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

Halfshaft, Bearing and Seal

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REMOVAL & INSTALLATION



Halfshaft Without the DOJ Case

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the right side halfshaft assembly (left halfshaft similar)-If the DOJ case does not need to be removed, the halfshaft can be removed without lowering the front axle assembly

If the DOJ case does not require servicing, as is the case with outer CV-joint servicing or inner CV-joint overhaul, use this procedure. The halfshaft, with the exception of the DOJ case, can be removed without removing the entire front axle assembly.

  1. If equipped with 4-wheel drive, 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 and underside skid plate.
  10.  
  11. 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 .
  12.  
  13. Remove the locking hub assembly and rotors on both sides, as described earlier in this section.
  14.  
  15. If equipped with ABS, unbolt the front wheel sensor brackets from the steering knuckles. Move the sensors out of the work area. They do not need to be disconnected.
  16.  
  17. Use a ball joint separator tool to disconnect the upper and lower ball joints and tie rod ends, and then remove the steering knuckles.
  18.  
  19. If necessary for added clearance, matchmark and disconnect the pitman arm and idler arm. Remove the steering linkage as an assembly.
  20.  
  21. Remove the inner CV-joint boot clamp, then slide the boot away from the joint. To remove the clamp, it may be necessary to pry the hooked end of the clamp up with a small prytool.
  22.  
  23. Remove the circlip from the DOJ case, then pull the halfshaft away from the DOJ case.
  24.  
  25. Remove the halfshaft from the vehicle.
  26.  

To install:
  1. If the halfshaft was not overhauled, clean the DOJ joint of all dirt and grease, then fill the inner boot and DOJ with 5.25 oz. (150g) new grease. Install the halfshaft into the DOJ case and install the circular clip into the groove so the open ends are positioned away from the ball groove.
  2.  
  3. Slide the boot onto the DOJ case, insert a tool under the boot lip to allow the pressure to equalize and tighten the new boot clamps. The boot should be installed so the edge of the smaller end is 6.5 in. (16.5cm) from the opposite edge of the DOJ case.
  4.  
  5. Install the steering knuckles and assemble any suspension components that were disconnected or removed.
  6.  
  7. Install the rotor and hub assemblies, as described earlier in this section.
  8.  
  9. Install the caliper mounting brackets and the brake calipers. For more information, refer to Brakes .
  10.  
  11. If necessary, install the steering linkage assembly.
  12.  
  13. If equipped, reconnect the ABS front wheel sensors.
  14.  
  15. Install the radiator skid plate. Tighten the bolts to 58 ft. lbs. (78 Nm).
  16.  
  17. Install the transfer case skid plates and tighten their bolts to 27 ft. lbs. (37 Nm).
  18.  
  19. Install the front wheels.
  20.  
  21. Lower the vehicle, remove the rear wheel blocks and adjust the ride height.
  22.  
  23. If the steering linkage was removed, have the front wheel alignment checked by a reputable automotive technician.
  24.  
  25. If necessary, bleed the brake system.
  26.  
  27. Verify that the front axle and hubs engage and disengage properly.
  28.  
  29. Road test the vehicle.
  30.  

Entire Halfshaft Assembly, Bearing and Seal

See Figure 1

If the entire halfshaft (including the DOJ case) must be removed from the vehicle, the entire front axle assembly should be removed from the vehicle for ease of disassembly, since the mounting brackets for the axle assembly are also the halfshaft-to-differential mounting brackets. These brackets must be unfastened to remove the inner DOJ case from the assembly.

1981-87 PICK-UP AND 1985-87 TROOPER MODELS

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: Front axle assembly on all 1981-95 models

  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 front differential housing and axles as an assembly. Refer to the axle assembly removal and installation procedure later in this section.
  12.  
  13. Drain the differential case and remove the 4 bolts attaching the axle mounting brackets to the case and to the axle tube flange.
  14.  
  15. Pull the shaft and mounting assemblies from the case on both sides.
  16.  
  17. Remove the outer snapring and remove the front axle shaft bearing.
  18.  
  19. Remove the inner snapring, the O-ring, and the front axle shaft seal.
  20.  
  21. Remove the halfshaft from the axle mounting bracket.
  22.  

