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Home >> Isuzu Truck >> 1999 >> Hombre S Regular Cab 2WD L4-2.2L CPC >> Repair and Diagnosis >> Transmission and Drivetrain >> Differential Assembly >> Service and Repair >> Unit Overhaul >> Standard >> Disassembly

Disassembly

Drive Axle Disassemble

Disassembly Procedure

Tools Required
- J 2619-01 Slide Hammer
- J 22813-01 Axle Bearing Puller
- J 8107-2 Differential Side Bearing Remover Plug
- J 22888 Side Bearing Remover
- J 8614-01 Companion Flange Holder
- J 25320 Rear Pinion Bearing Remover

1. Raise the vehicle. Support the vehicle.
2. Support the axle with a suitable portable safety stand.
3. Remove both brake drums.




4. Remove the axle cover bolts, the cover and the gasket. Drain the axle lubricant.




5. Remove the pinion shaft lock bolt.
6. Remove the pinion shaft.
- Push the axle shaft in towards the center of the differential case. Remove the Cycles if lock from the end of the axle shaft.




7. Remove the axle shaft from the axle housing.
8. Remove the oil seal, using a special removal tool. Do not to damage the housing.

Important: The tangs of the tool must engage the bearing outer race.




9. Remove the bearing, using J 2619-01 and J 22813-01.




10. Remove the differential pinion and the side gears.
11. Bolt the pinion gears out of the case with the pinion thrust washers.
12. Mark the gears and the differential case left and right when removing the side gears and the side gear thrust washers.
13. Remove the bearing caps and bolts. Mark the caps and the housing left and right.

Notice: When prying the differential case out of the axle housing, be careful not to damage the cover gasket surface. The differential case must be supported when being removed to prevent falling and possible damage.

14. Remove the differential case.




15. Pry the case from the axle housing at the differential window.
16. Remove the bearing outer races, the shims, and the spacers.
17. Mark the races and shims left and right. Place the races and the shims with the bearing caps.




18. Remove the differential side bearings, using J 8107-2 and J 22888. The jaws of J 22888 must pull from beneath the bearing cone and not the cage.




19. Remove the left handed threaded ring gear bolts.

Notice: Do not pry the ring gear from the case. This Will damage the ring gear and differential case.

20. Remove the ring gear from the differential. Drive the gear off with a brass drift if necessary.
21. Check the differential drive pinion bearing preload.
- If there is no reading, check the drive pinion gear for looseness by shaking the gear.
- When operating the rear axle for an extended period of time with loose bearings or a worn yoke, you will need to replace the ring and pinion gear.
22. Check the pinion assembly for looseness by moving the pinion back and forth. Looseness indicates excessive bearing wear.




23. Remove the pinion flange nut and washer using J 8614-01 to hold the pinion flange.




24. Remove the pinion flange using J 8614-01.




25. Remove the pinion from the axle housing.
- Thread the pinion nut halfway onto the pinion.
- Install the differential cover with two bolts in order to prevent the pinion from falling.
- Drive the pinion out of the housing with a hammer and a drift. Remove the pinion and cover.




26. Remove the collapsible spacer from the pinion. Discard the spacer.
27. Remove the outer seal, using a seal removal tool, and the outer pinion bearing.
28. Remove the inner bearing and the shim from the pinion.




29. Press the bearing oft of the pinion using J 25320.
30. Remove the shim.
31. Remove the drive pinion bearing cups from the axle housing using a hammer and punch in the slots provided. Move the punch back and forth between one side of the cup and the other in order to work the cups out of the housing evenly.

Bearings Inspection

Carefully and thoroughly inspect all drive unit parts before assembly. Thorough inspection of the drive parts for wear or stress with subsequent replacement of worn parts eliminates costly drive component repair after assembly.

Important: Headings and cups are matched sets. Replace both bearing and cup when either part requires replacement.
- Oil the bearings. Inspect the bearings for smooth rotation.
- Inspect the bearing rollers for wear.
- Inspect the bearing cups for wear, cracks, brinelling, and scoring.

Shims Inspection

Carefully and thoroughly inspect all drive unit parts before assembly. Thorough inspection of the drive parts for wear or stress with subsequent replacement of worn parts eliminates costly drive component repair after assembly.

Inspect shims for cracks and chips. Replace damaged shims with a service shim of an equal size.


Pinion Depth Adjustment

Installation Procedure

Tools Required
- J 29710 Differential Side Bearing Installer
- J 7818 Rear Pinion Bearing Cup Installer
- J 7817 Front Pinion Bearing Cup Installer J 8092 Driver Handle

1. Install the front pinion bearing cups using the J 29710, the J 7817, and the J 8092.




2. Install the rear pinion bearing cups, using the J 29710, the J 7818, and the J 8092.

Depth Adjustment Procedure

Tools Required
- J 21777-40 Rear Pilot Washer
- J 21777-42 Front Pilot Washer
- J 21777-43 Stud Assembly Bolt
- J 21777-45 Side Bearing Discs
- J 23597-1 Arbor
- J 23597-11 Gauge Plate
- J 8001-1 Dial Indicator Set

1. Clean all the gauge parts.
2. Lubricate the front and rear pinion bearings with axle lubricant.




3. Place the bearings into the pinion bearing cups. Install the J 21777-40, the J 21777-42, the J 21777-43, and the J 23597-11 into the pinion bore.
4. Hold the stud stationary at the flats of the stud.
Tighten
Tighten the stud nut to 2.2 N.m (20 lb in).
5. Rotate the gauge plate and bearings several complete revolutions in order to seat the bearings.
6. In order to keep the gauge plate in rotation, torque the stud nut to 1.6 - 2.2 N.m (15 - 25 lb in).
Tighten
Tighten the stud nut to 1.6 - 2.2 N.m (15 - 25 lb in).
7. Assemble the J 21777-45 , the J 23597-11, and the J 8001 to the differential bearing bores. The bores must be clean and free of burrs.




8. Install the side bearing caps.
9. Tighten the bolts finger tight.
10. Rotate the gauge plate until the gauging areas are parallel with the discs.
11. Position the gauge shaft assembly in the carrier so that the dial indicator rod is centered on the gauge area of the gauge block.
12. Set the dial indicator at zero. Push the indicator shaft down until the needle rotates approximately 3/4 turn clockwise. Tighten the dial indicator in this position.
13. Slowly rotate the gauge shaft back and forth until the dial indicator reads the greatest deflection. This shows when the indicator needle is centered.
14. Set the dial indicator to zero, at the point of greatest deflection. Repeat the rocking action of the gauge shaft in order to verify the zero reading.
15. Rotate the gauge shaft until the dial indicator rod does not touch the gauge block.
16. Record the actual number on the dial indicator. Do not record the number that represents how far the needle travels. This value is the nominal pinion setting.
Example: If the indicator needle moved counterclockwise 1.70 mm (0.067 in) to a dial reading of 0.84 mm (0.033 in), record the dial reading of 0.84 mm (0.033 in). Do not record the reading of 1.70 mm (0.067 in). The dial indicator should be within the 0.50-1.27 mm (0.020-0.050 in) range.
17. All drive pinion gears are manufactured to a nominal depth with no markings. The dial indicator reading is the shim selection.
18. Remove the bearing caps and depth gauging tools.
19. Install the correct pinion shim to the pinion.


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