torque ISUZU AXIOM 2002 Service Owners Manual

4A2±12DIFFERNTIAL (REAR)
3. By using the seal installer J±37263, install a new oil
seal (1) that has grease on seal lip.
425RS004
4. Install flange.
5. The pinion washer and a new nut while holding the
pinion flange with J±8614±01.

Tighten the nut until the pinion end play is just taken
up. Rotate the pinion while tightening the nut to seat
the bearings. Once there is not end play in the
pinion, the preload torque should be checked.

Remove J±8614±01. Using an inch-pound torque
wrench, check to make sure the pinion preload is
equal to or slightly over the reading recorded during
removal.
425RW018
6. Install propeller shaft to the frange.
7. Install bolt and nut. Tighten the bolt and nut to the
specified torque.
Torque: 63 N´m (46 lb ft)

DIFFERENTIAL (REAR)4A2±17
425RW020
2. Clean all the gauge parts.
3. Lubricate the outer and inner bearings with axle
lubricant.
4. Place the bearings into the pinion bearing races.
5. Place the inner oil slinger onto the inner pinion
bearing.
NOTE: The inner oil slinger must be placed between
gauge plate and inner pinion bearing when measuring the
pinion depth.
6. Install gauge plate J±39837±2, inner J±42827 stud
and nut J±21777±43 and outer pilot J±42824 to the
pinion bore.
420RW005
7. Hold the stud stationary at the flats of the stud (and).
Tighten the stud nut
Torque: 2.2 N´m (1.6 lb ft)
8. Rotate the gauge plate and bearings several
complete revolutions to seat the bearings.
9. Tighten the stud nut until a torque of 1.6 to 2.2 N´m
(1.2 to 1.6 lb ft.) is required to keep the gauge plate in
rotation.10. Assemble discs J±39837±1, arbor J±23597±1 and
dial indicator J±8001 to the side bearing bores.
NOTE: The bearing bores must be clean and burr-free.
420RW005
11. Install the side bearing caps and tighten the bolts to
the specified torque.
Torque: 108 N´m (80 lb ft)
12. Rotate the gauge plate until the gauging area is
parallel with the discs.
13. Position the arbor assembly in the carrier so that the
plunger is centered on the gauge area of the gauge
plate.

4A2±20DIFFERNTIAL (REAR)
19. Remove bearing caps and depth gauging tools.
20. Install the correct pinion shim and inner oil slinger
onto pinion.
NOTE: Do not install pinion gear into housing at this time.
21. If the exciter ring was removed, install the new exciter
ring onto the differential case by pressing using the
ring gear as a pilot.
425RS047
22. Install ring gear(1) to the differential case(2)
425RW021
23. Install new ring gear bolts.

Tighten the ring gear bolts alternately in stages,
gradually pulling the ring gear onto the differential
case.
Tighten the ring gear bolts in sequence
Torque: 108 N´m (80 lb ft)
NOTE: Discard used bolts and install new ones.
415RS016
Side Bearing Preload Adjustment
1. The side bearing preload adjustment must be made
before installing the pinion.
2. The side bearing preload is adjusted by changing the
thickness of both the left and right shims equally. This
maintain the original backlash.
3. Install master side bearings J±39836 onto the case.
Remove all nicks, burrs, dirt etc., from the hubs to
allow the master bearings to rotate freely.
425RW026

DIFFERENTIAL (REAR)4A2±21
4. Assemble the differential case into the housing (less
pinion). Install bearing caps and finger tight bolts.
Mount a dial indicator with a magnetic base to the
housing and indicate on the flange or head of screw.
Force the differential assembly as far as possible in
the dirction towards the indicator.
With force still applied, set indicator at zero(0).
NOTE: Dial indicator set should be capable of a minimum
travel of 5.08 mm (0.2 in).
425RS107
5. Force the differetial assembly as far as it will go in the
opposite direction. Repeat these steps until the same
reading is obtained.
6. RECORD THE READING OF THE INDICATOR.
This amount, in shims, will be included in the final
assembly shim stack to establish side bearing
preload and ring gear and pinion backlash.
7. After marking sure the readings are correct, remove
the indicator and differetial assembly from the
housing.
Pinion Installation

The bearing cups should have been installed in Pinion
Depth Adjustment in this section.
1. Place the shim(1) and inner oil slinger(2) on the pinion
gear, then install the pinion inner bearing(3) using
installer J±42828.
425RW023

Drive the bearing until the bearing cone seats on the
pinion shims.
2. Install a new collapsible spacer.

