NOTICE

Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended that
you carefully read and thoroughly understand the information
contained in Section-0A under the headings “GENERAL REPAIR
INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.

All material contained in this Manual is based on the latest product

information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.

Applicable Model

F & G-Series

This manual is applicable to 1996 year model and later vehicles.

For the disassembly, reassembly, and inspection of ROCKWELL
made rear axle used in FVR / FVD / FVL / FVZ / FVY / GVR / GVZ,
refer to the ROCKWELL rear axle Workshop Manual.
00-6 SERVICE INFORMATION

MAIN DATA AND SPECIFICATIONS

Propeller Shaft
TUBULAR SHAFT CENTER BEARING

Outside Diameter × Spider Pin Center Bearing Outside Diameter ×

Type
Thickness Diameter Inside Diameter × Width mm (in)

P30 90.0 × 3.2 (3.54 × 0.13) 23.02 (0.9063) 85 × 45 × 19 (3.35 × 1.77 × 0.75)

P46 90.0 × 4.0 (3.54 × 0.16) 29.12 (1.1465) 85 × 45 × 19 (3.35 × 1.77 × 0.75)

P60H 101.6 × 4.0 (4.0 × 0.16) 30.517 (1.2015) 120 × 55 × 29 (4.72 × 2.17 × 1.14)

P90H 114.3 × 4.5 (4.5 × 0.16) 36.0 (1.4173) 130 × 60 × 31 (5.12 × 2.36 × 1.22)

P115HS 114.3 × 5.5 (4.5 × 0.22) 41.0 (1.6142) 140 × 65 × 33 (5.51 × 2.56 × 1.30)

1610 90.0 × 6.0 (3.5 × 0.24) — —

Rear Axle
MODEL
13.5" 14.5" 15.5" 16.5" 17.5"
ITEMS
Rear Axle Type Banjo Fully Floating
Gear Type Hypoid
Ring Gear Pitch
Diameter mm (in) 343 (13.50) 365.5 (14.39) 398 (15.67) 419.8 (16.53) 444.5 (17.5)
Adjusting Method of Collapsible
Shim
Pinion Bearing Preload Spacer
Oil Capacity Reference (liters) 5.5 6.5 9.0 14.0 14.0
 SERVICE INFORMATION 00-9

SERVICE STANDARD
PROPELLER SHAFT

ITEMS SERVICE STANDARD SERVICE LIMIT

Pin Diameter of Spider mm (in) If excessive wear or

P30 23.02 (0.9063) pressure marks are found
P46 29.12 (1.1465) at needle bearing fitting
P60H 30.517 (1.2015) surface and end surface,
P90H 36.0 (1.4173) replace the spider.
P115HS 41.0 (1.6142)
Spider End Play mm (in)
P30 0.05 — 0.15 (0.0020 — 0.0059)
P46 0.02 — 0.08 (0.0008 — 0.0031)
P60H, P90H 0.005 — 0.065 (0.0002 — 0.0026)
P115HS – 0.21 — 0.04 (– 0.0083 — 0.0016)
Propeller Shaft Run-out mm (in) 0.3 (0.0118) or less 0.5 (0.0197)
Play in Splines in Normal
Direction of Rotation mm (in) 0.1 (0.0039) or less 0.5 (0.0197)

REAR AXLE

ITEMS SERVICE STANDARD SERVICE LIMIT

Rear Hub
Hub Bearing Preload
See Page 4B–10
Differential
Clearance between Spider and
Differential Pinion
(except No - spin Differential) mm (in)
13.5" 0.05 — 0.13 (0.0020 — 0.0051) 0.2 (0.0079)
14.5", 15.5" 0.04 — 0.13 (0.0016 — 0.0051) 0.2 (0.0079)
16.5" 0.03 — 0.10 (0.0012 — 0.0039) 0.2 (0.0079)
17.5" 0.06 — 0.15 (0.0024 — 0.0059) 0.2 (0.0079)
Clearance between Side Gear and
Differential Cage mm (in)
13.5", 14.5", 15.5" 0.13 — 0.20 (0.0051 — 0.0079) 0.5 (0.0197)
16.5" 0.15 — 0.22 (0.0059 — 0.0087) 0.5 (0.0197)
17.5" 0.18 — 0.25 (0.0071 — 0.0098) 0.5 (0.0197)
Play in Splines between Side
Gear and Axle Shaft mm (in) 0.2 (0.0079) 0.5 (0.0197)
00-16 SERVICE INFORMATION

