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

Axle Housing Assembly

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REMOVAL & INSTALLATION



Pick-Up, Amigo and 1985-91 Trooper Models
  1. Raise and safely support the vehicle under the frame. Remove the rear wheels.
  2.  
  3. Disconnect the shock absorbers from the spring plates.
  4.  
  5. Matchmark the driveshaft to the flange and disconnect the driveshaft from the flange, use wire to hold it out of the way.
  6.  
  7. Disengage the speed sensor connector, if equipped.
  8.  
  9. Disconnect and plug the brake line on the rear axle housing.
  10.  
  11. Disconnect the parking brake cables from the rear brake shoes and backing plates.
  12.  
  13. If equipped with rear disc brakes, remove the calipers and hang them out of the way without disconnecting the brake lines.
  14.  
  15. Remove the housing to leaf spring U-bolts.
  16.  
  17. Raise and support the rear housing with a floor jack and maneuver the housing to the left. Once the right side of the housing clears the leaf spring, tilt that end down and swing the left side over the leaf spring. Remove the rear axle housing from the vehicle.
  18.  

When removing the rear housing, use a least 2 people to avoid damaging the housing or the driveshaft yoke. Also, it is optional to lower the rear of the leaf springs and then remove the differential housing.

To install:
  1. Position the axle housing on the rear springs.
  2.  

If the rear springs were lowered, secure them at this time. Verify that the rear housing is positioned properly on the rear springs Tighten the rear leaf spring shackle bolts to 69-76 ft. lbs. (94-103 Nm).

  1. Install the U-bolts and the anchor plate. Tighten the nuts evenly in 2 steps; first to 18 ft. lbs. (25 Nm) and then to 49 ft. lbs. (66 Nm).
  2.  
  3. Align the matchmark and connect the driveshaft to the pinion flange.
  4.  
  5. Install the shock absorber to the spring plate.
  6.  
  7. Connect the parking brake cables to the rear brakes.
  8.  
  9. Connect the brake line to the connection on the rear axle housing.
  10.  
  11. If quipped with disc brakes, install the brake calipers, as described in Brakes .
  12.  
  13. Attach the speed sensor connector, if applicable.
  14.  
  15. Check the lubricant in the rear housing and add lubricant if needed.
  16.  
  17. Install the wheels and tires.
  18.  
  19. Bleed the rear brakes and lower the vehicle to the floor.
  20.  

1992-96 Trooper Models
  1. Raise and safely support the vehicle under the frame. Remove the rear wheels.
  2.  
  3. Disconnect the rear caliper brake lines at the center flexible hose connection. Plug the lines to prevent fluid loss.
  4.  
  5. Matchmark the driveshaft to the flange and disconnect the driveshaft from the flange. Use wire to hold the driveshaft up and out of the way.
  6.  
  7. Disconnect the parking brake cables from the rear brake shoes and backing plates.
  8.  
  9. Disconnect the breather hose from the differential case.
  10.  
  11. If equipped with ABS, unbolt the wheel sensor wire brackets and move the sensor wire out of the way. Do not disconnect the sensor wire.
  12.  
  13. Raise the axle slightly with a suitable jack. Support the axle with stands.
  14.  
  15. Disconnect the shock absorbers from their axle mounting brackets.
  16.  
  17. Disconnect the stabilizer linkages from the axle housing.
  18.  
  19. Disconnect the lateral link from the axle housing.
  20.  
  21. Disconnect the center link and trailing rods from the axle housing.
  22.  
  23. Lower the axle housing slightly and remove the coil springs and spring insulators.
  24.  
  25. Remove the axle housing from the vehicle.
  26.  

To install:
  1. Position the coil springs and their insulators onto the axle tube spring perches.
  2.  
  3. Raise the axle and springs into position and install the trailing rod, center link, and the lateral link. Only hand-tighten the rod and link fasteners at this time.
  4.  
  5. Install the shock absorbers to the axle housing.
  6.  
  7. Connect the stabilizer linkages to the axle housing.
  8.  
  9. Install the ABS speed sensor wire brackets.
  10.  
  11. Connect the parking brake cables to the rear brakes.
  12.  
  13. Align the matchmark and connect the driveshaft to the pinion flange. Tighten the flange bolts to 46 ft. lbs. (63 Nm).
  14.  
  15. Refill the differential with fresh gear oil of the correct type.
  16.  
  17. Install the rear wheels.
  18.  
  19. Bleed the rear brakes.
  20.  
  21. Adjust the parking brake cable.
  22.  
  23. Lower the vehicle to the floor. Tighten the rear suspension components to their final torque specifications:
    1. Lower shock absorber mounts-58 ft. lbs. (78 Nm)
    2.  
    3. Lateral link nut-58 ft. lbs. (78 Nm)
    4.  
    5. Trailing rod and center link nuts-101 ft. lbs. (137 Nm)
    6.  
    7. Stabilizer bar linkage nuts-37 ft. lbs. (50 Nm)
    8.  

  24.  
  25. Make sure the ABS system functions correctly.
  26.  

