oil level ISUZU AXIOM 2002 Service Repair Manual

0A±1
GENERAL INFORMATION
AXIOM
GENERAL INFORMATION
CONTENTS
General Information 0A. . . . . . . . . . . . . . . . . . . . .
Maintenance and Lubrication 0B. . . . . . . . . . . . .
General Information
CONTENTS
General Repair Instruction 0A±1. . . . . . . . . . . . . . . .
Illustration Arrows 0A±2. . . . . . . . . . . . . . . . . . . . . . .
Identification 0A±3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Theft Prevention Standard 0A±5. . . . . . . . . . . . . . . . Lifting Instructions 0A±9. . . . . . . . . . . . . . . . . . . . . . .
Standard Bolts Torque Specifications 0A±11. . . . . .
Abbreviations Charts 0A±12. . . . . . . . . . . . . . . . . . . .
Service Parts Identification Plate 0A±13. . . . . . . . . .
General Repair Instruction
1. If a floor jack is used, the following precautions are
recommended.
Park vehicle on level ground, ªblockº front or rear
wheels, set jack against the recommended lifting
points (see ªLifting Instructionsº in this section), raise
vehicle and support with chassis stands and then
perform the service operations.
2. Before performing service operations, disconnect
ground cable from the battery to reduce the chance of
cable damage and burning due to short circuiting.
3. Use a cover on body, seats and floor to protect them
against damage and contamination.
4. Brake fluid and anti±freeze solution must be handled
with reasonable care, as they can cause paint
damage.
5. The use of proper tools and recommended essential
and available tools, where specified, is important for
efficient and reliable performance of service repairs.
6. Use genuine Isuzu parts.
7. Used cotter pins, plastic clips, gaskets, O±rings, oil
seals, lock washers and self±locking nuts should be
discarded and new ones should be installed, as
normal function of the parts cannot be maintained if
these parts are reused.
8. To facilitate proper and smooth reassembly
operation, keep disassembled parts neatly in groups.
Keeping fixing bolts and nuts separate is very
important, as they vary in hardness and design
depending on position of installation.
9. Clean the parts before inspection or reassembly. Also
clean oil ports, etc. using compressed air, and make
certain they are free from restrictions.
10. Lubricate rotating and sliding faces of the parts with
oil or grease before installation.
11. When necessary, use a sealer on gaskets to prevent
leakage.
12. Carefully observe all specifications for bolt and nut
torques.13. When removing or replacing parts that require
refrigerant to be discharged from the air conditioning
system, be sure to use the Vehicle Refrigerant
Recovery and Recycling Equipment (VRRRE) to
recover and recycle Refrigerant±134a.
14. When a service operation is completed, make a final
check to be sure the service has been done properly
and the problem has been corrected.
15. SUPPLEMENTAL RESTRAINT SYSTEM
The vehicle is equipped with a Supplemental
Restraint System (SRS) ± Air Bags. This system is
not to be serviced without consulting the appropriate
service information. Consult Section 9J ªSRS
Systemº if work is to be done on the front of the
vehicle such as bumper, sheet metal, seats, wiring,
steering wheel or column. Also review SRS system
information if any arc welding is to be done on the
vehicle. The SRS system equipped vehicle can be
identified by:
1. ªAIR BAGº warning light on the instrument
cluster.
2. A Code ªKº or ªMº for fifth digit of Vehicle
Identification Number.