4. Coat inside hub with Multi-purpose grease.

Retightening Wheel Nut

6 and 8 Stud Disc Wheel
The wheel nuts on the right side wheels have right-
hand threads and the wheel nuts on the left side
wheels have left-hand threads.
10 Stud Disc Wheel
The all wheel nuts on the wheels have right-hand
threads.
Wheel Nut Torque N•m (kg•m / lb•ft)
6 stud 539 to 588 (55 — 60 / 398 — 434)
8 stud 539 to 588 (55 — 60 / 398 — 434)
10 stud 490 to 539 (50 — 55 / 362 — 398)

Wheel Replacement
1. Jack up the wheel, remove the wheel nuts and
wheel, then install the spare wheel.
NOTE:
When replacing wheels, be sure to remove and install
them with their air valve down.
2. Clean the wheel pins and nuts and apply engine oil
or equivalent to the threads.
Install the semi-tighten the wheel nuts and lower
the wheel to the ground.
NOTE:
When replacing rear outer wheel only, also check the
wheel pin nuts on the inner wheel for looseness.
3. With the wheel wrench, tighten the wheel nuts in
sequence as shown in the figure.
Do not overtighten the wheel nuts.
Wheel Nut Torque N•m (kg•m / lb•ft)
6 stud 539 to 588 (55 — 60 / 398 — 434)
8 stud 539 to 588 (55 — 60 / 398 — 434)
10 stud 490 to 539 (50 — 55 / 362 — 398)
 SERVICE INFORMATION 00-19

Rear Axle Oil Replacement

(except Eaton-made Axle)
Drain the rear axle case by removing the drain plug
(D) on the under surface of the rear axle case. Install
the drain plug and fill the rear axle case up to the
level plug (L) with specified gear oil through the level
plug hole.
Oil Capacity (Reference) Liters (US gal./lmp gal.)
13.5” 5.5 (1.45 / 1.21)
14.5” 6.5 (1.71 / 1.43)
15.5” 9.0 (2.38 / 1.98)
16.5” 14.0 (3.70 / 3.08)
17.5” 14.0 (3.70 / 3.08)
 SERVICE INFORMATION 00-23

4. Camber, Caster Angle and King Pin Inclination

Measurement
Follow the specific instructions of the equipment
manufacturer.
Refer to “Camber, Caster angle and king pin
inclination” table on Main Data and Specifications.

5. Measurement of Side Slippage

When inspection and adjustments of toe-in, camber,
caster and kingpin inclination are completed, check
for side slippage using a side slip tester.
Roll the wheels over the side slip tester as slowly as
possible and take reading on the tester. If the amount
of side slippage is in excess of 5 mm per 1 m, recheck
the wheel alignment.

6. Retightening Wheel Nut

6 and 8 Stud Disc Wheel
The wheel nuts on the right side wheels have right-
hand threads and the wheel nuts on the left side
wheels have left-hand threads.
10 Stud Disc Wheel
The all wheel nuts on the wheels have right-hand
threads.
Wheel Nut Torque N•m(kg•m/lb•ft)
6 stud 539 to 588 (55 — 60 / 398 — 434)
8 stud 539 to 588 (55 — 60 / 398 — 434)
10 stud 490 to 539 (50 — 55 / 362 — 398)
00-24 SERVICE INFORMATION

Wheel Replacement
1. Jack up the wheel, remove the wheel nuts and
wheel, then install the spare wheel.
NOTE:
When replacing wheels, be sure to remove and install
them with their air valve down.
2. Clean the wheel pins and nuts and apply engine oil
or equivalent to the threads.
Install the semi-tighten the wheel nuts and lower
the wheel to the ground.
NOTE:
When replacing rear outer wheel only, also check the
wheel pin nuts on the inner wheel for looseness.
3. With the wheel wrench, tighten the wheel nuts in
sequence as shown in the figure.
Do not overtighten the wheel nuts.
Wheel Nut Torque N•m(kg•m/lb•ft)
6 stud 539 to 588 (55 — 60 / 398 — 434)
8 stud 539 to 588 (55 — 60 / 398 — 434)
10 stud 490 to 539 (50 — 55 / 362 — 398)
00-30 SERVICE INFORMATION