To install:
  1. Install the halfshaft into the axle mounting bracket.
  2.  
  3. Install a new grease seal and O-ring.
  4.  
  5. Install the inner snapring, the front axle shaft bearing, and the outer snapring.
  6.  

Before installing the axle shaft bearing, lightly lubricate the bearing with differential lube.

  1. Connect the axle mounting bracket and halfshaft assembly to the differential. Tighten the axle mounting bracket bolts to 40-47 ft. lbs. (54-64 Nm) for 1981-87 Pick-Up models, or to 61 ft. lbs. (83 Nm) for 1985-91 Trooper models.
  2.  
  3. Install the differential and axle assembly into the vehicle.
  4.  
  5. Install the rotors and locking hub assemblies on both sides.
  6.  
  7. Install the front disc brake calipers and caliper mounting brackets.
  8.  
  9. Install the front wheels and skid plate.
  10.  
  11. Lower the vehicle and adjust ride height.
  12.  
  13. 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.
  14.  
  15. Road test the vehicle and verify proper operation.
  16.  

1988-95 TROOPER AND PICK-UP, 1989-94 AMIGO AND 1991-95 RODEO MODELS

See Figures 1 and 2

The right axle shaft is an integral part of the right halfshaft assembly. Removal of the left axle shaft involves disassembling the shift-on-the-fly four-wheel drive gearbox. The inboard joints of both halfshafts fit through the axle mounting brackets, which are bolted to the axle housing, therefore the axle housing should be removed from the vehicle for ease of disassembly.

  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 bracket 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 ABS, unbolt the front wheel sensor brackets from the steering knuckles. Move the sensors out of the work area. They do not need to be disconnected.
  24.  
  25. Use a ball joint separator tool to disconnect the upper and lower ball joints and tie rod ends, and then remove the steering knuckles.
  26.  
  27. Matchmark and disconnect the pitman arm and idler arm. Remove the steering linkage as an assembly.
  28.  
  29. Unbolt and remove the suspension crossmember from its brackets at the lower control arms.
  30.  
  31. Matchmark the front driveshaft flanges to the differential and transfer case flanges. Unbolt and remove the front driveshaft.
  32.  
  33. Support the front axle assembly with a floor jack and safety stands.
  34.  
  35. Remove the 4 bolts which secure the right halfshaft axle mounting bracket to the differential. Do not unbolt the left halfshaft from the axle.
  36.  
  37. Remove the mounting bracket bolts which secure the right and left axle mounting brackets to the vehicle's frame.
  38.  
  39. Separate the right halfshaft and axle mounting bracket assembly from the differential and allow it to rest on the lower control arm. If only the right halfshaft needs servicing, stop the axle removal procedure at this point. Remove the right halfshaft from the vehicle along with the axle assembly mounting bracket. Skip to Step 22 for further right halfshaft disassembly.
  40.  


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, if still installed.
    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. Follow these steps to remove the right axle shaft seal and bearing:
    1. Remove the snapring from the splined shaft.
    2.  
    3. Remove the shaft bearing. Use a puller if necessary, but don't damage the shaft or splines.
    4.  
    5. Remove the inner snapring.
    6.  
    7. Remove the axle mounting bracket and oil seal from the right halfshaft.
    8.  

  4.  
  5. With the axle out of the vehicle, unbolt the left halfshaft from the axle case. Remove the halfshaft together with the left axle mounting bracket.
  6.  
  7. Follow these steps to remove the left axle shaft seal and bearing:
    1. Remove the snapring from the splined shaft.
    2.  
    3. Remove the shaft bearing. Use a puller if necessary, but do not damage the shaft or splines.
    4.  
    5. Remove the inner snapring.
    6.  
    7. Remove the axle mounting bracket and oil seal from the left halfshaft.
    8.  

  8.  