0B±5 MAINTENANCE AND LUBRICATION
Explanation of Complete Vehicle
Maintenance Schedule
Brief explanations of the services listed in the preceding
Maintenance Schedule are presented below.
Replace all questionable parts and note any necessary
repairs as you perform these maintenance procedures.
Front and Rear Axle Lubricant
Replacement
Check the lubricant level after every 7,500 miles (12,000
km) of operation and add lubricant to level of filler hole if
necessary.
Replace the front and rear axle lubricant at 15,000 miles
(24,000 km) and 30,000 miles (48,000 km) and after
every 30,000 miles (48,000 km) of operation thereafter.
Air Cleaner Element Replacement
Replace the air cleaner under normal operating
conditions every 30,000 miles (48,000 km).
Operation of the vehicle in dusty areas will necessitate
more frequent replacement.
Spark Plug Replacement
Replace the plugs at 100,000 miles (160,000 km)
intervals with the type specified at the end of this section.
Cooling System Service
Drain, flush and refill system with new engine coolant.
Refer to
ªRecommended Fluids and Lubricantsº in this
section, or ENGINE COOLING (SEC.6B).
Timing Belt Replacement
Replacement of the timing belt is recommended at every
100,000 miles (160,000 km).
Failure to replace the timing belt may result in serious
damage to the engine.
Valve Clearance Adjustment
Incorrect valve clearance will result in increased engine
noise and reduced engine output.
Retorque the camshaft bracket bolts before checking and
adjusting the valve clearance.
Check and adjust the valve clearance whenever
increased engine noise is heard.
Tire Rotation
Rotate tires every 7,500 miles (12,000 km).
Front Wheel Bearings Lubricant
Replacement (Vehicles Produced Before
July/31/2001)
Clean and repack the front wheel bearings at 30,000
miles (48,000 km) intervals.
Refer to DRIVE SHAFT SYSTEM (SEC. 4C).
Front Wheel Bearings Check (Vehicles
Produced After Aug./1/2001)
Inspect hub unit bearing at every 60,000 miles (96,000
km).
If there is abnormal condition, replace hub unit bearing.
Radiator Core and Air Conditioning
Condenser Cleaning
Clean the front of the radiator core and air conditioning
condenser, at 60,000 miles (96,000 km) intervals.
Fluid Level Check
A fluid loss in any system (except windshield
washer) may indicate a problem. Repair the system
at once.
Engine oil level
Check level and add if necessary. The best time to check
the engine oil level is when the oil is warm. After stopping
the engine with the vehicle on a level surface, wait a few
minutes for the oil to drain back to the oil pan. Pull out the
oil level indicator (dipstick). Wipe it clean and push the oil
level indicator back down all the way. Pull out the oil level
indicator, keeping the tip down, and look at the oil level on
it.
Add oil, if needed, to keep the oil level above the ªADDº
mark and between the ªADDº and ªFULLº marks in the
operating range area. Avoid overfilling the engine since
this may cause engine damage. Push the oil level
indicator back down all the way after taking the reading.
If you check the oil level when the oil is cold, do not run the
engine first. The cold oil will not drain back to the pan fast
enough to give a true oil level.
Engine coolant level and condition
Check engine coolant level in the coolant reservoir and
add engine coolant if necessary. Inspect the engine
coolant and replace it if dirty or rusty.
Windshield washer fluid level
Check washer fluid level in the reservoir and add if
necessary.
Power steering system reservoir level
Check and keep at the proper level.
Brake master cylinder reservoir level
Check fluid. Keep fluid at proper level. A low fluid level can
indicate worn disc brake pads which may need to be
serviced.
Hydraulic clutch system
Check fluid level in the reservoir. Add fluid as required.
Battery fluid level
Check fluid level in the battery.
Fluid Leak Check
Check for fuel, water, oil or other fluid leaks by looking at
the surface beneath the vehicle after it has been parked
for a while. Water dripping from the air conditioning
system after use is normal. If you notice gasoline fumes or
fluid at any time, locate the source and correct it at once.
Engine Oil and Oil Filter Replacement
Always use API SE, SF, SG, SH or ILSAC GF±1 quality
oils of the proper viscosity.
When choosing an oil, consider the range of
temperatures the car will be operated in before the next oil
change. Then, select the recommended oil viscosity from
the chart.