PROPELLER SHAFT
N•m (kg•m/lb•ft)

P30, P46 56 ( 5.7 / 41)

P60H, P90H 106 (10.8 / 78)
P90H 186 (19 / 137)

P30, P46 539 (55 / 398)

P60H, P90H 54 (5.6 / 40) P60H, P90H 687 (70 / 506)
P115HS 1080 (110 / 796)

P30, P46 52 (5.3 / 39)

M12 103 (10.5 / 76)
P60H 95 (9.6 / 70)
M14 157 (16.0 / 116)
M16 255 (26.0 / 188)

206 (21.0 / 152)

Cross Serration Type

3/8 - 24UNF 72 (7.3 / 53)
M12 103 (10.5 / 76)
M14 206 (21 / 152)

M12 103 (10.5 / 76)

7/16 - 20UNF 98 (10 / 72)
 SERVICE INFORMATION 00-31

REAR AXLE
Rear Hub N•m (kg•m/lb•ft)
00-32 SERVICE INFORMATION

Differential N•m (kg•m/lb•ft)

 SERVICE INFORMATION 00-33

FRONT AXLE
Front Hub N•m (kg•m/lb•ft)
4A-2 PROPELLER SHAFT

GENERAL DESCRIPTION
PROPELLER SHAFT

1st and 2nd Propeller Shaft (P115HS)

End Propeller Shaft (P115HS)

1st and 2nd Propeller Shaft (P60H)

1st and 2nd Propeller Shaft (P60H, P90H)

End Propeller Shaft (P60H, P90H)

1st and 2nd Propeller Shaft (P30, P46)

401MT006
 PROPELLER SHAFT 4A-3

End and Front Driving

Propeller Shaft (P30, P46)

FSS/FTS Transmission to Transfer Case

FVZ Interdifferential Propeller Shaft

(DANA made: Type #1610)

Center Bearing (P60H, P90H and P115HS) Center Bearing (P30, P46 and P60H)

Engine torque is transmitted from the trans- The center bearing is used to support the center
mission to the rear axle and the front driving axle portion of the driveline when 2 or 3 propeller shaft
through propeller shafts, the center bearing and are coupled together depending on the
universal joint assembly. wheelbase. The bearing is a ball type and is
The propeller shaft has universal joint and slip mounted in a rubber cushion that is attached to a
joint that absorb road shock and vibration. frame crossmember.
A slip joint is used at the front shaft, forward end The universal joint bearings are installed in the
of the rear shaft and the shaft between transmission bearing cages which are retained in the yoke by
and transfer. snap ring or lock plates and bolts.
 PROPELLER SHAFT 4A-5

PROPELLER SHAFT
REMOVAL

ISUZU Wing Type DANA 1610

Removal Steps
1. Bolt, (washer) and nut : differential side 7. Bracket (P30, P46 and P60H)
2. Bolt, (washer) and nut 8. Lock plate and bolt
3. End propeller shaft 9. Bearing
4. Nut (and washer) : transmission side 10. Bolt and washer
5. Bolt , nut, (cotter pin) and washer 11. Bolt and washer
6. 1st and 2nd propeller shaft assembly 12. Interdifferential propeller shaft assembly
4A-6 PROPELLER SHAFT

Removal Steps

Preparation
Before removing the propeller shafts assembly, apply
setting marks for correct alignment.

CAUTION:
Before disconnecting, support the propeller shaft
assembly with a hoist or wire to eliminate possible safety
hazard.
1. Bolt, (Washer) and Nut : Differential Side
2. Bolt, (Washer) and Nut
3. End Propeller Shaft
4. Nut (and Washer) : Transmission Side
5. Bolt , Nut, (Cotter Pin) and Washer
6. 1st and 2nd Propeller Shaft Assembly
7. Bracket (P30, P46 and P60H)
8. Lock Plate and Bolt (DANA 1610)
9. Bearing (DANA 1610)
Remove the lock plate and bolt, then disconnect the
propeller shaft and the differential.

