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 Re: 5.38 gear install kit?
#114552
06/11/03 08:09 PM
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Joined: Jan 2000
Posts: 2,437
Body Damage is Cool
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Step 18 - remove the driver's side lower a-arm.
Shep is right though, if you take both off it is just a matter of using the floor jack to drop it and raise it back up. Working in my one-car garage I prefer to do most of the work from one-side of the vehicle.
Steve
1990 Amigo XS 4x4, BFG MT 35s, Front & Rear ARBs, 5.38s, Tera Lows, custom springs, custom nerf bars, DOR Front Bumper, custom rear bumper, HD 9500 winch, some CalMini & other stuff
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Re: 5.38 gear install kit?
#114553
06/11/03 09:14 PM
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Joined: Sep 2000
Posts: 202
Wheeler
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Steve, thanks for spelling it out. Gives me a better idea of what to expect than what the Haynes gives me.
It would be my first time pulling the front (and
rear for that matter).
Now to do some inner soul searching, do I attempt it myself, do it now or wait until Fall/winter...
Time is a major constraint...
Kim
'99 2wd Rodeo LS, '90 4x4 Isuzu Pick up
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Re: 5.38 gear install kit?
#114554
06/12/03 01:38 AM
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Joined: Jun 2002
Posts: 78
Getting the Wheeling Fever
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I did my 5.38 front install while everyone else was in Moab!
Talking about a 91 Trooper here, so yours may vary.
Take off the brake caliper and tie it up out of the way. The front stabilizer bar will have to come off(no biggie). The tie-rod end does not have to come off. The hub does not have to come off. I removed the top ball joint by just taking out the four bolts(propping it up with a big wrench) and then letting the lower arm swing gently down, using my legs as a dropping bench(I had already flipped the ball joints). Took the CV joint inner boot loose, and pulled the circlip out of the inner can, then gently worked the CV shaft around, turning the wheel hub, until the ball collector thinging just came out. It will come out, along with all the balls, but you need to clean them up anyway prior to re-installing them. Learned this technique from Jerry Lemond!
Bought all my parts from Jerry as well. Had Fort Worth Gear & Axle install the 5.38 set AND the front ARB locker. Their bill was $200.00. Don't let the gear changers buy the parts! They will buy them from Isuzu dealers and add a nice(for them)markup. Buy the stuff from Jerry. If you do, you will also enjoy a very nice learning experience. I bought all seals, crush sleeve, carrier bearings, etc from him. Saved a lot of money.
Goes back together easily the same way. Look out, that front axle housing is very heavy and you will need to wiggle the lower a-frame a little to get the clearance necessary to drop it out as it will still have the inner cans attached.
Have the t-case at FW B&T now for the Teralow install. Should have it back this week and will be up and running shortly!!!!!!!
Bob
'91 Trooper 3.4 V6 ARBs F&R, 33" BFG, 3.07 Teralows, 5.38 F&R, 4" lift, boulder bars, roof rack, torsion bars, Matt's tie-rod ends, manual hubs, heavy springs, homemade front and rear bumpers,rock sliderz, etc. 2000 Trooper
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Re: 5.38 gear install kit?
#114555
06/13/03 07:15 AM
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Joined: Jan 2000
Posts: 2,437
Body Damage is Cool
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</font><blockquote><font size="1" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">quote:</font><hr /><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">The front stabilizer bar will have to come off(no biggie).</font><hr /></blockquote><font size="2" face="Verdana, Tahoma, Arial, Helv, Helvetica, Sans">Oh yeah, the stabilizer bar. Thats that crooked piece of steel that's been leaning against my garage wall for the last 9 or 10 years.
Steve
1990 Amigo XS 4x4, BFG MT 35s, Front & Rear ARBs, 5.38s, Tera Lows, custom springs, custom nerf bars, DOR Front Bumper, custom rear bumper, HD 9500 winch, some CalMini & other stuff
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Re: 5.38 gear install kit?
