ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Axle Housing Assembly

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REMOVAL & INSTALLATION



1981-87 Pick-Up and 1985-87 Trooper Models

See Figure 1

  1. Apply the parking brake and block the rear wheels.
  2.  
  3. Raise and safely support the front of the vehicle on jackstands.
  4.  
  5. Remove the front wheels and underside skid plate.
  6.  
  7. Remove the front brake calipers and caliper mounting brackets. Do not disconnect the brake line. Hang the brake calipers from a wire, do not allow the calipers to hang from the brake hoses. For more information, refer to Brakes .
  8.  
  9. Remove the locking hub assembly and rotors on both sides, as described earlier in this section.
  10.  
  11. Remove the steering knuckles and steering linkage, as described in Suspension & Steering .
  12.  
  13. Matchmark and disconnect the front driveshaft from the differential unit, as described earlier in this section.
  14.  
  15. Support the axle housing with 2 hydraulic floor jacks (one under each mounting bracket).
  16.  
  17. Remove the 4 axle housing mounting nuts (2 on each mounting bracket), the flat washers and the bushings.
  18.  
  19. Carefully lower the axle housing out of the vehicle, then pull it out from under the vehicle.
  20.  

To install:
  1. Position the axle housing, on the 2 floor jacks, under the front of the vehicle, then slowly raise the axle housing into position.
  2.  
  3. Position the axle housing so the mounting bolts are installed in the mounting bracket holes, then install the bushings, washers and tighten the mounting bracket nuts to 29-51 ft. lbs. (39-69 Nm).
  4.  
  5. Remove the 2 floor jacks.
  6.  
  7. Install the steering knuckles and steering linkage. For more details, refer to General Information & Maintenance .
  8.  
  9. Connect the driveshaft to the front differential, as described earlier in this section.
  10.  
  11. Install the rotors and locking hub assemblies on both sides.
  12.  
  13. Install the front disc brake calipers and caliper mounting brackets.
  14.  
  15. Install the front wheels and skid plate.
  16.  
  17. Lower the vehicle and adjust ride height.
  18.  
  19. Refill the differential with the proper lubricant. For more information regarding filling the front drive axle, refer to General Information & Maintenance . If necessary, bleed the brake system.
  20.  
  21. Road test the vehicle and verify proper operation.
  22.  



Click image to see an enlarged view

Fig. Fig. 1: Front axle assembly on all 1981-95 models

1988-96 Models

See Figures 1, 2 and 3

The procedure for the 1996 Trooper and Rodeo models is very similar to the earlier models, however since the 1996 models utilize a shift-on-the-fly system, certain steps will vary.

  1. Shift the transfer case shift lever into 2H . Drive the vehicle a few feet forward and reverse to verify that the front axle is disengaged.
  2.  
  3. Set the front wheels and steering wheel in the straight-ahead position. Lock the steering column in this position, and remove the key.
  4.  
  5. Apply the parking brake and block the rear wheels.
  6.  
  7. Raise and safely support the front of the vehicle on jackstands.
  8.  
  9. Remove the front wheels.
  10.  
  11. Remove the radiator skid plate.
  12.  
  13. Remove the transfer case skid plates.
  14.  
  15. Drain the oil from the differential.
  16.  
  17. Unbolt the calipers from their brackets. Support the calipers out of the way on wire hangers. Don't disconnect the brake hoses. For more information, refer to Brakes .
  18.  
  19. Remove the caliper mounting brackets from the steering knuckle.
  20.  
  21. Remove the automatic hub and brake rotor assemblies. Note the positions of the hub snaprings, shims, and lockwashers for reassembly.
  22.  
  23. If equipped with four-wheel ABS, unbolt the front wheel sensor brackets from the steering knuckles. Move the sensors out of the work area. They don't need to be disconnected.
  24.  
  25. On 1996 models, remove the shift-on-the-fly four-wheel drive actuator, as follows:
    1. Remove the skid plate from the shift-on-the-fly gear housing.
    2.  
    3. Label and disconnect the Vacuum Switching Valve (VSV) hoses and 2P connector from the gear housing.
    4.  
    5. Unbolt the VSV assembly from the left axle tube and remove it so it will not be damaged. Do not disconnect the 2 vacuum hoses from the body of the VSV.
    6.  