10. Bolt and washer (ISUZU Wing Type)

11. Bolt and washer (ISUZU Wing Type)
12. Interdifferential Propeller Shaft Assembly
 PROPELLER SHAFT 4A-7

INSTALLATION

ISUZU Wing Type DANA 1610

Installation Steps
1. Interdifferential propeller shaft assembly 7. 1st and 2nd propeller shaft assembly
2. Bearing 8. Nut (and washer)
3. Lock Plate and Bolt 9. Bolt, nut, (cotter pin) and washer
4. Bolt and washer 10. Bolt, (washer) and nut
5. Bolt and washer 11. End propeller shaft assembly
6. Bracket (P30, P46 and P60H) 12. Bolt, (washer) and nut : differential side
4A-8 PROPELLER SHAFT

Installation Steps

NOTE:
Align the setting mark which is applied at removal.
1. Interdifferential Propeller Shaft Assembly
2. Bearing (DANA 1610)
NOTE:
Do not strike the bearings with the hammer.
3. Lock Plate and Bolt (DANA 1610)
Tighten bolts to the specified torque.
Journal Bolt Torque N·m(kg·m / lb·ft)
3/8 - 24UNF 72 (7.3 / 53)

4.Bolt and washer

5.Bolt and washer

Tighten bolts to the specified torque.
Journal Bolt Torque N·m(kg·m / lb·ft)
M12 103 (10.5 / 76)
7/16 - 20UNF 98 (10 / 72)

6.Bracket (P30, P46 and P60H)

For selective use of bolt holes according to the
position of installation of center bearing.
Bracket Bolt Torque N·m(kg·m / lb·ft)
P30, P46 56 ( 5.7 / 41)
P60H 106 (10.8 / 78)
 PROPELLER SHAFT 4A-9

7. 1st and 2nd Propeller Shaft Assembly

Install the propeller shaft with the “UP” mark on the
center bearing facing up.

8. Nut (and Washer)

Propeller Shaft Nut Torque N·m(kg·m / lb·ft)
Nut Size Torque
M12 103 (10.5 / 76)
M14 157 (16.0 / 116)
M14 (Cross Serration Type) 206 (21.0 / 152)
M16 255 (26.0 / 188)

9. Bolt, Nut, (Cotter pin) and Washer

Attach the cushion rubber making sure that it is firmly
seated and is not being forced to the front or rear.
Center Bearing Bolt Torque N·m(kg·m / lb·ft)
P30, P46 52 ( 5.3 / 39)
P60H 95 ( 9.6 / 70)
P60H, P90H, P115HS 186 (19.0 / 137)

10. Bolt, (Washer) and Nut

Propeller Shaft Nut Torque N·m(kg·m / lb·ft)
Bolt Size Torque
M12 103 (10.5 / 76)
M14 157 (16.0 / 116)
M14 (Cross Serration Type) 206 (21.0 / 152)
M16 255 (26.0 / 188)

11. End Propeller Shaft Assembly

4A-10 PROPELLER SHAFT

12. Bolt, (Washer) and Nut : Differential Side

Propeller Shaft Bolt Torque N·m(kg·m / lb·ft)

Bolt Size Torque
M12 103 (10.5 / 76)
M14 157 (16.0 / 116)
M14 (Cross Serration Flange) 206 (21.0 / 152)
M16 255 (26.0 / 188)
 PROPELLER SHAFT 4A-11

DISASSEMBLY

DANA 1610

ISUZU Wing Type

Disassembly Steps
1. Bolt, lock plate and cover (P60H and 12. Sleeve yoke assembly
P90H) 13. Dust cover (P60H)
Snap ring (P30, P46 and P115HS) 14. Sleeve yoke
2. Needle roller bearing 15. End or front driving propeller shaft
3. Flange yoke 16. Bolt
4. Spider 17. Bearing
5. Lock nut 18. Spider
6. Flange and dust cover 19. Bolt and washer
7. Center bearing assembly 20. Journal assembly
8. 1st or 2nd propeller shaft with dust 21. Sleeve yoke assembly
cover 22. Interdifferential propeller shaft
9. Bearing, retainer or case and oil seal 23. Seal cap
10. Cushion rubber and oil seal 24. Sleeve yoke
11. Seal
4A-12 PROPELLER SHAFT

Disassembly Steps

NOTE:
Before disassembly, apply setting marks to coupling
parts for correct alignment.
1. Bolt, Lock Plate and Cover (P60H and P90H)
Snap Ring (P30, P46 and P115HS)

2. Needle Roller Bearing

Tap out the bearing by applying a shock to the
shoulder of the yoke.

