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

    Pinion Seal

    Print

    REMOVAL & INSTALLATION



    Pick-Up, Amigo and Trooper Models
    BANJO TYPE

    See Figure 1



    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of the differential flange, bearing and oil seal-Banjo type rear axle

    1. Safely raise and support the vehicle.
    2.  
    3. Matchmark the driveshaft, then remove the bolts attaching the driveshaft to the rear axle flange.
    4.  
    5. Remove the driveshaft from the pinion flange and support out of the way.
    6.  
    7. Check the preload with an inch-pound torque wrench.
    8.  
    9. Remove the flange nut. Use a flange holding wrench (Tool J-8614-01 for 1995 Pick-Ups, Tool J-37221 for 1995-96 Troopers), or equivalent, when removing the flange nut.
    10.  
    11. Place a suitable container under the differential to catch any gear oil.
    12.  
    13. Remove the pinion flange.
    14.  
    15. Remove the pinion oil seal from the differential.
    16.  
    17. Remove the oil seal slinger.
    18.  
    19. Remove the pinion bearing using a outer bearing remover (Tool J-39602 or equivalent).
    20.  
    21. Remove and discard the collapsible spacer from the differential.
    22.  

    To install:
    1. Inspect the pinion flange for tool marks, nicks, or damage such as a groove worn by the seal. Replace the flange if necessary. Inspect the carrier bore for burrs that may cause leaks around the outside of the seal.
    2.  
    3. Install a new collapsible spacer onto the pinion.
    4.  
    5. Install the outer bearing onto the pinion. Do not drive the bearing into position; it will be installed when the flange nut is tightened.
    6.  
    7. Install the oil seal slinger.
    8.  
    9. Lubricate the new oil seal with axle lubricant.
    10.  
    11. Install the new oil seal with a seal installer (Tool J-23911 for 1995 Pick-Ups, J-37263 for 1995-96 Troopers, or equivalent).
    12.  
    13. Install the pinion flange to the pinion, by tapping it lightly with a soft faced hammer, until a few threads show through the pinion flange.
    14.  
    15. Install the pinion washer and nut. Tighten the pinion nut to the following torque values:

      Trooper-180-216 ft. lbs. (245-294 Nm)
       
      Pick-Up and Amigo with drum brakes-130-202 ft. lbs. (177-275 Nm) for new bearings, 65-101 ft. lbs. (88-137 Nm) for used bearings
       
      Pick-Up and Amigo with disc brakes-181-217 ft. lbs. (245-294 Nm) for new bearings, 90-109 ft. lbs. (123-147 Nm)
       

    16.  

    Rotate the pinion while tightening the nut to seat the bearings.

    1. Check the preload torque (the amount of force necessary to turn the pinion flange). Use an inch-pound torque wrench to check the preload, make sure the pinion preload is equal to or slightly over the reading recorded during removal.
    2.  
    3. Stake the flange nut at 2 points, to keep the flange nut from loosening.
    4.  
    5. Connect the driveshaft to the flange and install the nuts and bolts. Tighten the nuts and bolts to 46 ft. lbs. (63 Nm).
    6.  
    7. Check the level of lubricant in the rear axle and add as necessary.
    8.  
    9. Lower the vehicle.
    10.  

    SALISBURY TYPE (SAGINAW)
    1. Block the front wheels.
    2.  
    3. Safely raise and support the front of the vehicle on jackstands.
    4.  
    5. Matchmark the driveshaft flanges and remove the bolts from the rear driveshaft flange.
    6.  
    7. Remove the driveshaft from the pinion flange and support out of the way.
    8.  
    9. Matchmark the pinion flange, pinion shaft and the nut to obtain the proper bearing preload during installation. Remove the
    10.  

    flange nut and washer. Use a flange-holding wrench (Tool J-8614-01 or equivalent) when removing the flange nut.

    1. Place a drain pan under the differential to catch any gear oil.
    2.  
    3. Remove the pinion flange by using the special Tools J-8614-1, J-8614-2 and J-8614-3, or their equivalents.
    4.  
    5. Remove the pinion oil seal from the differential.
    6.  

    To install:
    1. Inspect the pinion flange for tool marks, nicks, or damage such as a groove worn by the seal. Replace the flange if necessary. Inspect the carrier bore for burrs that may cause leaks around the outside of the seal.
    2.  
    3. Lubricate the new oil seal with axle lubricant.
    4.  
    5. Install the new oil seal with a seal installer (Tool J-23911 or equivalent).
    6.  
    7. Apply a small amount of sealant to the spline of the pinion flange. Install the pinion flange to the pinion, by tapping it lightly with a soft-faced hammer, until a few threads show through the pinion flange.
    8.  
    9. Install the washer and nut to the pinion, hold the flange in place and tighten the nut. Tighten the nut 1 / 16 in. (1.59 mm) beyond the alignment marks.
    10.  
    11. Connect the driveshaft to the flange and install the nuts and bolts. Tighten the nuts and bolts to 46 ft. lbs. (63 Nm).
    12.  
    13. Refill the rear axle with lubricant. For more information, refer to General Information & Maintenance .
    14.  
    15. Lower the vehicle and remove the front wheel blocks.
    16.  