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. Visually inspect the axle shafts for wear and damage.
  2.  
  3. Lightly lubricate the bearing and grease seal with differential oil before installation.
  4.  
  5. Assemble the left and right halfshaft and axle mounting bracket assemblies
    1. Install the axle mounting bracket onto the halfshaft.
    2.  
    3. Lubricate and install a new oil seal.
    4.  
    5. Install a new inner snapring.
    6.  
    7. Install a new bearing.
    8.  
    9. Install a new outer snapring.
    10.  

  6.  
  7. Place the right halfshaft and axle mounting bracket assembly into position, and rest it on the right lower control arm. If only the right halfshaft was removed, skip Step 28.
  8.  
  9. Position the axle and left halfshaft assembly on a floor jack. Raise the axle into position.
  10.  
  11. 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.
  12.  
  13. Install the mounting brackets and halfshafts to the axle housing. Tighten the mounting bolts to the following specifications:

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

  14.  
  15. Raise the axle assembly into its final position and support it with safety stands.
  16.  
  17. 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:

    1988-96 Amigo and Pick-Up-112 ft. lbs. (152 Nm)
     
    1988-95 Trooper and Rodeo-112 ft. lbs. (152 Nm)
     

  18.  
  19. Install the steering knuckles and assemble any suspension components that were disconnected or removed.
  20.  
  21. Install the brake backing plates and the rotor and hub assemblies.
  22.  
  23. Install the caliper mounting brackets and the brake calipers.
  24.  
  25. Check the lubricant level in the differential and add oil if needed.
  26.  
  27. Verify that all axle assembly mounting components have been installed.
  28.  
  29. Align the front driveshaft matchmarks. Install the driveshaft flange bolts and tighten them to 46 ft. lbs. (63 Nm).
  30.  
  31. Install the suspension crossmember and tighten the bolts to 58 ft. lbs. (78 Nm).
  32.  
  33. Install the steering linkage assembly.
  34.  
  35. If equipped, reconnect the ABS front wheel sensors.
  36.  
  37. Install the radiator skid plate. Tighten the bolts to 58 ft. lbs. (78 Nm).
  38.  
  39. Install the transfer case skid plates and tighten their bolts to 27 ft. lbs. (37 Nm).
  40.  
  41. Install the front wheels.
  42.  
  43. Lower the vehicle, remove the rear wheel blocks and adjust the ride height.
  44.  
  45. Check and adjust the front wheel alignment.
  46.  
  47. Tighten the suspension bushing fasteners to their final torque specifications. Refer to Suspension & Steering for these specifications.
  48.  
  49. If necessary, bleed the brake system.
  50.  
  51. Verify that the front axle and hubs engage and disengage properly.
  52.  
  53. Road test the vehicle.
  54.  

1996 MODELS

See Figures 3, 4, 5, 6, 7, 8 and 9



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Fig. Fig. 3: Exploded view of the front axle and mounting fasteners-1996 Trooper and Rodeo models



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the left-hand halfshaft, axle shaft and Shift-on-the-fly housing



Click image to see an enlarged view

Fig. Fig. 5: Make sure to install the front axle mounting bracket bolts in the proper direction



Click image to see an enlarged view

Fig. Fig. 6: Use snapring pliers to remove the snapring from the axle case, then remove the axle from the case



Click image to see an enlarged view

Fig. Fig. 7: Use the Oil Seal Installer J-41693, or equivalent, to install a new oil seal into the axle case



Click image to see an enlarged view

Fig. Fig. 8: Apply a bead of liquid gasket to the contact surface of the front axle case, then install the Shift-on-the-fly housing



Click image to see an enlarged view

Fig. Fig. 9: Apply liquid gasket to the contact surface on the actuator, as shown

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

The right axle shaft is an integral part of the right halfshaft assembly. Removal of the left axle shaft involves disassembling the shift-on-the-fly four-wheel drive gearbox. The inboard joints of both halfshafts fit through the axle mounting brackets, which are bolted to the axle housing, thereby requiring the removal of the axle assembly as a unit.