3. Flange Yoke
4. Spider

5. Lock Nut
Flange yoke bracket : 9-8522-1243-1

NOTE:
Be sure not to reuse the lock nut.

6. Flange and Dust Cover

7. Center Bearing Assembly
To remove the center bearing assembly from the
propeller shaft end, use a puller or equivalent.

8. 1st and 2nd Propeller Shaft with Dust Cover

 PROPELLER SHAFT 4A-13

9. Bearing, Retainer or Rear Case and Oil Seal

NOTE:
Remove the bearing from the case carefully so as not
to cause damage to the oil seal.

10. Cushion Rubber and Oil Seal

11. Seal
12. Sleeve Yoke Assembly
13. Dust Cover
14. Sleeve Yoke
15. End or Front Driving Propeller Shaft
16. Bolt
17. Bearing
18. Spider
19. Bolt and Washer
20. Journal Assembly
21. Sleeve Yoke Assembly
22. Interdifferential Propeller Shaft
23. Seal Cap
24. Sleeve Yoke

INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are
found through inspection.

Visual Check
Inspect the follwing parts for wear, damage or other
abnormal conditions.
4A-14 PROPELLER SHAFT

Pin Diameter of Spider

Pin Diameter of Spider mm (in)
Standard
P30 23.02 (0.9063)
P46 29.12 (1.1465)
P60H 30.517 (1.2015)
P90H 36.0 (1.4173)
P115HS 41.0 (1.6142)

If excessive wear or pressure marks are found at

needle roller bearing fitting surface or end surface,
replace the spider.

Spider End Float Adjustment

P60H and P90H
1) Install the spider and needle roller bearing to the
flange yoke.
2) Measure the gap "t" between the flange yoke and
the needle roller bearing as figure.
3) Select the shim of proper thickness as a chart.
Thickness of Shims available mm
Gap "t" mm (in.) Shim
less than 0.065 (0.0026) None
0.065 (0.0026) or more, 0.03
less than 0.105 (0.0041)
0.105 (0.0041) or more, 0.05
less than 0.145 (0.0057)
0.145 (0.0057) or more 0.07
4) Install the shim between the needle roller bearing
and the cover as figure ("A" and "B").
NOTE:
Be careful not to damage to the shim.
Spider end float can be adjusted to the specified value
by varying the thickness of the shim.
Spider End Float mm (in.)
0.005 (0.0002) -- 0.065 (0.0026)

P30 and P46

1) Install the spider to the flange yoke.
2) Use a plastic hammer to install the needle roller
bearing to one side of the flange yoke.
3) Use a snap ring pliers to install a 2mm(white) snap
ring to flange yoke.
4) Install the needle roller bearing to the other side of
flange yoke.
5) Install a 2mm(white) snap ring to The other side of
flange yoke.
6) Use a plastic hammer to lightly strike the flange
yoke shoulder to set the position of needle roller
bearings, spider and snap rings.
 PROPELLER SHAFT 4A-15

7) Move the spider. If the spider does not turn easily,

replace one of the 2mm snap rings with a
1.95mm(blue) snap ring.
Thickness of Snap Ring Available
Thickness mm (in) Painted Color
1.95 (0.077) Blue
2.00 (0.079) White
2.05 (0.081) No Painted

P115HS
1) Install the spider to the flange yoke.
2) Use a plastic hammer to install the needle roller
bearing to one side of the flange yoke.
3) Use a snap ring pliers to install a 2.2mm(yellow)
snap ring to flange yoke.
4) Install the needle roller bearing to the other side of
flange yoke.
5) Install a 2.2mm(yellow) snap ring to The other side
of flange yoke.
6) Use a plastic hammer to lightly strike the flange
yoke shoulder to set the position of needle roller
bearings, spider and snap rings.
7) Move the yoke. If more than 15N·m (1.5kg·m/11lb·ft)
is required, the spider and (or) needle roller
bearing must be replaced.
Thickness of Snap Ring
Thickness mm (in) Painted Color
2.20 (0.087) yellow

