Inspection And Repair; Reassembly - Isuzu 1999 RODEO Workshop Manual

12. Remove differential plate retainer from both clutch
packs to allow separation of the plates and discs.
NOTE:
f Keep the discs and plates in the same order as they
were removed.
Legend
(1) Differential Plate
(2) Differential Disc
(3) Dished Spacer
(4) Side Gear

Inspection and Repair

Cleaning
f All parts with solvent.
Visual Inspection
f Clean all parts with solvent.
f Plates and Discs. If any one disc or plate in either
stack shows evidence of excessive wear or scoring,
the complete stack is to be replaced on both sides.
f Side Gears and Pinion Mate Gears. The gear teeth of
these parts should be checked for extreme wear and
possible cracks. The external teeth of the side gear,
which retain the concentric groove discs, should also
be checked for wear or cracks.
f If replacement of one gear is required due to wear,
etc., then both side gears, pinion mate gears, and
thrust washers are to be replaced.
f Differential Shaft. If excessive wear is evident, the
differential shaft should be replaced.
f Differential Plate Retainers. If wear is evident on any
one of the differential plate retainers, all four retainers
must be replaced.
f Differential Case. If scoring, wear or metal pickup is
evident on the machined surfaces, replacement of
the case is necessary.

Reassembly

1. Lubricate thrust face of side gears, plates and discs
with the proper limited slip rear axle lubricant.
2. Assemble plates and discs in exactly in the same
position as they were removed, regardless of whether
they are new or original.
3. Install differential plate retainer to ears of plates.
NOTE:
f Make sure both retainers are Completely seated on
ears of plates.
4. Install clutch pack and side gear into bottom side gear
bore. Make sure clutch pack stays assembled to side
gear splines, and that retainers are completely seated
into pockets of case.
NOTE:
f To prevent clutch pack from falling out of case, hold
clutch pack in place by hand while repositioning case
on bench.
5. Install other side gear and clutch pack. Make sure
clutch pack stays assembled to side gear splines, and
retainers are completely seated into pockets of case.
6. Hold clutch pack in position and assemble screw cap
J–34174–2, cap J–34174–1 and forcing screw
425RW009
J–22342–15. Tighten forcing screw into bottom cap
to hold both clutch packs in position.
7. With tools assembled to case, position case on holder
J–39824 by aligning splines of side gear with those of
shaft. Tighten forcing screw to compress clutch packs
in order to provide clearance for pinion mate gears.
8. Install pinion mate gears.
f Place the pinion mate gears into the differential 180
degrees apart.
DIFFERENTIAL (REAR) 4A2–29
901RW069