[Re: lttlbddy]
#114556
02/13/04 02:55 AM
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Joined: Sep 2000
Posts: 202
Wheeler
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Procedure for removing front axle housing: 1) Loosen lug nuts from both front tires 2) Jack up front end, secure safely with jack stands 3) Drain oil out of housing 4) Remove front tires 5) Relieve pressure on torsion bars 6) Remove both hubs 7) Remove c-clips from both axles Note - my choice was to work from the drivers side, so: 8) Remove driver's side brake caliper and secure up and out of the way 9) Remove drivers side shock 10) Remove steering stabilizer (if applicable) 11) Remove crossmember 12) Detach front end of front driveshaft 13) Detach steering center link from steering box, steering idler and tie rods. 14) Remove at least 3 of the bolts holding the steering idler to frame (loosen the last one) - this will give enough clearance to get the center link out of the mounting point. This is necessary to provide enough clearance to get the axle housing out. 15) Remove the 4 bolts for the upper ball joint (you may need to break the ball joint loose - if you have done a balljoint flip it is not necessary to break ball joint loose) 16) Remove 4 bolts from lower ball joint 17) Remove driver's side rotor and steering knuckle 18) Remove driver's side lower a-arm 19) Remove the hose from the axle vent tube Note - the next step requires either a floor jack and at least one jack stand or a strong friend who is willing to hold and muscle the axle housing on his/her chest. 20) Secure the axle housing while removing the 4 bolts/nuts that hold the housing to the frame At this point the housing should be free and ready to come out. By moving the housing toward the drivers side, I was able to slide the passenger side axle out of the rotor/steering knuckle assembly and gentle set it on the floor. 21) Remove the 4 bolts from both the drivers side and passenger side of the axle housing. This will allow you to remove both axles from the housing. You may need to use a rubber mallet (or something) to persuaid the axles to part company with the housing. Once the axles are out: 22) Remove all of the bolts the hold the third member onto the housing. 23) Remove the third member from the housing. There!! You are done. <img src="/forums/images/graemlins/kewl.gif" alt="" /> <img src="/forums/images/graemlins/lol.gif" alt="" /> <img src="/forums/images/graemlins/shiner.gif" alt="" /> <small>[ June 11, 2003, 04:36 PM: Message edited by: lttlbddy ]</small> Thanks Steve, I finally took the front out today. Your write along with Haynes and it is on the floor! Tomorrow the 3rd member will go to the shop and hopefully will get it back by next week. Not the 10 weeks a different shop had my rear for, but thats a different nightmare. I didn't take out the lower a-arms, used a floor jack and bottle jack to lower and push-pull. Putting it back in will be just as much fun. I think I'll try a sissor jack with the floor jack though. Thanks again for the help.
Kim
'99 2wd Rodeo LS, '90 4x4 Isuzu Pick up
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Re: 5.38 gear install kit?
[Re: Roadends]
#114557
02/13/04 03:33 AM
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Joined: Jun 2001
Posts: 846
Rock Warrior
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Is it possible to pull the front without lowering the entire housing? I'm looking at swapping in another 3rd with a limited slip(thanks lttlbddy!) and wasn't expecting to have to undo the whole dang thing. What about all those part #'s from Jerry? Can anyone post up a list? zuzusan, better late then never huh? <img src="/forums/images/graemlins/smile.gif" alt="" /> shoots, if I'm going to have to go through all the steps on Steve's list I think it may take me that long too! <img src="/forums/images/graemlins/shiner.gif" alt="" />
2.6 Trooper
2.0 Impulse Turbo
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Re: 5.38 gear install kit?
[Re: pucci]
#114558
02/13/04 04:08 AM
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Joined: Apr 2000
Posts: 7,268
Isuzu Moderator
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What about all those part #'s from Jerry? Can anyone post up a list?Dude, in the spirit of me being the search nazi this week, SEARCH!!! <img src="/forums/images/graemlins/smile.gif" alt="" /> It is either in Tech or maybe the Archives. There is a post with all the part numbers from Jerry and those I sourced and crossed with Timken #'s. I would post up, but it has already been done!!! <img src="/forums/images/graemlins/smile.gif" alt="" /> Michael
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Re: 5.38 gear install kit?
[Re: pucci]
#114559
02/13/04 04:56 PM
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Anonymous
Unregistered
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Kim, too bad about the rear gear fiasco..... (who was that ? ) If it isn't too late, River City Differential in Sacramento is highly regarded and stands behind their work. He just completed my 5.38 12-bolt w/ARB for very reasonable $$$....They have already seen one Isuzu so they wont laugh as hard this time <img src="/forums/images/graemlins/lol.gif" alt="" /> (916) 852-7109
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Re: 5.38 gear install kit?
#114560
02/13/04 06:40 PM
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Joined: Sep 2000
Posts: 202
Wheeler
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A local place (Suisun City). I blame myself for not doing better research. Around here (Fairfield, Vallejo, Vacaville) there is only one Isuzu dealer remaining (Vallejo) and "the shop" I used only dealt with the dealer (probably because they didn't know where else to look). I was raped, but I blame myself, was in to much of a hurry and didn't bother checking around. My front will be done by a shop in Vacaville (no ARB). I've talked to the tech on the phone and he sounds like he knows what he's doing. A $250.00 quote (not counting bearings) I have the list of part numbers(as provided by Michael, thanks). For the inquire above do a search for "Diff bearings source????" that was started 03/03/03 <img src="/forums/images/graemlins/rolleyes.gif" alt="" /> Thanks for the info in Sac the bigger cities have all the good shops <img src="/forums/images/graemlins/coolg.gif" alt="" />
Kim
'99 2wd Rodeo LS, '90 4x4 Isuzu Pick up
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