Isuzu Trooper (1998-2002 year). Manual - part 98

DIFFERENTIAL (FRONT)

4A1–22

4. Remove the cross pin, using a soft metal rod and a

hammer.

425RS043

5. Remove pinion gear.
6. Remove side gear.
7. Remove thrust washer.

Inspection and Repair

Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal conditions are
found through inspection.
Check the following parts:

1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal

Ring gear replacement:

1. The ring gear should always be replaced with the

drive pinion as a set.

2. Clean the ring gear threaded holes to remove the

locking agent.

3. When installing the ring gear, apply LOCTITE 271 or

equivalent to all the threaded area and half of the
unthreaded area of the bolt.

4. Discard used bolts and install new ones.

Torque: 108 N·m (11kg·m/80 lb ft)

5. Tighten the fixing bolts in a diagonal sequence as

illustrated.

415RS016

Clearance between the differential pinion
and the cross pin measurement:

Standard: 0.06 – 0.12 mm (0.002–0.005 in)

Limit: 0.2 mm (0.008 in)

425RS045

4A1–23

DIFFERENTIAL (FRONT)

Clearance between the side gear and the
differential box:

Standard: 0.03–0.10 mm (0.001–0.004 in)

Limit: 0.15 mm(0.006 in)

425RS046

Legend

(1) Side Gear
(2) Differential Box

Play in splines between the side gear and
the axle shaft: 

Standard: 0.08–0.36 mm(0.003 –0.014 in)

Limit:0.5m (0.02 in)

425RS047

Reassembly

1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear by engaging it with the side

gears while turning both pinion gears simultaneously
in the same direction.

425RS048

4. Install cross pin.

1. Be sure to install the cross pin so that it is in

alignment with the lock pin hole in the differential
cage.

425RS049

2. Adjust the backlash between the side gear and

the pinion gear.

Backlash:0.03 – 0.08 mm (0.001– 0.003 in)

DIFFERENTIAL (FRONT)

4A1–24

Thickness of thrust washers available:

1.00 mm, 1.05 mm, 1.10 mm (0.039 in, 0.041 in,
0.043 in)

425RS050

5. Install lock pin. After lock pin installation, stake the

cage to secure the lock pin.

425RS051

Legend

(1) Staked Portion
(2) Lock Pin

6.  Clean the ring gear threaded holes to remove the

locking agent. When installing the ring gear, apply
LOCTITE 271 or equivalent to all the threaded area
and half of the unthreaded area of the bolt.

7. Tighten the bolts in diagonal sequence as illustrated.

Torque: 108 N·m (11kg·m/80 lb ft)

NOTE: Discard used bolts and install new ones.

415RS016

4A1–25

DIFFERENTIAL (FRONT)

Main Data and Specifications

General Specifications

Axle tube Type

It consists of the duct, a cast iron housing and the axle

tube.

Gear type

Hypoid

Gear ratio

(to 1)

4.100(6VE1)

4.300(4JX1, 6VE1)

4.555(4JG2–TC, 6VD1)

4.777(4JG2)

Differential type

Two pinion

Oil capacity

liter (Imp qt/US

qt)

1.4 (1.2/1.5) (Differential)

0.12 (0.11/0.13) (Actuator Housing: Shift on the fly)

Type of lubricant

75W–90 GL–5 (Multi grade type)

Refer to General Information

Axle shaft type

Constant velocity joint 

(Birfield joint type and double offset joint)