0B±6MAINTENANCE AND LUBRICATION
Always change the oil and the oil filter as soon as possible
after driving in a dust storm.
Engine Cooling System Inspection
Inspect the coolant/anti±freeze. If the coolant is dirty or
rusty, drain, flush and refill with new coolant. Keep coolant
at the proper mixture for proper freeze protection,
corrosion inhibitor level and best engine operating
temperature. Inspect hoses and replace if cracked,
swollen or deteriorated. Tighten the hose clamps if
equipped with screw±type clamps. Clean outside of
radiator and air conditioning condenser. Wash filler cap
and neck. To help ensure proper operation, a pressure
test of both the cooling system and the cap is also
recommended.
Exhaust System Inspection
Visually inspect the exhaust pipes, muffler, heat shields
and hangers for cracks, deterioration, or damage.
Be alert to any changes in the sound of the exhaust
system or any smell of fumes. These are signs the system
may be leaking or overheating. Repair the system at
once, if these conditions exist. (See also ªEngine Exhaust
Gas Safetyº and ªThree Way Catalytic Converterº in the
Owner's manual.)
Fuel Cap, Fuel Lines, and Fuel Tank
Inspection
Inspect the fuel tank, the fuel cap and the fuel lines every
60,000 miles (96,000 km) for damage which could cause
leakage.
Inspect the fuel cap and the gasket for correct sealing and
physical damage. Replace any damaged parts.
Drive Belt Inspection
Check the serpentine belt driving for cracks, fraying,
wear, and correct tension every 30,000 miles (48,000
km). Replace as necessary.
Wheel Alignment, Balance and Tires
Operation
Uneven or abnormal tire wear, or a pull right or left on a
straight and level road may show the need for a wheel
alignment. A vibration of the steering wheel or seat at
normal highway speeds means a wheel balancing is
needed. Check tire pressure when the tires are ªcoldº
(include the spare).
Maintain pressure as shown in the tire placard, which is
located on the driver's door lock pillar.
Steering System Operation
Be alert for any changes in steering operation. An
inspection or service is needed when the steering wheel
is harder to turn or has too much free play, or if there are
unusual sounds when turning or parking.
Brake Systems Operation
Watch for the ªBRAKEº light coming on. Other signs of
possible brake trouble are such things as repeated pulling
to one side when braking, unusual sounds when braking
or between brake applications, or increased brake pedaltravel. If you note one of these conditions, repair the
system at once.
For convenience, the following should be done when
wheels are removed for rotation: Inspect lines and hoses
for proper hookup, bindings, leaks, crack, chafing etc.
Inspect disc brake pads for wear and rotors for surface
condition.
Inspect other brake parts, including parking brake drums,
linings etc., at the same time. Check parking brake
adjustment.
Inspect the brakes more often if habit or conditions
result in frequent braking.
Parking Brake and Transmission Park
Mechanism Operation
Park on a fairly steep hill and hold the vehicle with the
parking brake only. This checks holding ability. On
automatic transmission vehicles, shifting from ªPº
position to the other positions cannot be made unless the
brake pedal is depressed when the key switch is in the
ªONº position or the engine is running.
WARNING: B E F O R E C H E C K I N G T H E S TA R T E R
SAFETY SWITCH OPERATION BELOW, BE SURE TO
HAVE ENOUGH ROOM AROUND THE VEHICLE.
THEN FIRMLY APPLY BOTH THE PARKING BRAKE
AND THE REGULAR BRAKE. DO NOT USE THE
ACCELERATOR PEDAL. IF THE ENGINE STARTS,
BE READY TO TURN OFF THE KEY PROMPTLY.
TAKE THESE PRECAUTIONS BECAUSE THE
VEHICLE COULD MOVE WITHOUT WARNING AND
POSSIBLY CAUSE PERSONAL INJURY OR
PROPERTY DAMAGE.
Starter Safety Switch Operation
Check by trying to start the engine in each gear while
setting the parking brake and the foot brake. The starter
should crank only in ªPº (Park) or ªNº (Neutral).
Accelerator Linkage Lubrication
Lubricate the accelerator pedal fulcrum pin with chassis
grease.
Steering and Suspension Inspection
Inspect the front and rear suspension and steering
system for damaged, loose or missing parts or signs of
wear. Inspect power steering lines and hoses for proper
hookup, binding, leaks, cracks, chafing, etc.
Body and Chassis Lubrication
Lubricate the key lock cylinders, the hood latch, the hood
and door hinges, the door check link, the parking cable
guides, the underbody contact points, and the linkage.
Propeller Shaft Inspection and Lubrication
Check the propeller shaft flange±to±pinion bolts for
proper torque to 63 Nwm (46 lb ft) for front and rear
propeller shaft.

