Pinion Installation - Isuzu 1999 RODEO Workshop Manual

4. Assemble the differential case into the housing (less
pinion). Install bearing caps and finger tight bolts.
Mount a dial indicator with a magnetic base to the
housing and indicate on the flange or head of screw.
Force the differential assembly as far as possible in
the dirction towards the indicator.
With force still applied, set indicator at zero(0).
NOTE: Dial indicator set should be capable of a minimum
travel of 5.08 mm (0.2 in).
5. Force the differetial assembly as far as it will go in the
opposite direction. Repeat these steps until the same
reading is obtained.
6. RECORD THE READING OF THE INDICATOR.
This amount, in shims, will be included in the final
assembly shim stack to establish side bearing
preload and ring gear and pinion backlash.
7. After marking sure the readings are correct, remove
the indicator and differetial assembly from the
housing.

Pinion Installation

f The bearing cups should have been installed in Pinion
Depth Adjustment in this section.
1. Place the shim(1) and inner oil slinger(2) on the pinion
gear, then install the pinion inner bearing(3) using
installer J–42828.
f Drive the bearing until the bearing cone seats on the
pinion shims.
2. Install a new collpsible spacer.
f Lubracate the pinion bearings with axle lublicant.
3. Install pinion to the axle housing.
4. Install outer pinion bearing onto the pinion.
f Hold the pinion forward from inside the case while
driving the bearing onto the pinion.
5. Install oil seal slinger.
425RS107
6. Install pinion oil seal using installer J–37263.
7. Install the pinion flange to the pinion by tapping it with
a rawhide hammer until a few threads show through
the pinion flange.
8. Install pinion washer and a new nut while holding the
pinion flange with flange holder J–8614–01.
f Tighten the nut until the pinion end play is just taken
up. Rotate the pinion while tightening the nut to seat
the bearings.
Torque:217-678 N·m (160-500 lb ft)
Once there is no end play in the pinion, the preload
torque should be checked.
f Remove flange holder J–8614–01. Using an
inch-pound torque wrench, check the pinion
preload by rotating the pinion with the wrench.
DIFFERENTIAL (REAR) 4A2–21
425RW023