  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. Remove the shift-on-the-fly four-wheel drive actuator:
    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. If only the right halfshaft needs servicing, remove it from the vehicle and skip to Step 23.
  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. Follow these steps to remove the right axle shaft seal and bearing:
    1. Remove the snapring from the splined shaft.
    2.  
    3. Remove the shaft bearing. Use a puller if necessary, but don't damage the shaft or splines.
    4.  
    5. Remove the inner snapring.
    6.  
    7. Remove the axle mounting bracket and oil seal from the right halfshaft.
    8.  

  4.  
  5. Drain the lubricant from the shift-on-the-fly gearbox.
  6.  
  7. With the axle out of the vehicle, unbolt the left halfshaft from the axle case. Remove the halfshaft together with the left axle mounting bracket.
  8.  
  9. Loosen the shift-on-the-fly actuator mounting bolts in a crisscross pattern. Remove the actuator assembly from the gearbox.
  10.  
  11. Unbolt the shift-on-the-fly actuator gearbox from the axle tube flange.
  12.  
  13. Slowly pull the gearbox straight off the axle tube. Be careful not to loose the sleeve and clutch gear if they fall out of the gearbox.
  14.  
  15. Remove the outer snapring from the left axle shaft. Draw the axle shaft out of the axle tube.
  16.  
  17. Remove the left axle shaft oil seal from the axle tube. Be careful not to damage the sealing surface.
  18.  
  19. Inspect the axle shaft, bearing, and clutch gear components for any damage:
    1. Inspect the axle shaft splines for damage, and replace as necessary. Use a dial gauge and center blocks to inspect the shaft run-out. If run-out exceeds 0.02 in. (0.5mm), replace the shaft. Don't try to heat the axle shaft to correct excess run-out.
    2.  
    3. Insert the clutch gear into the axle shaft and inspect the motion and play of the inner bearing and needle bearing. If either bearing exhibits smoothness or play, they should be replaced.
    4.  
    5. Check the clutch sleeve for wear. First, coat the clutch gear with gear oil, and then slide the clutch sleeve back and forth over the gear to simulate operation. If the sleeve and gear exhibit smoothness or play, they must be replaced.
    6.  
    7. Check the clutch sleeve groove width. Groove width should not exceed 0.28 in. (7.1mm).
    8.  
    9. Check the external diameter of the narrowest part of the clutch gear. The diameter shouldn't exceed 1.456 in. (36.98mm).
    10.  

  20.  
  21. Remove the inner snapring from the axle shaft bearing.
  22.  
  23. Remove the inner shaft bearing:
    1. Install tool No. J-37452, or an equivalent bearing remover onto the axle shaft.
    2.  
    3. Place the axle shaft and the bearing remover into a press.
    4.  
    5. Press the bearing from the axle shaft. Don't damage the axle shaft.
    6.  

  24.  
  25. Remove the needle bearing from the axle shaft clutch gear:
    1. Support the axle shaft in a padded vise.
    2.  
    3. Install tool No. J-26941 into the bearing. Install tool No. J-2619-01, or an equivalent slide hammer onto the bearing removal tool.
    4.  
    5. Work the slide hammer to gradually remove the needle bearing from the axle shaft.
    6.  

  26.  

