Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 1971

4C2-4 SERVICE INFORMATION

• When transfer lever is shifted from 2H to 4H, indicator light is not actuated.

Trace this chart from the start
after repair or replace.

Trace this chart from the start
after repair or replace.

Trace this chart from the start after
repair.

Disassemble axle ASM for check.

Does actuator work all right?
Is the circuit to actuator all right?

⋅ Is controller all right?

⋅ Is the circuit to controller all right?

Yes

No

Yes

Yes

No

Yes

No

No

All right.

Trace this chart from the start after
repair.

Disassemble axle ASM for check.

⋅ Is actuator switch all right?

⋅ Is the circuit to indicator all right?

When the left side of front wheel is
rotated, the right side dose not rotates.

Jack up from tires.

Drive show 100 - 200m after a few
minutes’ idling. As a result, indicator light
is actuated.

SERVICE INFORMATION 4C2-5

SERVICE STANDARD

Items

Service Standard

Servise Limit

Wear of the Thrust Washer

mm (in)

1.3 (0.05)

Depth of the Differential Cage

(A-B)

(See Text)

mm (in)

(C)

(See Text)

mm (in)

80.58 (3.17)

10.58 (0.41)

Depth of the Differential Cage

(F-B)

(See Text)

mm (in)

(G)

(See Text)

mm (in)

82.03 (3.23)

12.03 (0.47)

Limited Slip Differential Starting Torque

N

⋅m (kg⋅m/lb⋅ft)

64-98 (6.5-10.0/47-72)

FRONT DIFFERENTIAL

Pinion Bearing Starting Torque

New Bearing

N

⋅m (kg⋅cm/lb⋅in)

Used Bearing

N

⋅m (kg⋅cm/lb⋅in)

0.7-1.1 (6.5-11.5/5.64-9.98)

0.4-0.5 (3.3-5.7/2.86-4.94)

Ring Gear Backlash

mm (in)

0.155 (0.006)

Ring Gear Run-Out

mm (in)

0.02 (0.001)

0.05 (0.002)

Clearance between the Differential
Pinion and the Cross Pin

mm (in)

0.06-0.12 (0.002-0.005)

0.2 (0.008)

Clearance between the Side Gear and
the Differential Box

mm (in)

0.03-0.10 (0.001-0.004)

0.15 (0.006)

Play in Splines between the Side Gear and
the Axle Shaft

mm (in)

0.07-0.36 (0.003-0.014)

0.5 (0.02)

Backlash between the Side Gear and the
Pinion Gear

mm (in)

0.03-0.08 (0.001-0.003)

SHIFT ON THE FLY SYSTEM

Inner shaft Deflection

mm (in)

0.5 (0.02)

Sleeve center Groove

mm (in)

7.1 (0.28)

Clutch Gear Out side diameter

mm (in)

36.98 (1.46)

FRONT HUB

Front Hub Bearing Preload

New Bearing and New Oil Seal

N (kg/lb)

Reused Bearing and New Oil Seal

N (kg/lb)

20-25 (2-2.5/4.4-5.5)

12-18 (1.2-1.8/2.6-4.0)

FRONT HUB

Clearance between the Free Wheeling
Hub Body and the Snap Ring

mm (in)

0-0.3 (0-0.01)

MANUAL LOCKING HUB GREASE AMOUNT

Hub

g (oz)

Outer Bearing

g (oz)

Inner Bearing

g (oz)

35 (1.23)

10 (0.35)

15 (0.53)

4C2-6 SERVICE INFORMATION

SERVICING

CHANGE THE REAR DIFFERENTIAL GEAR OIL

1. Remove the drain plug and filler plug and, drain the gear oil.

2. Tighten the drain plug to specified torque.

Drain Plug Torgue

N

⋅m (kg⋅m/lb⋅ft)

78 (8/58)

3. Fill the rear axle case with hypoid gear lubricant, to just

below the filler hole.

4. Tighten the filler plug to specified torque.

Filler Plug Torque

N

⋅m (kg⋅m/lb⋅ft)

78 (8/58)

CHANGE THE FRONT DIFFERENTIAL GEAR OIL

1. Remove the drain plug and filler plug, and drain the gear oil.

2. Tighten the drain plug to specified torque.

Drain Plug Torque

N

⋅m (kg⋅m/lb⋅ft)

25 (2.6/19)

3. Fill the rear axle case with hypoid gear lubricant, to just

below the filler hole.

4. Tighten the filler plug to specified torque.

Filler Plug Torque

N

⋅m (kg⋅m/lb⋅ft)

78 (8/58)

INSPECTION OF SHIFT ON THE FLY SYSTEM
GEAR OIL

1. Open filler plug and make sure that the oil up to the plug

port.

If the oil is short, replenish with gear oil GL-5 grade.

2. Tighten the filler plug to specified torque.

Filler Plug Torque

N

⋅m (kg⋅m/lb⋅ft)

78 (8/58)

SERVICE INFORMATION 4C2-7

Front Drive Axle

N

⋅⋅⋅⋅m (kg⋅⋅⋅⋅m/lb⋅⋅⋅⋅ft)