0B±12MAINTENANCE AND LUBRICATION
Maintenance Service Data
Service Data and Specifications
ENGINEValve clearance (cold)Intake 0.28+0.05 mm (0.011+0.002 in)
Exhaust 0.3+0.05 mm (0.012+0.002 in)
Spark plug typeK16PR-P11/PK16PR11/RC10PYP4
Spark plug gap1.05 mm (0.04 in)
BRAKEBrake pedal free play6±10 mm (0.24±0.39 in)
Parking brake travel6±7 notches
WHEEL ALIGNMENTToe-in (Front)0 to +2 mm (0 to +0.08 in)
Toe-in (Rear)0+5 mm (0+0.2 in)
Camber (Front)0
+30'
Camber (Rear)0
+1

Caster (Front)2
30'+45'
Toe±Axis (Rear)+1

PROPELLER SHAFTFlange torque63 N´m (46 lb ft)
WHEEL AND TIRESSizeP235/65R17
Wheel nut torque118 N´m (87 lb ft)
Tire inflation pressure (Front)180 kPa (26 psi)
* Tire inflation pressure (Rear)180 kPa (26 psi)
* Unless otherwise specified on tire information label on the vehicle.
Approximate Capacities
ItemsMetric MeasureU.S. Measure
Fuel tank74 L19.5 Gal.
* CrankcaseOil Change with Filter4.7 L5.0 Qt
Oil Change without Filter4.0 L4.2 Qt
CoolantA/T11.1 L11.7 Qt
TransmissionAutomatic8.6 L9.1 Qt
Transfer1.35 L1.4 Qt
AxleRear1.77 L1.87 Qt
Front1.25 L1.33 Qt
Shift on the fly system0.12 L0.13 Qt
Power steering1.0 L1.1 Qt
Air conditioning (R-134a)0.6 L1.32 Qt
*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±59
Compressor Oil
Oil Specification

The HFC-134a system requires a synthetic (PAG)
compressor oil whereas the R-12 system requires a
mineral compressor oil. The two oils must never be
mixed.

Compressor (PAG) oil varies according to
compressor model. Be sure to use oil specified for the
model of compressor.

Always use HFC-134a Vane Rotary Type
Compressor Oil (AIPDN Part No.2-90188-301-0)
Handling of Oil

The oil should be free from moisture, dust, metal
powder, etc.

Do not mix with other oil.

The water content in the oil increases when exposed
to the air. After use, seal oil from air immediately.
(HFC-134a Vane Rotary Compressor Oil absorbs
moisture very easily.)