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. Clean and dry all axle and shift-on-the-fly gearbox sealing surfaces.
  2.  
  3. Thoroughly lubricate a new axle shaft seal with clean gear oil. Use tool No. J-41693, or an equivalent seal driver to install it into the axle tube.
  4.  
  5. Use tool No. J-41694, or an equivalent bearing driver to install a new needle bearing.
  6.  
  7. Install a new inner snapring.
  8.  
  9. Use tool No. J-4169, or an equivalent press base to press a new bearing onto the axle shaft.
  10.  
  11. Install the axle shaft into the axle tube. Don't damage the new oil seal. Install a new outer snapring.
  12.  
  13. Lubricate the clutch gear and clutch sleeve with SAE 75W-90 GL-5 gear oil and install them.
  14.  
  15. Apply a 1mm-wide bead of liquid gasket to the axle tube sealing surface. Install the shift-on-the-fly gearbox onto the axle tube before the sealant cures.
  16.  
  17. Tighten the shift-on-the-fly gearbox bolts to 85 ft. lbs. (116 Nm) in a two-step crisscross pattern.
  18.  
  19. Install the shift position switch onto the actuator and tighten it to 29 ft. lbs. (39 Nm).
  20.  
  21. Install the actuator assembly:
    1. Apply a 1mm-wide bead of liquid gasket to the actuator sealing surface. Don't allow the sealant to cure before installation.
    2.  
    3. Align the shift fork arms with the groove of the clutch sleeve and install the actuator.
    4.  
    5. Tighten the actuator mounting bolts to 10 ft. lbs. (13 Nm) in a crisscross sequence.
    6.  

  22.  
  23. Install the spacer onto the left front halfshaft.
  24.  
  25. Install the halfshaft and axle mounting bracket assembly onto the axle. Tighten the bolts to 85 ft. lbs. (116 Nm) in a crisscross sequence.
  26.  
  27. After the sealant has fully cured, refill the shift-on-the-fly gearbox with SAE 75W-90 GL-5 gear oil.
  28.  
  29. Assemble the right halfshaft and axle mounting bracket assembly, as follows:
    1. Install the axle mounting bracket onto the halfshaft.
    2.  
    3. Lubricate and install a new oil seal.
    4.  
    5. Install a new inner snapring.
    6.  
    7. Install a new bearing.
    8.  
    9. Install a new outer snapring.
    10.  

  30.  
  31. Place the right halfshaft and axle mounting bracket assembly into position, and rest it on the right lower control arm.
  32.  
  33. Position the axle and left halfshaft assembly on a floor jack. Raise the axle into position.
  34.  
  35. 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.
  36.  
  37. Tighten the right halfshaft and axle mounting bracket assembly mounting bolts to 85 ft. lbs. (116 Nm) in a crisscross sequence.
  38.  
  39. Raise the axle assembly into its final position and support it with safety stands.
  40.  
  41. 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).
  42.  
  43. Install the steering knuckles and assemble any suspension components that were disconnected or removed.
  44.  
  45. Install the brake backing plates and the rotor and hub assemblies.
  46.  
  47. Install the caliper mounting brackets and the brake calipers.
  48.  
  49. Install the VSV onto the axle tube. Reconnect the vacuum hoses and the 2P connector. Then, install the VSV skid plate.
  50.  
  51. 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).
  52.  
  53. Verify that all axle assembly mounting components have been installed.
  54.  
  55. Align the front driveshaft matchmarks. Install the driveshaft flange bolts and tighten them to 46 ft. lbs. (63 Nm).
  56.  
  57. Install the suspension crossmember and tighten the bolts to 58 ft. lbs. (78 Nm).
  58.  
  59. Install the steering linkage assembly.
  60.  
  61. If equipped, reconnect the ABS front wheel sensors.
  62.  
  63. Install the radiator skid plate. Tighten the bolts to 58 ft. lbs. (78 Nm).
  64.  
  65. Install the transfer case skid plates and tighten their bolts to 27 ft. lbs. (37 Nm).
  66.  
  67. If necessary, bleed the brake system.
  68.  
  69. Install the front wheels.
  70.  
  71. Lower the vehicle and remove the rear wheel blocks.
  72.  
  73. Tighten the suspension bushing fasteners to their final torque specifications.
  74.  
  75. Verify that the front axle and hubs engage and disengage properly.
  76.  
  77. If equipped with shift-on-the-fly four-wheel drive, make sure the VSV and actuator function correctly.
  78.  
  79. Check and adjust the front wheel alignment and ride height.
  80.  
  81. Road test the vehicle.
  82.  