Lubracate the pinion bearings with axle lublicant.
3. Install pinion to the axle housing.
4. Install outer pinion bearing onto the pinion.

Hold the pinion forward from inside the case while
driving the bearing onto the pinion.
5. Install oil seal slinger.
6. Install pinion oil seal using installer J±37263.
7. Install the pinion flange to the pinion by tapping it with
a rawhide hammer until a few threads show through
the pinion flange.
8. Install pinion washer and a new nut while holding the
pinion flange with flange holder J±8614±01.

Tighten the nut until the pinion end play is just taken
up. Rotate the pinion while tightening the nut to seat
the bearings.
Torque:217-678 N´m (160-500 lb ft)
Once there is no end play in the pinion, the preload
torque should be checked.

Remove flange holder J±8614±01. Using an
inch-pound torque wrench, check the pinion
preload by rotating the pinion with the wrench.

4A2±22DIFFERNTIAL (REAR)
425RW018Preload should be at 1.0 to 1.6 N´m (8 to 14 in lbs.)
on new bearings, or 0.46 to 0.69 N´m (4 to 6 in lbs.)
for used bearings.

If the preload torque is below the preloads given
above, continue torquing the nut in small
increments. Check the preload after each
tightening. Each tightening increases the bearing
preload by several pounds. If the bearing preload is
exceeded, the pinion will have to be removed, and a
new collapsible spacer installed.

Once a preload of 1.0 to 1.4 N´m (8 to 12 in lbs.)
has been obtained, rotate the pinion several times
to assure that the bearings have seated. Recheck
the preload, and adjust if necessary.
Determination of Backlash & Preload
Shims
1. Install master side bearings onto the case.
2. Install differential assembly into the carrier.
3. Install the bearing cap and finger tight bolts.
4. Set up the dial indicator.
5. Force the differential assembly away from the pinion
gear until it is completely seated against the cross
bore face of the carrier.
6. With force still applied to the differential case, place
the tip of dial indicator on a machined surface of the
differential case, if available, or on the head of a ring
gear screw, and set the indicator at zero(0).
7. Force the ring gear to mesh with the pinion gear. Rock
the ring gear slightly to make sure the gear teeth are
meshed. Repeat this procedure several times until
the same reading is obtained each time. Be sure the
indicator reads zero(0) each time the ring gear is
forced back into contact with the cross bore face. This
reading will be the necessary amount of shims to be
placed between the differential case and side bearing
cone on the ring gear side.8. The remaining amount of shims, which is the
difference between the overall found in step 6 of Side
Bearing Pre-load Adjustment and step(7) above,
should be placed on the other side of the differential
case, plus additional 0.38 mm (0.015 in) for obtaining
preload and backlash.
9. Place the required amount of shims on each hub as
determined in the previous steps and assemble side
bearing cone by using installer J±21784 and handle
J±8592.
425RW022
10. Total torque to rotate Ð Increase of pinion torque to
rotate due to differential case assembly shall not
exceed 3.4 N´m (30 in lbs.) divided by the gear ratio.
11. Assembly the spreader J±24385±B and indicator to
the carrier as shown in figure. Spread the carrier
0.5 mm (0.02 in) for differential installation.
420RW004
CAUTION: Do not spread the carrier over 0.5 mm
(0.02 in).
12. Remove the indicator.

DIFFERENTIAL (REAR)4A2±23
Backlash Adjustment
1. Install the differential case assembly and bearing
caps.
2. Rotate the case several times to seat the bearings.
3. Remove the spreader.
4. Install the side bearing cap bolts.
Tighten side bearing cap bolts
Torque: 108 N´m (80 lb ft)
5. Install a dial indicator to the case using a magnetic
base.
6. Place the indicator stem at the heel end of a tooth.

Set the dial indicator so that the stem is in line with
the gear rotation and perpendicular to the tooth
angle.
425RS087
7. Check and record the backlash at three points around
the ring gear.

The pinion must be held stationary when checking
backlash.