The compressor oil must be stored in steel
containers, not in plastic containers.
Compressor Oil Check
The oil used to lubricate the compressor is circulating with
the refrigerant.
Whenever replacing any component of the system or a
large amount of gas leakage occurs, add oil to maintain
the original amount of oil.
Oil Capacity
Capacity total in system: 150cc (5.0 fl.oz)
Compressor (Service parts) charging amount:
150 cc (5.0 fl.oz)
Checking and Adjusting Oil Quantity
for Used Compressor
1. Perform oil return operation. Refer to Oil Return
Operation in this section.
2. Discharge and recover refrigerant and remove the
compressor.
3. Drain the compressor oil and measure the extracted
oil with a measuring cylinder.
4. If the amount of oil drained is much less than 90 cc
(3.0 fl. oz.), some refrigerant may have leaked out.
Conduct a leak tests on the connections of each
system, and if necessary, repair or replace faulty
parts.
5. Check the compressor oil contamination. (Refer to
Contamination of Compressor Oil in this section.)
6. Adjust the oil level following the next procedure
below.(Charging Amount)
(Collected Amount)
more than 90cc (3.0
fl.oz)same as collected
amount
less than 90 cc (3.0 fl.oz)90cc (3.0 fl.oz)
7. Install the compressor, then evacuate, charge and
perform the oil return operation.
8. Check system operation.
When it is impossible to preform oil return operation,
the compressor oil should be checked in the
following order:
1. Discharge and recover refrigerant and remove the
compressor.
2. Drain the compressor oil and measure the extracted
oil with a measuring cylinder.
3. Check the oil for contamination.
4. If more than 90 cc (3.0 fl. oz.) of oil is extracted from
the compressor, supply the same amount of oil to the
compressor to be installed.
5. If the amount of oil extracted is less than 90 cc (3.0 fl.
oz.), recheck the compressor oil in the following
order.
6. Supply 90 cc (3.0 fl. oz.) of oil to the compressor and
install it onto the vehicle.
7. Evacuate and recharge with the proper amount of
refrigerant.
8. Perform the oil return operation.
9. Remove the compressor and recheck the amount of
oil.
10. Adjust the compressor oil, if necessary.
(Collected Amount)
(Charging Amount)
more than 90 cc (3.0
fl.oz)same as collected
amount
less than 90 cc (3.0 fl.oz)90 cc (3.0 fl.oz)

1A±60
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Checking and Adjusting for
Compressor Replacement
150 cc (5.0 fl.oz.) of oil is charged in compressor (service
parts). So it is necessary to drain the proper amount of oil
from the new compressor.
1. Perform oil return operation.
2. Discharge and recover the refrigerant and remove the
compressor.
3. Drain the compressor oil and measure the extracted
oil.
4. Check the compressor oil for contamination.
5. Adjust the oil level as required.
(Amount of oil drained
from used compressor)
(Draining amount of oil
from new compressor)
less than 90 cc (3.0 fl.oz)Same as drained
amount
more than 90 cc (3.0
fl.oz)90 cc (3.0 fl.oz)
6. Evacuate, charge and perform the oil return
operation.
7. Check the system operation.
Contamination of Compressor Oil
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even if the compressor runs for a long
period of time (approximately one season), the oil never
becomes contaminated as long as there is nothing wrong
with the compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:

The capacity of the oil has increased.

The oil has changed to red.

Foreign substances, metal powder, etc., are present
in the oil.
If any of these conditions exists, the compressor oil
is contaminated. Whenever contaminated
compressor oil is discovered, the receiver/drier must
be replaced.
Oil Return Operation
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with
the refrigerant in the system. When checking the amount
of oil in the system, or replacing any component of the
system, the compressor must be run in advance for oil
return operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to ªONº
and set the fan control knob at its highest position.
3. Run the compressor for more than 20 minutes
between 800 and 1,000 rpm in order to operate the
system.
4. Stop the engine.
Replacement of Component Parts
When replacing the system component parts, supply the
following amount of oil to the component parts to be
installed.
(Component parts to be
installed)
(Amount of Oil)
Evaporator 50 cc (1.7 fl. oz.)
Condenser30 cc (1.0 fl. oz.)
Receiver/dryer30 cc (1.0 fl. oz.)
Refrigerant line (one
piece)10 cc (0.3 fl. oz.)