1991-96 Rodeo Models
  1. Raise and safely support the vehicle under the frame. Remove the rear wheels.
  2.  
  3. If equipped with ABS, disconnect the rear wheel sensor wiring from the main ABS harness.
  4.  
  5. Disconnect the brake hoses from the brake lines on the rear axle housing, then plug both the lines and hoses to prevent fluid leakage and contamination.
  6.  

The brake calipers or shoe assemblies may be removed from the rear axle before it is removed from the vehicle.

  1. Disconnect the parking brake cables from the rear brake shoes and backing plates.
  2.  
  3. Disconnect the shock absorbers from the leaf spring anchor plates.
  4.  
  5. Matchmark the U-joint flange to the differential pinion flange. Then, unbolt the driveshaft from the differential. Use wire to suspend the driveshaft out of the way.
  6.  
  7. Use an hydraulic floor jack to raise the rear axle enough to support it with safety stands.
  8.  
  9. Remove the axle housing U-bolts from the leaf spring anchor plates.
  10.  
  11. With the axle safely supported, unbolt the front mount of each leaf spring from its frame bracket.
  12.  
  13. Lower the rear axle assembly from the vehicle.
  14.  

To install:
  1. Raise the rear axle assembly into position. Support the axle with safety stands.
  2.  
  3. Connect the front leaf spring mounts to their frame brackets. Install the through-bolt and nut, but only hand-tighten them.
  4.  
  5. Move the axle into position. Install the U-bolts and the anchor plates. Tighten the U-bolt nuts in a two-step sequence; first to 18 ft. lbs. (25 Nm) and then to 49 ft. lbs. (66 Nm).
  6.  
  7. Reconnect the shock absorber to the leaf spring anchor plate. Tighten the self-locking nut to 29 ft. lbs. (40 Nm).
  8.  
  9. Align the matchmarks and connect the driveshaft to the pinion flange. Tighten the bolts to 46 ft. lbs. (63 Nm).
  10.  
  11. If removed, install the rear calipers or brake shoe assemblies.
  12.  
  13. Reconnect the rear wheel sensors.
  14.  
  15. Connect the parking brake cables to the rear brakes.
  16.  
  17. Connect the brake line to the axle housing, then connect the brake lines to the brake hose. Tighten the hose attaching bolt to 10 ft. lbs. (13 Nm) and tighten the brake line fittings to 12 ft. lbs. (16 Nm).
  18.  
  19. Check the lubricant in the rear housing and refill if necessary.
  20.  
  21. Bleed the brake system.
  22.  
  23. Install the rear wheels and lower the vehicle.
  24.  
  25. With all 4 wheels on the ground, tighten the front leaf spring mount nut to 113 ft. lbs. (152 Nm).
  26.  

Hombre Models
  1. Raise and support the rear of the vehicle safely using jackstands.
  2.  

When supporting the rear of the vehicle, be sure to place the jackstands under the frame.

  1. Position a floor jack under and support the rear axle housing.
  2.  
  3. Remove the rear tire and wheel assemblies, then remove the brake drums.
  4.  
  5. Remove the shock absorber-to-axle housing nuts and bolts, then swing the shock absorbers away from the axle housing.
  6.  
  7. Matchmark and remove the driveshaft from the rear axle. The driveshaft may either be removed completely from the vehicle or supported on a wire.
  8.  
  9. Disconnect the brake lines from the axle housing clips and the wheel cylinders.
  10.  

When disconnecting the brake lines from the wheel cylinders, IMMEDIATELY plug all openings minimize fluid loss and prevent system contamination. YOU MUST keep dirt from entering the lines.

  1. Disconnect the parking brake cable.
  2.  
  3. Disconnect the axle housing-to-spring U-bolt nuts, the U-bolts and the anchor plates. Refer to the Leaf Spring procedures in Suspension & Steering for details and safety.
  4.  
  5. Remove the vent hose from the top of the axle housing.
  6.  
  7. Using the floor jack, carefully lower the axle housing and remove from the vehicle.
  8.  

To install:
  1. Using the floor jack, raise the axle housing to the vehicle.
  2.  
  3. Install the vent hose to the top of the axle housing.
  4.  
  5. Connect the axle housing-to-spring U-bolt nuts, the U-bolts and the anchor plates. Tighten the bolts to specification.
  6.  
  7. Connect the brake lines to the axle housing clips and the wheel cylinders.
  8.  
  9. Connect the brake cables, then install the brake drums and bleed the hydraulic brake system. For details, refer to Brakes of this repair guide.
  10.  
  11. Matchmark and install the driveshaft.
  12.  
  13. Install the shock absorber-to-axle housing nuts and bolts. Tighten the shock absorber-to-axle housing nuts/bolts to 75 ft. lbs. (102 Nm).
  14.  
  15. Install the rear tire and wheel assemblies.
  16.  
  17. Check and fill the axle housing, as necessary. For details, please refer to General Information & Maintenance of this repair guide. Remember that in order to check fluid level or properly refill the housing, the vehicle MUST be level (supported at 4 points).
  18.  
  19. Remove the jackstands and carefully lower the vehicle.
  20.  

 
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