Propeller Shaft Run–out

Support the propeller shaft at its ends and check for
the run–out by holding the probe of a dial indicator
against the center part of the shaft.
If the amount of run–out is beyond the standard value
for assembly, correct with a bench press or replace
with a new one.
Propeller Shaft Run–out mm (in)
Standard Limit
0.3 (0.0118) or less 0.5 (0.0197)

Play in Splines in Normal Direction of Rotation

Check the amount of play in the sleeve yoke and
propeller shaft splines in direction of rotation using a
pointed feeler gauge.
Play in Splines in Normal
Direction of Rotation mm (in)
Standard Limit
0.15 (0.0059) or less 0.5 (0.0197)
4A-16 PROPELLER SHAFT

REASSEMBLY

DANA 1610

ISUZU Wing Type

Reassembly Steps
1. Sleeve yoke 14. End or front driving propeller shaft
2. Seal cap 15. Cushion rubber and oil seal
3. Interdifferential propeller shaft 16. Bearing, retainer or case and oil seal
4. Sleeve yoke assembly 17. 1st or 2nd propeller shaft
5. Spider 18. Center bearing assembly
6. Bearing 19. Flange and dust cover
7. Bolt 20. Lock nut
8. Journal assembly 21. Spider
9. Bolt and washer 22. Flange yoke
10. Sleeve yoke 23. Needle roller bearing
11. Dust cover (P60H) 24. Bolt, lock plate and cover (P60H and
12. Seal P90H)
13. Sleeve yoke assembly Snap ring (P30, P46 and P115HS)
 PROPELLER SHAFT 4A-17

Reassembly Steps

NOTE:
Align the setting mark which is applied at disassembly.
1. Sleeve Yoke
2. Retainer or Seal Cap
3. Interdifferential Propeller Shaft
4. Sleeve Yoke Assembly
5. Spider
Before assembling the journal assembly on the
flanges, clean the fitting portions and remove any
foreign matter.
6. Bearing
NOTE:
Do not strike the bearings with hammer.
7. Bolt
Tighten the bolts to the specified torque.
Journal Bolt Torque N·m(kg·m / lb·ft)
3/8 - 24UNF 72 (7.3 / 53)

8. Journal Assembly
Before assembling the journal assembly on the
flanges, clean the fitting portions and remove any
foreign matter.
NOTE:
Do not strike the bearings with hammer.
9. Bolt and Washer
Tighten the bolts to the specified torque.
Journal Bolt Torque N·m(kg·m / lb·ft)
M12 103 (10.5 / 76)
7/16 - 20UNF 98 (10 / 72)

10. Sleeve Yoke

4A-18 PROPELLER SHAFT

11. Dust Cover (P60H)

After installing the parts, caulk the felt retainer or the
dust cover at the three portions.

12. Seal
13. Sleeve Yoke Assembly
14. End or Front Driving Propeller Shaft
Apply multi-purpose type grease to the sleeve splines.
15. Cushion Rubber and Oil Seal
16. Bearing, Retainer or Case and Oil Seal
Refill the center bearing with multi-purpose type
grease.

17. 1st or 2nd Propeller Shaft

Apply multi-purpose type grease to the sleeve splines.
18. Center Bearing Assembly
Install the center bearing assembly by using an
adequate installer.

19. Flange and Dust Cover

 PROPELLER SHAFT 4A-19

20. Lock Nut

Flange yoke bracket : 9-8522-1243-1
Tighten the lock nut to the specified torque.
Lock Nut Torque N·m(kg·m / lb·ft)
P115HS 1080 (110 / 796)
P60H, P90H 687 (70 / 506)
P30, P46 539 (55 / 398)

Caulking the lock nut against the groove in the shaft.

Be sure to use a new lock nut.
After caulking, make sure that the flange of the nut is
in contact with the spline of the shaft at three different
point as illustrated.

21. Spider
Install the grease fitting at the specified angle to the
spider.
4A-20 PROPELLER SHAFT

22. Frange Yoke

The relative parts positions should be aligned as
follows.
 PROPELLER SHAFT 4A-21

23. Needle Roller Bearing

Insert the spider to the flange yoke. Using the spider
as a guide, install the needle roller bearing into the
hole in the arm of the flange yoke by tapping with a
soft-faced hammer.