2A±10
POWER±ASSISTED STEERING SYSTEM
The steering column has three important features in
addition to the steering function:
1. The column is energy absorbing, designed to
compress in a front-end collision to minimize the
possibility of injury to the driver of the vehicle.
2. The ignition switch and lock are mounted
conveniently on the column.
3. With the column mounted lock, the ignition and
steering operation can be locked to prevent theft of
the vehicle.The column can be disassembled and reassembled.
However, to insure the energy absorbing action, use only
the specified screws, bolts and nuts as designated, and
tighten them to the specified torque.
Handle the column with care when it is removed from the
vehicle. A sharp blow on the end of steering shaft or shift
lever, or dropping the assembly could shear or loosen the
fasteners that maintain column rigidity.
Power Steering System Test
Test Procedure
C02RW001
Legend
(1) Fluid Reservoir(2) Power Steering Unit
(3) Power Steering Pump
Test of fluid pressure in the power steering system is
performed to determine whether or not the oil pump and
power steering unit are functioning normally.
The power steering system test is used to identify and
isolate hydraulic circuit difficulties. Prior to performing
this test, the following inspections and corrections, if
necessary, must be made.

Inspect pump reservoir for proper fluid level.

Inspect pump belt for proper tension.

Inspect pump driver pulley condition. 1. Place a container under the pump to catch the fluid
when disconnecting or connecting the hoses.
2. With the engine NOT running, disconnect the
pressure hose at the power steering pump and install
power steering tester J-29877-A. The gage must be
between the shutoff valve and pump. Open the
shutoff valve.
3. Check the fluid level. Fill the reservoir with power
steering fluid, to the ªFullº mark. Start the engine,
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.

POWER±ASSISTED STEERING SYSTEM2A±11
4. Bleed the system. Refer to Bleeding the Power
Steering System
in this section.
5. Start the engine and check the fluid level. Add power
steering fluid if required. When the engine is at
normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could become
damaged internally.
6. Fully close the shutoff valve. Record the highest
pressures.

If the pressure recorded is within 9300±9800 kPa
(1350±1420 psi), the pump is functioning within its
specifications.

If the pressure recorded is higher than 9800 kPa
(1420 psi), the valve in the pump is defective.

If the pressure recorded is lower than 9300 kPa
(1350 psi), the valve or the rotating group in the
pump is defective.
7. If the pump pressures are within specifications, leave
the valve open and turn (or have someone else turn)
the steering wheel fully in both directions. Record the
highest pressures and compare with the maximum
pump pressure recorded in step 6. If this pressure
cannot be built in either side of the power steering
unit, the power steering unit is leaking internally and
must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and front
suspension must be thoroughly examined.
Maintenance
The hydraulic system should be kept clean and fluid level
in the reservoir should be checked at regular intervals and
fluid added when required. Refer to
Recommended
Fluids and Lubricants in General Information
section for
the type of fluid to be used and the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause spongy
action and noisy operation. When a hose is disconnected
or when fluid is lost, for any reason, the system must be
bled after refilling. Refer to
Bleeding the Power Steering
System
in this section.

Inspect belt for tightness.

Inspect pulley for looseness or damage. The pulley
should not wobble with the engine running.

Inspect hoses so they are not touching any other
parts of the vehicle.

Inspect fluid level and fill to the proper level.
Fluid Level
1. Run the engine until the power steering fluid reaches
normal operating temperature, about 55
C (130
F),
then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from the
system. Refer to
Bleeding the Power Steering
System
in this section.
Bleeding The Power Steering System
When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle is
operated. If air is allowed to remain in the power steering
fluid system, noisy and unsatisfactory operation of the
system may result.
Bleeding Procedure
When bleeding the system, and any time fluid is added to
the power steering system, be sure to use only power
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and let
the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so that
the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right
and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full steer
positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to set
a few minutes, then repeat the above procedure.
Flushing The Power Steering System
1. Raise and support the front end of the vehicle off the
ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch the
draining fluid.
3. While running the engine at idle, fill the reservoir with
new power steering fluid. Turn the steering wheel in
both directions. Do not contact or hold the steering
wheel to the wheel stops. This will cause the pump to
go to pressure relief mode, which may cause a
sudden fluid overflow at the reservoir.

