly






NOTE: For the left side, follow the same steps as right side.

1. Band






- Raise the hooked end of the band with a screwdriver or equivalent.
2. Band






3. Circlip
- Pry off with a screwdriver or equivalent
4. Drive shaft joint assembly






5. Ball
- Remove the six balls with a screwdriver or equivalent.






6. Snap ring
- Using snap ring pliers, remove the snap ring fastening the ball retainer to the center shaft
7. Ball retainer
8. Ball guide
9. Bellows






10. Band
- Raise the hooked end of the band with a screwdriver or equivalent.
11. Band
12. Bellows
13. Dust seal
14. BJ shaft assembly
15. Bolt
- Remove the mounting bracket fixing bolts, and then remove the front axle drive shaft from the axle case.
16. DOJ case assembly
17. Axle case and differential
18. Snap ring
19. Bearing
20. Snap ring
21. Oil seal
22. Bracket
23. DOJ case

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.
- Drive shaft joint assembly
- DOJ case, ball, ball guide, ball retainer
- Bellows
- Bearing
- Dust seal, oil seal

Bushing Replacement






- Remove the bushings using a remover and hammer.
- Remover: J-39378-1






Press fit the bushings into the bracket.
- Installer: J-39378-2
- Base: J-39378-3

Reassembly
23. DOJ case
22. Bracket
21. Oil seal
20. Snap ring
19. Bearing
18. Snap ring
17. Axle case and differential
16. DOJ case assembly
15. Bolt
- Tighten the bracket bolt to the specified torque.
- Torque N.m (lb.ft) 116 (85)
14. BJ shaft assembly
- Enclose 50g (1.8 oz) of the specified grease in BJ.
13. Dust seal
12. Bellows
- Apply a thin coat of grease to the shaft for smooth installation.






11. Band
- Note the setting direction.
- After installation, check that the bellows is free from distortion.
10. Band
9. Bellows
8. Ball guide
- Install the ball guide with the smaller diameter side ahead onto the shaft.
7. Ball retainer
6. Snap ring
- Using snap ring pliers, install the snap ring securing the ball retainer to the shaft.






5. Ball
- Align the track on the ball retainer with the window in the cage, and install the six balls into position.

4. Drive shaft joint assembly











- Enclose 50g (1.8 oz) of the specified grease in DOJ case, and after reassembly, move the DOJ longitudinally several times to get to fit.
3. Circlip Install the circlip so that open ends are positioned away from the ball groove.
2. Bellows






- Before installation, insert the appropriate amount of specified grease into the DOJ case. Adjust the air pressure within the bellows by inserting a screwdriver or equivalent, so that it equals atmospheric pressure

1. Band
- After installation, check that the bellows is free from distortion.
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