24. Bolt, Lock Plate and Cover (P60H and P90H)

Snap Ring (P30, P46 and P115HS)
Be sure to use a new lock plate.
Lock Plate Bolt Torque N·m(kg·m / lb·ft)
54 (5.6 / 40)

After tightening the bolt, bend down the lock plate

both sides to lock the bolt.
 REAR AXLE 4B-1

SECTION 4B
REAR AXLE

CONTENTS

PAGE
General Description ........................................................................................................... 4B- 2
Rear Hub
Disassembly ....................................................................................................................4B- 4
Inspection and Repair.....................................................................................................4B- 7
Reassembly .....................................................................................................................4B- 8
Differential
(Single Axle, FVM Forward Rear Axle)
Removal ...........................................................................................................................4B-13
Installation.......................................................................................................................4B-15
Disassembly ....................................................................................................................4B-16
Inspection and Repair.....................................................................................................4B-22
Reassembly .....................................................................................................................4B-26

NOTE:
For the disassembly, reassembly, and inspection of ROCKWELL made rear axle used in FVR / FVD / FVL /
FVZ / FVY / GVR / GVD, refer to the ROCKWELL rear axle Workshop Manual.
 REAR AXLE 4B-11

9. Lock Washer
If the holes in the lock washer do not align with the
threaded holes in the nut, reverse the lock washer. If
an alignment can not be obtained with the lock
washer reversed, turn the nut in as necessary.

10. Axle Shaft

Axle Shaft Bolt Torque N·m (kg·m/lb·ft)

13.5”, 14.5” 113 (11.5 / 83)
15.5”, 16.5” 177 (18.0 / 130)
17.5” 181 (18.5 / 134)

11. Tire and Wheel

NOTE:
When installing wheels, be sure to install them with
their air valve down.

12. Wheel Nut

1) Clean the wheel pins and nuts, and apply a coat of
engine oil or equivalent to the threads.
2) Tighten the wheel nuts in the sequence shown in
the illustration.
Do not overtighten the wheel nuts.
Wheel Nut Torque N·m(kg·m/lb·ft)
6 stud 539 to 588 (55 — 50 / 398 — 434)
8 stud 539 to 588 (55 — 60 / 398 — 434)
10 stud 490 to 539 (50 — 55 / 362 — 398)

3) Check the brake lining clearance.

4) Check the front wheel alignment.
5) Should be bleed the brake hydraulic circuit (except
Full Air Brake).
 REAR AXLE 4B-15

Installation Steps

3. Differential Carrier Assembly

Before installing the differential carrier assembly to
the axle case, wipe off the oil on the installation
surface with thinner, etc. Then, install it after applying
the whole liquid gasket (Three Bond 1215, LOCTITE
17430 or equivalent) avoiding the position just
opposite to the bolt hole for removing the differential
carrier.
• Apply liquid gasket (LOCTITE 242 or equivalent) to
threads on differential carrier fixing bolts.

Differential Carrier Bolt N·m(kg·m/lb·ft)

Differential size Torque
13.5” 67 ( 6.8 / 49)
14.5” 104 (10.6 / 77)
15.5” 157 (16.0 / 116)
16.5”, 17.5” 186 (19.0 / 137)

2. Propeller Shaft
NOTE:
When install the propeller shaft, align the setting
marks which is applied at removal.
Propeller Shaft Bolt Torque N·m(kg·m/lb·ft)
Bolt Size Torque
M12 103 (10.5 / 76)
M14 157 (16.0 / 116)
M16 255 (26.0 / 188)
M14(Cross Serration Type) 206 (21 /152)
3/8 - 24UNF 72 (7.3 / 53)
7/16 - 20UNF 98 (10 / 72)

1. Axle Shaft
Axle Shaft Bolt Torque N·m(kg·m/lb·ft)
Differential size Torque
13.5”, 14.5” 113 (11.5 / 83)
15.5”, 16.5” 177 (18.0 / 130)
17.5” 181 (18.5 / 134)
4B-16 REAR AXLE

DISASSEMBLY
Differential Carrier Assembly

Disassembly Steps
1. Lock plate 6. Drive pinion and cage assembly
2. Bearing cap 7. Drive pinion depth adjusting shim
3. Adjusting nut 8. Pilot bearing retainer
4. Side bearing outer race 9. Pilot bearing outer race
5. Differential cage and ring gear assembly
 REAR AXLE 4B-17

Disassembly Steps

1. Lock Plate
2. Bearing Cap
Apply a mark to the right and left side bearing caps to
prevent interchanging them.

3. Adjusting Nut
To facilitate installation of the adjusting nuts into
original position apply a mark to the appropriate
position.
As the right and left side adjusting nuts are differently
thick, be sure to mark them during disassembly to
prevent confusion.