  26.  
  27. Use a ball joint separator tool to disconnect the upper and lower ball joints and tie rod ends, and then remove the steering knuckles.
  28.  
  29. Matchmark and disconnect the pitman arm and idler arm. Remove the steering linkage as an assembly.
  30.  
  31. Unbolt and remove the suspension crossmember from its brackets at the lower control arms.
  32.  
  33. Matchmark the front driveshaft flanges to the differential flange and transfer case flange. Unbolt and remove the front driveshaft.
  34.  
  35. Support the front axle assembly with a floor jack and safety stands.
  36.  
  37. Remove the 4 bolts which secure the right halfshaft axle mounting bracket to the differential. Do not unbolt the left halfshaft from the axle.
  38.  
  39. Remove the mounting bracket bolts which secure the right and left axle mounting brackets to the vehicle's frame.
  40.  
  41. Separate the right halfshaft and axle mounting bracket assembly from the differential and allow it to rest on the lower control arm.
  42.  


WARNING
Be careful not to damage the CV-joints, boots, or splined shafts when removing the axle.

  1. Follow these steps to remove the axle assembly:
    1. Verify that the axle assembly is securely supported by the floor jack. Remove the safety stands.
    2.  
    3. First, slide the axle to the left to release the splined stub axle of the right halfshaft.
    4.  
    5. Next, lower the axle slightly and slide it to the right so the left halfshaft clears the left lower control arm.
    6.  
    7. Finally, completely lower the axle from the vehicle.
    8.  

  2.  
  3. Remove the right halfshaft from the vehicle.
  4.  

To install:

Use new self-locking nuts and color-coded bolts when assembling the axle assembly mounts and suspension components. Suspension fasteners should be tightened to their final torque specifications when the vehicle is on the ground.

  1. Place the right halfshaft and axle mounting bracket assembly into position, and rest it on the right lower control arm.
  2.  
  3. Position the axle and left halfshaft assembly on a floor jack. Raise the axle into position.
  4.  
  5. Fit the right halfshaft and axle mounting bracket assembly into the differential. Make sure the splined stub axle shaft is fully seated. Be careful not to distort the oil seal when connecting the right mounting bracket to the differential.
  6.  
  7. Tighten the right halfshaft and axle mounting bracket assembly mounting bolts in a crisscross fashion to the following values:

    1996 Rodeo and 1995-96 Trooper-85 ft. lbs. (116 Nm)
     
    1995 1 / 2 Rodeo with an air bag-85 ft. lbs. (116 Nm)
     
    1988-95 Amigo, Rodeo and Pick-Up-61 ft. lbs. (82 Nm)
     
    1988-94 Trooper-61 ft. lbs. (82 Nm)
     

  8.  
  9. Raise the axle assembly into its final position and support it with safety stands.
  10.  
  11. Install the mounting bracket bolts, nuts, and spacers. The washer fits under the bolt and the spacer is used with the nut. Tighten the mounting nuts and bolts to 112 ft. lbs. (152 Nm).
  12.  
  13. Install the steering knuckles and assemble any suspension components that were disconnected or removed.
  14.  
  15. Install the brake backing plates and the rotor and hub assemblies.
  16.  
  17. Install the caliper mounting brackets and the brake calipers.
  18.  
  19. If equipped, install the VSV onto the axle tube. Reconnect the vacuum hoses and the 2P connector. Then, install the VSV skid plate.
  20.  
  21. Refill the differential with gear oil. Check the oil level in the gear case. Use new crush washers and tighten both drain plugs to 58 ft. lbs. (78 Nm).
  22.  
  23. Verify that all axle assembly mounting components have been installed.
  24.  
  25. Align the front driveshaft matchmarks. Install the driveshaft flange bolts and tighten them to 46 ft. lbs. (63 Nm).
  26.  
  27. Install the suspension crossmember and tighten the bolts to 58 ft. lbs. (78 Nm).
  28.  
  29. Install the steering linkage assembly.
  30.  
  31. If equipped, reconnect the ABS front wheel sensors.
  32.  
  33. Install the radiator skid plate. Tighten the bolts to 58 ft. lbs. (78 Nm).
  34.  
  35. Install the transfer case skid plates and tighten their bolts to 27 ft. lbs. (37 Nm).
  36.  
  37. If necessary, bleed the brake system.
  38.  
  39. Install the front wheels.
  40.  
  41. Lower the vehicle and remove the rear wheel blocks.
  42.  
  43. Tighten the suspension bushing fasteners to their final torque specifications.
  44.  
  45. Verify that the front axle and hubs engage and disengage properly.
  46.  
  47. If equipped with shift-on-the-fly four-wheel drive, make sure the VSV and actuator function correctly.
  48.  
  49. Check and adjust the front wheel alignment and ride height.
  50.  
  51. Road test the vehicle.
  52.  



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the front axle and mounting fasteners-1996 Trooper and Rodeo models



Click image to see an enlarged view

Fig. Fig. 3: Make sure to install the front axle mounting bracket bolts in the proper direction

 
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