DIFFERENTIAL (FRONT) 4A1±2
Front Drive Axle
Diagnosis
ConditionPossible causeCorrection
Oil Leak At Front AxleWorn or defective oil seal.Replace the oil seal.
Front axle housing cracked.Repair or replace.
Oil Leak At Pinion ShaftToo much gear oil.Correct the oil level.
Oil seal worn or defective.Replace the oil seal.
Pinion flange loose or damaged.Tighten or replace.
Noises In Front Axle Drive Shaft
JointBroken or worn drive shaft joints and
bellows (BJ and DOJ).Replace the drive shaft joints and
bellows.
ªClankº When Accelerating From
ªCoastºLoose drive shaft joint to output shaft
bolts.Tighten.
Damaged inner drive shaft joint.Replace.
Shudder or Vibration During
Acceleration
Excessive drive shaft joint angle.Repair.
AccelerationWorn or damaged drive shaft joints.Replace.
Sticking spider assembly (inner drive
shaft joint).Lubricate or replace.
Sticking joint assembly (outer drive
shaft joint).Lubricate or replace.
Vibration At Highway SpeedsOut of balance or out of round tires.Balance or replace.
Front end out of alignment.Align.
Noises in Front AxleInsufficient gear oil.Replenish the gear oil.
Wrong or poor grade gear oil.Replace the gear oil.
Drive pinion to ring gear backlash
incorrect.Adjust the backlash.
Worn or chipped ring gear, pinion
gear or side gear.Replace the ring gear, pinion gear or
side gear.
Pinion shaft bearing worn.Replace the pinion shaft bearing.
Wheel bearing worn.Replace the wheel bearing.
Differential bearing loose or worn.Tighten or replace.
Wanders and PullsWheel bearing preload too tight.Adjust the wheel bearing preload.
Incorrect front alignment.Adjust the front alignment.
Steering unit loose or worn.Tighten or replace.
Tire worn or improperly inflated.Adjust the inflation or replace.
Front or rear suspension parts loose
or broken.Tighten or replace.
Front Wheel ShimmyWheel bearing worn or improperly
adjusted.Adjust or replace.
Incorrect front alignment.Adjust the front alignment.
Worn ball joint or bush.Replace the ball joint or bush.
Steering unit loose or worn.Tighten or replace.
Tire worn or improperly inflated.Replace or adjust the inflation.
Shock absorber worn.Replace the shock absorber.

4A2±4DIFFERNTIAL (REAR)
Rear Axle Noise
ConditionPossible causeCorrection
Noise in DriveExcessive pinion to ring gear
backlash.Adjust.
Worn pinion and ring gear.Replace
Worn pinion .bearings.Replace.
Loose pinion bearings.Adjust.
Excessive pinion end play.Adjust.
Worn side bearings.Replace.
Loose side bearings.Adjust.
Excessive ring gear run-out.Replace.
Low oil level.Replenish.
Wrong or poor grade oil.Replace.
Bent axle housing.Replace.
Noisy when coastingAxle noise heard when driving will
usually be heard also on coasting,
although not as loud.Adjust or replace.
Pinion and ring gear too tight (audible
when slowing down and disappears
when driving).Adjust.
Intermittent noiseWarped bevel ring.Replace.
Loose differential case bolts.Tighten.
Constant noiseFlat spot on pinion or ring gear teeth.Replace.
Flat spot on bearing.Replace.
Worn pinion splines.Replace.
Worn axle shaft dowel holes.Replace.
Worn hub studs.Replace.
Bent axle shaft.Replace.
Noisy on turnsWorn differential side gears and
pinions.Replace.
Worn differential shaft.Replace.
Worn axle shaft splines.Replace.
Limited Slip Differential
ConditionPossible causeCorrection
Does not lockBroken clutch plates.Replace the clutch plates.
Chatters in turnsLubricant contaminated.Drain lube when hot. Wipe carrier
clean. Refill with lube specified in
Main Data and Specifications at the
end of this section.
Clutch plates dateriorated.Replace clutch plates.
Noise (in addition to normal clutch
engagement)
Broken clutch plates.Replace clutch plates.
engagement)Damaged case.Replace unit.
Broken differential gears.Replace gears.