ISUZU AXIOM 2002 Service Repair Manual

4C±84
DRIVE SHAFT SYSTEM

Aluminum tube type only: Inspect the aluminum
tubing for surface scratches and dents. These
scratches may not exceed 0.2 mm (0.008 in) in depth.
401RW022

Aluminum tube type only: Visually inspect the circle
welds and fittings for any signs of cracks or signs of
deterioration. If there are any cracks that exceed 0.2
mm (0.008 in) in depth, the assembly must be
replaced.

Aluminum tube type only: Check to be sure there are
no missing balance weights. If balance weights are
missing and void has occurred in the aluminum tubing
greater than 0.2 mm (0.008 in), the assembly must be
replaced.
Universal Joint Reassembly
1. Pack the four grease cavities of the spider with a high
quality, extreme pressure N.L.G.I. Grade 2 grease.
Do not add additional grease to bearing cup
assembly.
2. Move one end of the spider to cause a trunnion to
project through the spider hole beyond the outer
machined face of the yoke lug. Place a bearing over
the trunnion diameter and align it to the spider hole.
Using an arbor press, hold the trunnion in alignment
with the spider hole and place a solid plug on the
upper bearing. Press the bearing into the spider hole
enough to install snap ring.
401RW026
3. Install a snap ring.
NOTE: Be sure the snap rings are properly seated in the
grooves.
4. Repeat steps 2 and 3 to install the opposite bearing. If
the joint is stiff, strike the yoke ears with a soft
hammer to seat the bearing.
5. Align the setting marks and join the yokes.

4C±85 DRIVE SHAFT SYSTEM
Slip Joint Reassembly
401RX00001
Legend
(1) Spline Yoke and Universal Joint Assembly
(2) Clamp(3) Boot
(4) Clamp
(5) Tube and Universal Joint Assembly
1. Apply grease evenly to both the female and male
splines.
2. Apply a small amount of grease by finger to the outer
lips of the boot.
3. Slide the boot (smaller diameter side) onto the spline
yoke shaft being careful not to damage the spline
coating or boot.
4. Insert the spline yoke shaft spline into the tube
assembly being careful to maintain proper phasing.
The spider holes should be in line as originally marked
prior to disassembly.
5. Position boot onto tube and yoke shaft in its
assembled position.
6. Attach boot clamps and secure using pliers.7. Be sure clamp is properly seated and secure.
CAUTION: Only use a similar type or same as the
original type clamp. Using any other clamp may
create an imbalanced shaft or lead to grease leakage.

4C±86
DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
2WD Model4WD Model
EngineY22SE6VD16VD1
TransmissionM/TA/TM/TA/TM/TA/T
Type (See illustration)121223
Length
between two spiders
center)1314.4mm
(51.75in)1334.7mm
(52.55in)1298.4mm
(51.12in)1323.0mm
(52.09in)1191.2mm
(46.9in)1021.2mm
(40.21in)
Universal joint typeCardan type
Torque Specifications
401R100001

4D2±1 TRANSFER CASE (TOD)
AXIOM
DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution 4D2±1. . . . . . . . . . . . . . . . . . . . . .
General Description 4D2±2. . . . . . . . . . . . . . . . . . . . .
Removal and Installation of Tfansfer Case
Assembly 4D2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 4D2±4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal 4D2±6. . . . . . . . . . . . . . . . . . .
Removal 4D2±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD Control Unit 4D2±8. . . . . . . . . . . . . . . . . . . . . . . .
Removal 4D2±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4D2±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair 4D2±9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Reassembly of Major
Components 4D2±9. . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 4D2±10. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4D2±10. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Cover Assembly 4D2±13. . . . . . . . . . . . . . . .
Disassembly 4D2±13. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4D2±14. . . . . . . . . . . . . . . . . . Reassembly 4D2±15. . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pack and Clutch Cam
(Transfer Case Assembly) 4D2±16. . . . . . . . . . . . . . .
Disassembly 4D2±16. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4D2±18. . . . . . . . . . . . . . . . . . . . . . . . . .
Chain, Sprocket and Mechanical Lock
(Transfer Case Assembly) 4D2±20. . . . . . . . . . . . . . .
Disassembly 4D2±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4D2±22. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly 4D2±24. . . . . . . . . . . . . . . . .
Disassembly 4D2±24. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4D2±26. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
(Transfer Case Assembly) 4D2±28. . . . . . . . . . . . . .
Main Data and Specification 4D2±32. . . . . . . . . . . . . .
General Specification 4D2±32. . . . . . . . . . . . . . . . . .
Torque Specifications 4D2±33. . . . . . . . . . . . . . . . . .
Torque Specifications (Cont'd) 4D2±34. . . . . . . . . . .
Torque Specifications (Cont'd) 4D2±35. . . . . . . . . . .
Special Tools 4D2±36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

