Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 1151

4C–16

DRIVE SHAFT SYSTEM

Shift On The Fly System

Shift On The Fly System and Associated Parts

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Legend

(1) Filler Plug
(2) Bolt
(3) Oil Seal
(4) Snap Ring(External)
(5) Inner Shaft Bearing
(6) Snap Ring(Internal)
(7) Inner Shaft

(8) Needle Bearing
(9) Clutch Gear

(10) Sleeve

(11) Housing

(12) Front Axle Drive Shaft(LH side) with Bracket
(13) Bolt
(14) Actuator Assembly
(15) Bolt

DRIVE SHAFT SYSTEM

4C–17

Disassembly

1. Remove filler plug and gasket, drain oil.

2. Loosen mounting bracket fitting bolts and remove

front axle drive shaft from front axle case.

3. Remove actuator assembly and draw out actuator

ASM.

4. Remove housing.

5. Remove sleeve.

6. Remove clutch gear.

7. Remove snap ring from front axle case by using

snap ring pliers.

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8. Take out inner shaft from front axle case.

9. Remove snap ring from inner shaft by using snap

ring pliers.

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10. Remove inner shaft bearing.

NOTE:  Be careful not to damage the shaft.

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11. Remove needle bearing from inner shaft by using a

remover J–26941 and sliding hammer J–2619–01.

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12. Remove oil seal from front axle case.

NOTE:  Be careful not to damage the front axle case.

4C–18

DRIVE SHAFT SYSTEM

Inspection And Repair

Inspect the removed parts. If there are abnormalities
such as wear and damage, take corrective action or
replace.

Visual Check

1. Check and see if the inner shaft has such

abnormalities as wear and damage.

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2. Replace the shaft if any signs of deterioration in the

gear is present.

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Inner Shaft Run–Out

With both end centers supported, rotate the shaft slowly
and measure deflection with a dial gauge.

Limit:0.5 mm (0.02 in)

NOTE:  Do not heat the shaft to correct its bend.

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Inner Shaft Bearing

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1. Inspect the inner shaft bearing for any signs of

deterioration, replace if uneven.

2. Insert the clutch gear and inspect the needle

bearing.

3. Replace the needle bearing if found to be uneven.

Legend

(1) Inner Shaft Bearing
(2) Inner Shaft
(3) Clutch Gear

DRIVE SHAFT SYSTEM

4C–19

Sleeve Condition

Check and see that there is not wear damage, or
cracking in the sleeve.

NOTE:  Close inspection of the groove and inner gear
are required because those are important parts.

Sleeve Function

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Test the sleeve for smoothness by sliding it between the
inner shaft and the clutch gear, replace the   sleeve if its
difficult to slide.

NOTE:  Gear oil should be applied to the contact
surface of gear.
Check the width of sleeve center groove.

Limit:7.1 mm (0.28 in)

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Clutch Gear Condition

Check for wear, damage, crack or any other
deterioration in the clutch gear.

Clutch Gear Function

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Test the sleeve for smoothness by sliding it across the
clutch gear, replace the clutch gear if its   difficult to
slide.

NOTE:  When inspecting, gear oil should be applied to
the contact surface of gear.

Clutch Gear Journal Diameter

Make sure of the size illustrated.

Limit:36.98 mm (1.456 in)

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