CV-JOINT OVERHAUL



See Figures 1, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 and 20



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Fig. Fig. 10: To separate the halfshaft from the DOJ case, remove the DOJ case retaining circlip



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Fig. Fig. 11: Use a prytool to pop the DOJ balls out of the ball guide



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Fig. Fig. 12: Remove the ball retainer snapring, then slide the ball retainer and ball guide off the shaft



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Fig. Fig. 13: When installing the new boot clamps, make sure they are positioned as shown



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Fig. Fig. 14: Install the DOJ case-to-DOJ assembly circlip so the ends are positioned away from the ball groove (as shown)



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Fig. Fig. 15: Position the boot on the DOJ case and shaft as shown, then allow excess pressure out of the boot



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Fig. Fig. 16: Clean the CV-joint housing prior to removing boot



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Fig. Fig. 17: Check the CV-boot for wear



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Fig. Fig. 18: Removing the outer band from the CV-boot



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Fig. Fig. 19: Removing the inner band from the CV-boot



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Fig. Fig. 20: Removing the CV-boot from the joint housing

The Isuzu trucks and Sport Utility vehicles use a Double Offset Joint (DOJ) for the inner CV-joint and a Birfield Joint (BJ) for the outer CV-joint. The BJ is not serviceable and must be replaced as an assembly.

  1. Remove the halfshaft from the vehicle, as described earlier in this section.
  2.  
  3. Clean the assembly of all grease and dirt.
  4.  
  5. Remove the inner CV-joint boot clamp, then slide the boot away from the joint. To remove the clamp, it may be necessary to pry the hooked end of the clamp up with a small prytool.
  6.  
  7. Remove the circlip from the DOJ case, then pull the case and inner shaft off the inner joint (ball guide, ball retainer and ball assembly).
  8.  
  9. Carefully pry the balls out of the ball guide with a prytool.
  10.  
  11. Using snapring pliers, remove the ball retainer snapring. Slide the ball retainer and ball guide from the splined shaft.
  12.  
  13. Remove the smaller inner boot clamp, then slide the inner boot off the shaft.
  14.  
  15. Remove the 2 outer CV-joint boot clamps, then slide the outer boot off the shaft.
  16.  
  17. The Birfield joint is not serviceable; replace the entire BJ assembly, if defective.
  18.  
  19. Clean all grease and dirt from the CV-joint components. Inspect the DOJ case, balls, ball guide, and ball retainer for wear, damage, corrosion or any other abnormal condition. Replace the components, if necessary.
  20.  

To assemble:
  1. With the Birfield joint shafts bent at a 40 degree angle, turn one of the shafts and make sure it turns smoothly and normally.
  2.  
  3. Place tape on the splines to prevent damage to the joint boots.
  4.  
  5. Coat the inner BJ shaft with a thin film of grease to help installation of the boots, then slide the outer boot and clamps onto the inner shaft. Make sure the boot is installed so the big end faces toward the BJ.
  6.  
  7. Fill the outer CV-joint boot with 5.25 oz. (150g) of new CV-joint grease, then install new clamps to hold the boot to the joint. Make sure the boot is free of distortion after installing the boot clamps.
  8.  
  9. Slide the inner joint boot and vibration damper, if so equipped, onto the shaft. Make sure the big end of the inner boot faces toward the inner end of the halfshaft.
  10.  
  11. Install the ball retainer, guide and snapring onto the shaft. Install the ball retainer with the smaller diameter side toward the Birfield joint end of the shaft.
  12.  
  13. Align the track on the ball retainer with the windows in the ball guide, then install the 6 DOJ balls.
  14.  
  15. Fill the inner boot and DOJ with 5.25 oz. (150g) new grease, then install the DOJ case over the ball guide and retainer. Install the circular clip into the groove so the open ends are positioned away from the ball groove.
  16.  
  17. Slide the boot over the DOJ and onto the DOJ case, insert a tool under the boot lip to allow the pressure to equalize and tighten the new clamps. Make sure the boot is installed so the edge of the smaller end is 6.5 in. (16.5cm) from the opposite edge of the DOJ case (refer to the illustration).
  18.  
  19. Install the shaft into the vehicle, as described earlier in this section.
  20.  

 
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