4D2±2
TRANSFER CASE (TOD)
General Description
A04R200003
The Torque-On-Demand (TOD) is an
electronically-controlled torque-split 4-wheel drive
system with the following features.
Shifting Between High and Low Ranges
The shifting mechanism consists of the cam and shaft rail
assembly, the high/low shift motor and the encoder. The
encoder is built-in to the motor.
The encoder senses high/low range shift motor rotation
position and sends this data to the TOD control unit.
Based on this data, the TOD control unit adjusts motor
rotation speed or stops the motor.
The shifting between the high and low ranges using the
TOD switch only is possible. The vehicle must be stopped
or nearly stopped (vehicle speed less than 2 km/h (1.2
mph) and engine speed less than 1,500 rpm), the
automatic transmission selector level must be in the
neutral (N) position, and the brakes must be applied.
Electronically-controlled Wet-type Multiple
Disc Clutch
The clutch automatically provides the optimum drive
power to the front wheels of the vehicle in response to
varying road surface conditions when the vehicle is
operated in the TOD mode. The delivered power ranges
from 0% to 100% of power train output. Superior
operational stability is maintained over a wide range of
operating conditions.
Front Output Drive
Front output drive is provided by a chain. This reduces the
loud noise associated with 4-wheel drive operation.
Oil Pump Lubrication
An oil pump is used to lubricate the transfer. This ensures
stable multiple-disc clutch operation and maintains the
lubricating oil at a constant temperature.

4D2±3 TRANSFER CASE (TOD)
Removal and Installation of Tfansfer Case Assembly
F07R200001
Legend
(1) Transfer Protector
(2) Front Propeller Shaft Assembly
(3) Speedometer Sensor Harness Connector
(4) Rear Propeller Shaft Assembly(5) Center Exhaust Pipe
(6) Transfer Case Bolt
(7) Transfer Case Assembly
(8) Transfer Case Harness Connector

4D2±4
TRANSFER CASE (TOD)
Removal
1. Disconnect the battery ground cable.
2. Remove the transfer protector.
3. Disconnect the rear propeller shaft assembly from the
transfer case.
4. Disconnect the front propeller shaft assembly from
the transfer case.
5. Remove the center exhaust pipe.
6. Disconnect the speedometer sensor harness
connector from the speedometer sensor, and remove
the harness clamp from the connector bracket of the
transfer case.
7. Disconnect the engine harness connector from the
transfer harness connector.
8. Support the transfer case with a transmission jack.
9. Remove the transfer bolts.
10. Remove the transfer case assembly.
Installation
1. Apply grease (Besco L2 or its equivalent) to the input
shaft spline.
260RY00011
2. Install the transfer case assembly to the transmission
assembly.
3. Install the transfer bolts to the specified torque (Refer
to
next page).
Torque: 46 N´m (34 lb ft)
4. Connect the engine harness connector to the transfer
harness connector.
5. Install the breather hose up to bottom of the transfer
case breather and clip them firmly.
6. Securely insert the breather hose into the cutout
portion of the transfer case.
260R200001

4D2±5 TRANSFER CASE (TOD)
7. Install the speedometer harness clamp to the
connector bracket of the transfer case, and then
connect the harness connector to the speedometer
sensor.
261R200008
8. Install the center exhaust pipe.
Torque: 43 N´m (32 lb ft)
9. Connect the front and rear propeller shaft assembly
to the transfer case.
Torque: 63 N´m (46 lb ft)
10. Install the transfer protector.
Torque: 37 N´m (27 lb ft)
11. Connect the battery ground cable.

4D2±6
TRANSFER CASE (TOD)
Transfer Rear Oil Seal
261R200002
Legend
(1) Transfer Rear Oil Seal(2) End Nut, Washer, Oil Seal and Rear
Companion Flange
(3) Rear Propeller Shaft Assembly
Removal
1. Disconnect the rear propeller shaft assembly from the
transfer case.
2. Using the flange holder J±8614±11, remove the end
nut.
3. Using the universal puller, remove the companion
flange, washer and oil seal.
4. Remove the transfer rear oil seal from the transfer
case.
Installation
1. Apply oil to the circumference of the transfer rear oil
seal.Fill the oil seal lip with grease (Besco L2 or its
equivalent).
2. Using the oil seal installer J±42804, install the transfer
rear oil seal to the transfer case.
261RY00017

4D2±7 TRANSFER CASE (TOD)
NOTE: When installing the oil seal, pay attention to the
direction.
261RW006
Legend
(1) Inside
(2) Outside
3. Install the companion flange.
4. Install the oil seal and washer, and using the flange
holder J±8614±11, install the new end nut to the
specified torque.
Torque: 167 N´m (123 lb ft)5. Securely stake the end nut at one spot.
NOTE: Be sure to confirm that there is no clack at the
staked portion of the end nut after staking.
266RY00003
266R200004
6. Connect the rear propeller shaft assembly to the
transfer case.
Torque: 63 N´m (46 lb ft)