    Rodeo and Hombre Models
    SALISBURY TYPE (DANA)

    See Figures 2, 3, 4 and 5



    Click image to see an enlarged view

    Fig. Fig. 2: To loosen the flange nut, hold the flange stable with Tool J-8614-01, or equivalent



    Click image to see an enlarged view

    Fig. Fig. 3: Remove the pinion flange from the pinion shaft with Tools J-8614-3, J-8614-2 and J-8614-1 or equivalents



    Click image to see an enlarged view

    Fig. Fig. 4: Remove the pinion oil seal with Special Tool J-39602, or equivalent



    Click image to see an enlarged view

    Fig. Fig. 5: Use the oil seal installer tool J-39829, or equivalent, to drive the new oil seal into the differential case

    The Dana rear drive axle on the 1995-96 Rodeo models is easy to distinguish from the Saginaw rear drive axle as follows: the Dana rear differential cover is asymmetrical and angular, whereas the Saginaw rear cover is symmetrical and oval-shaped.

    1. Block the front wheels.
    2.  
    3. Safely raise and support the front of the vehicle on jackstands.
    4.  
    5. Matchmark the driveshaft flanges. Remove the bolts from the rear driveshaft flange.
    6.  
    7. Separate the driveshaft from the pinion flange and support it out of the way.
    8.  
    9. Check and record the amount of torque required to turn the pinion shaft (preload) with an inch pound torque wrench. This figure will represent the preload of the pinion bearing and seal.
    10.  
    11. Remove the flange nut. Use a flange-holding wrench (part No. J-8614-01 or equivalent) when removing the flange nut.
    12.  
    13. Place a drain pan under the differential to catch any gear oil.
    14.  
    15. Pull the flange from the pinion shaft.
    16.  
    17. Remove the pinion oil seal from the differential with a small prytool. Make sure not to scratch, gouge or otherwise damage the inside bore of the differential case.
    18.  
    19. Remove the oil seal slinger, if equipped.
    20.  
    21. Remove the pinion bearing using a outer bearing remover (Tool J-39602 or equivalent).
    22.  
    23. Remove and discard the collapsible spacer from the differential.
    24.  

    To install:
    1. Inspect the pinion flange for tool marks, nicks, or damage such as a groove worn by the seal. Replace the flange if any such damage is evident. Inspect the carrier bore for burrs that may cause leaks around the outside of the seal.
    2.  
    3. Install a new collapsible spacer onto the pinion.
    4.  
    5. Install the outer bearing onto the pinion. Do not drive the bearing into position; it will be correctly positioned when the flange nut is tightened.
    6.  
    7. Install the oil seal slinger.
    8.  
    9. Lubricate the new oil seal with axle lubricant, then install the new oil seal with a seal installer (part No. J-39829, or equivalent).
    10.  
    11. FIt the pinion flange to the pinion. Then, install it by tapping lightly with a soft-faced hammer until a few threads show through the pinion flange.
    12.  
    13. Install the pinion washer and nut. Tighten the pinion nut until the end-play starts to disappear. Rotate the pinion while tightening the nut to evenly seat the bearings.
    14.  
    15. Once there is no end-play in the pinion, check the preload torque. Use an inch-pound torque wrench to check the preload, make sure the pinion preload is equal to or slightly greater than the reading recorded during removal.
    16.  
    17. Connect the driveshaft to the pinion flange and install the nuts and bolts. Tighten the nuts and bolts to 46 ft. lbs. (63 Nm).
    18.  
    19. Refill the rear axle with lubricant.
    20.  
    21. Lower the vehicle and remove the front wheel blocks.
    22.  

    SALISBURY TYPE (SAGINAW)
    1. Block the front wheels.
    2.  
    3. Safely raise and support the front of the vehicle on jackstands.
    4.  
    5. Matchmark the driveshaft flanges and remove the bolts from the rear driveshaft flange.
    6.  
    7. Remove the driveshaft from the pinion flange and support out of the way.
    8.  
    9. Matchmark the pinion flange, pinion shaft and the nut to obtain the proper bearing preload during installation. Remove the flange nut and washer. Use a flange-holding wrench (Tool J-8614-01 or equivalent) when removing the flange nut.
    10.  
    11. Place a drain pan under the differential to catch any gear oil.
    12.  
    13. Remove the pinion flange.
    14.  
    15. Remove the pinion oil seal from the differential.
    16.  

    To install:
    1. Inspect the pinion flange for tool marks, nicks, or damage such as a groove worn by the seal. Replace the flange if necessary. Inspect the carrier bore for burrs that may cause leaks around the outside of the seal.
    2.  
    3. Lubricate the new oil seal with axle lubricant.
    4.  
    5. Install the new oil seal with a seal installer (Tool J-23911 or equivalent).
    6.  
    7. Apply a small amount of sealant to the spline of the pinion flange. Install the pinion flange to the pinion, by tapping it lightly with a soft-faced hammer, until a few threads show through the pinion flange.
    8.  
    9. Install the washer and nut to the pinion, hold the flange in place and tighten the nut. Tighten the nut 1 / 16 in. (1.59 mm) beyond the alignment marks.
    10.  
    11. Connect the driveshaft to the flange and install the nuts and bolts. Tighten the nuts and bolts to 46 ft. lbs. (63 Nm).
    12.  
    13. Refill the rear axle with lubricant. For more information, refer to General Information & Maintenance .
    14.  
    15. Lower the vehicle and remove the front wheel blocks.
    16.  

     
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