4. Side Bearing Outer Race

Keep the bearing caps, adjusting nuts and side
bearing outer races separate to prevent interchanging.

5. Differential Cage and Ring Gear Assembly

Place suitable bar through the axle shaft fitting hole
and lift the differential cage and ring gear assembly,
with a wire set against the bar, using a hoist.

6. Drive Pinion and Cage Assembly

7. Drive Pinion Depth Adjusting Shim
8. Pilot Bearing Retainer
9. Pilot Bearing Outer Race
 REAR AXLE 4B-35

Differential Carrier Assembly

Reassembly Steps
1. Pilot bearing outer race 6. Bearing cap
2. Pilot bearing retainer 7. Pinion depth adjusting shim
3. Differential cage and ring gear assembly 8. Drive pinion and cage assembly
4. Side bearing outer race 9. Lock plate
5. Adjusting nut
4B-40 REAR AXLE

4. When using Belco Bond 402, be sure to thin it with

a solvent (Three Bond 2801 or equivalent) before
application, since the undiluted solution of Belco
Bond 402 is too thick to apply.
The best ratio Belco Bond 402 : Solvent is 5 : 2
(cubic ratio).

9. Lock Plate
4C-16 FRONT AXLE

10. Wheel and Tire

NOTE:
When installing wheels, be sure to install them with
their air valve down.
11. Wheel Nut
(1) Clean the wheel pins and nuts and apply a coat of
engine oil or equivalent to the threads.
(2) Tighten the wheel nuts in the sequence shown in
the illustration.
Do not overtighten the wheel nuts.

Wheel Nut Torque N•m (kg•m / lb• ft)

6 stud 539 to 588 (55 — 60 / 398 — 434)
8 stud 539 to 588 (55 — 60 / 398 — 434)
10 stud 490 to 539 (50 — 55 / 362 — 398)

(3) Check the brake lining clearance.

(4) Check the front wheel alignment.
(5) Should be bleed the brake hydraulic circuit (Except
Full Air Brake).
 FRONT AXLE 4C-33

Installation Steps

3. U-bolt and Nut

Apply a coat of molybdenum disulfide grease to the
threads of the U-bolts.
U-bolt and Nut Torque N•m (kg•m / lb•ft)
M16 201 (20.5 / 148)
M18 373 (38.0 / 275)
M22 539 (55.0 / 398)

4. Drag Link
• Install the drag link with the front mark applied to
the drag link toward the vehicle front.
• Tighten nuts to the specified torque, with just
enough additional torque to align cotter pin holes.
• Be sure to use a new cotter pin.
Drag Link Nut Torque (Both Side) N•m (kg•m / lb•ft)
FTR, FTS, FVR, FVD, FVM,
265 (27 / 195)
FVL, FVZ, FVY, GVR, GVD
FRR, FSR, FSS 147 (15 / 108)

2. Shock Absorber
Install the shock absorber, nuts, washers and rubber
bushings in the sequence shown in the illustration.
Tighten the nut until the washer makes contact with
the shaft end fitting surface.

1. Brake Flexible Hose (Except Full Air Brake Models)

Install brake flexible hoses in position properly
without twisting.
Brake Flexible Hose Flare
Nut Torque N•m (kg•m / lb•ft)
93 (9.5 / 69)
 MGPRO-WE-9621

You are requested to order this manual using the

manual number that is shown above.

This manual is applicable for vehicles in all countries

except the USA and Canada.

All rights reserved. This manual may not be re-

produced in whole or in part, without the per-
mission in writing of ISUZU MOTORS LIMITED.

Issued by

ISUZU MOTORS LIMITED

INTERNATIONAL SERVICE DEPARTMENT

Tokyo, Japan

First edition Dec., 2002

No. MGPRO-WE-9621 PRINTED IN JAPAN