Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 92

4A2–26

DIFFERNTIAL (REAR)

Disassembly

1. Remove lock pin using a small drift.

425RS098

2. Remove the differential shaft by using a soft metal rod

and a hammer.

425RS043

3. Remove pinion mate gear and thrust washer.
4. Remove side gear and 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.

D

Ring gear, pinion gear

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Bearing

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Side gear, pinion mate gear, differential shaft

D

Differential case, carrier

D

Thrust washer

D

Oil seal

Reassembly

1. Install side gear with thrust washer.
2. Install the pinion mate gear with thrust washer by

engaging it with the side gears while turning both
pinion mate gears simultaneously in the same
direction.

425RS048

3. Install differential shaft.

1. Be sure to install the differential shaft so that it is in

alignment with the lock pin hole in the differential
case.

425RS049

4. Install lock pin.

After lock pin installation, stake the case to secure the
lock pin.

DIFFERENTIAL (REAR)

4A2–27

Limited Slip Differential Assembly

Disassembled View

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Legend

(1) Thrust Washer–Differential Pinion Mate Gear
(2) Pinion Mate Gear
(3) Dished Spacer
(4) Disc
(5) Plate

(6) Differential Plate Retainer
(7) Lock Pin
(8) Differential Case
(9) Ring Gear Bolts

(10) Differential Shaft

(11) Differential Side Gear

Disassembly

1. Place the holder J–39824 into a vise.

Position the differential on the holder with the ring
gear side down.

2. Remove Lock pin (1) from differential shaft using a

punch.

3. Remove Differential shaft (2) using hammer and

punch.
Place shop towel behind case to prevent differential
shaft from dropping out of case.

425RW005

4A2–28

DIFFERNTIAL (REAR)

4. Assemble clutch pack unloading tool .

a. Install cap J–34174–1 to the bottom differential

side gear.

b. Install threaded screw cap J–34174–2 to top

differential side gear. Thread forcing screws
J–22342–15 into threaded screw cap until it
becomes centered into the bottom cap.

901RW153

c. Tighten forcing screw until tight enough to collapse

dished spacers and allow looseness between side
and pinion mate gears.

5. Both pinion mate gear thrust washers using a shim

stock (1) of 0.51 mm (0.020 in.) or equivalent tool to
push out washers.

425RW007

6. Relieve tension of dished spacers by loosening

forcing screw.

NOTE:

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You may have to adjust the forcing screw slightly to
allow the case to rotate.

7. Assemble LSD service adapter J–39834 onto long

drive handle J–8592.Insert it into differential shaft
hole of case. Pull on handle and rotate case until
pinion mate gears can be removed.

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8. Remove pinion mate gears.
9. Hold side gear top clutch pack (1) with one hand and

remove positraction unloading tools.

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10. Remove top side gear and clutch pack.

NOTE:

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Keep the stack of plates and discs intact and in
exactly the same position while they are being
removed.

11. Remove case from holder.  Turn case with flange or

ring gear side up to allow side gear and clutch pack to
be removed from case.

DIFFERENTIAL (REAR)

4A2–29

12. Remove differential plate retainer from both clutch

packs to allow separation of the plates and discs.

NOTE:

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Keep the discs and plates in the same order as they
were removed.

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Legend  

(1) Differential Plate
(2) Differential Disc
(3) Dished Spacer
(4) Side Gear

Inspection and Repair

Cleaning

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All parts with solvent.

Visual Inspection

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Clean all parts with solvent.

D

Plates and Discs. If any one disc or plate in either
stack shows evidence of excessive wear or scoring,
the complete stack is to be replaced on both sides.

D

Side Gears and Pinion Mate Gears. The gear teeth of
these parts should be checked for extreme wear and
possible cracks. The external teeth of the side gear,
which retain the concentric groove discs, should also
be checked for wear or cracks.

D

If replacement of one gear is required due to wear,
etc., then both side gears, pinion mate gears, and
thrust washers are to be replaced.

D

Differential Shaft. If excessive wear is evident, the
differential shaft should be replaced.

D

Differential Plate Retainers. If wear is evident on any
one of the differential plate retainers, all  four retainers
must be replaced.

D

Differential Case. If scoring, wear or metal pickup is
evident on the machined surfaces, replacement of
the case is necessary.

Reassembly

1. Lubricate thrust face of side gears, plates and discs

with the proper limited slip rear axle lubricant.

2. Assemble plates and discs in exactly in the same

position as they were removed, regardless of whether
they are new or original.

3. Install differential plate retainer to ears of plates.

NOTE:

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Make sure both retainers are Completely seated on
ears of plates.

4. Install clutch pack and side gear into bottom side gear

bore. Make sure clutch pack stays assembled to side
gear splines, and that retainers are completely seated
into pockets of case.

NOTE:

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To prevent clutch pack from falling out of case, hold
clutch pack in place by hand while repositioning case
on bench.

5. Install other side gear and clutch pack. Make sure

clutch pack stays assembled to side gear splines, and
retainers are completely seated into pockets of case.

6. Hold clutch pack in position and assemble screw cap

J–34174–2, cap J–34174–1 and forcing screw
J–22342–15. Tighten forcing  screw into bottom cap
to hold both clutch packs in position.

7. With tools assembled to case, position case on holder

J–39824 by aligning splines of side gear with those of
shaft. Tighten forcing screw to compress clutch packs
in order to provide clearance for pinion mate gears.

901RW069

8. Install pinion mate gears.

D

Place the pinion mate gears into the differential 180
degrees apart.