The backlash should be the same at each point
within 0.07 mm (0.003 in). If the backlash varies
more than 0.07 mm (0.003 in), check for burrs, a
distorted case flange, or uneven bolting conditions.
8. Backlash at the minimum lash point measured should
be between 0.13 and 0.20 mm (0.005 and 0.008 in)
for all new gear sets.
9. If the backlash is not within specifications, move the
ring gear in or out from the pinion by increasing the
thickness of one shims, and decreasing the thickness
of the other shim by the same amount.
This will maintain the correct rear axls side bearing
preload.

Moving 0.05 mm (0.002 in) worth of shim from one
side of the differential to the other will change the
backlash adjustment by 0.03 mm (0.001 in).
10. After obtaining correct tooth contact described in
later, install ABS speed sensor.11. Install the cover with sealant.
Torque: 40 N´m (30 lb ft)
12. Fill the axle lubricant.
Gear Tooth Pattern Check
Checking the ring gear to pinion tooth pattern is to be
done only after setting up the axle according to the
methods in this section. The pattern check is NEVER to
be used as an initial check, or instead of checking pinion
depth and backlash adjustments.
This check is only to be verify the correct adjustment of
the gear set after set up.
425RS038
Legend
(1) Heel
(2) Toe
(3) Concave Side (Coast)
(4) Convex Side (Drive)
1. Wipe all oil out of the carrier, and carefully clean each
tooth of the ring gear.
2. Use gear marking compound 1052351 or equivalent
and apply this mixture sparingly to all ring gear teeth,
using a medium-stiff brush. When properly used, the
area of pinion tooth contact will be visible when hand
load is applied.
3. Tighten the bearing cap bolts to the specified torque.
4. Expand the brake shoes until a torque of 54 to 68 N´m
(40 to 50 lb ft.) is required to turn the pinion. A test
made without loading the gears will not give a
satisfactory pattern. Turn the pinion flange with a
wrench so that the ring gear rotates one full
revolution, then reverse the rotation so that the ring
gear rotates one revolution in the opposite direction.
5. Observe the pattern on the ring gear teeth and
compare this with figure.

DIFFERENTIAL (REAR)4A2±31
Main Data And Specifications
General Specifications
Rear axle
TypeSalisbury, Semi±floating
Rear axle Size226 mm (8.9 in)
Gear typeHypoid
Gear ratio4.300
Differential typeTwo pinion
Lubricant GradeGL±5: (Standard differential)
GL±5, LSD: (Limited slip differential)
Locking Differential Lubricant80W90 GL±5
(USE Limited Slip Differential Gear Lubricant or Friction
Modifier Organic Additive)
Capacity1.77 liter (1.87 US qt)
Torque Specifications
E04RX002

4B1±1
DRIVELINE CONTROL SYSTEM
AXIOM
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM
CONTENTS
Service Precaution 4B1±1. . . . . . . . . . . . . . . . . . . . . .
Shift On The Fly System 4B1±2. . . . . . . . . . . . . . . . .
Outline of Shift on The Fly System 4B1±2. . . . . . . . .
Functions of Indicator Lamp 4B1±4. . . . . . . . . . . . . .
Shift On The Fly Electrical Equipment 4B1±5. . . . . .
Axle Shaft Connection and Disconnection 4B1±5. . Shift On The Fly Controller 4B1±7. . . . . . . . . . . . . . .
Shift On The Fly Controller and
Associated Parts 4B1±7. . . . . . . . . . . . . . . . . . . . . .
Removal 4B1±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4B1±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

4B1±2
DRIVELINE CONTROL SYSTEM
Shift On The Fly System
Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2WD) and 4 wheel drive (4WD) electronically by the
driver turning the TOD switch on the instrument panel.
This system will control the following operations. (Shifting
between ª4Hº and ª4Lº must be performed by TOD
switch.)
1. Transmitting the torque to the front propeller shaft.
2. Connecting front wheels to, and disconnecting them
from, the front axles by axle motor actuator.
3. Indicating on instrument panel.
4. 4WD out signal to other Electronic Brake Control
Module (EBCM).
System Diagrams
412R200008

4B1±4
DRIVELINE CONTROL SYSTEM
Functions of Indicator Lamp
TOD Switch and Indication of Drive Mode
The TOD switch sends signals to the TOD control unit
which selects drive modes and controls the shift on the fly
system (axle disconnect : ADC).
TOD
switch
tt
Drive modeTransfer shift conditionTransfer posi-
tion detectionShift on the flyTOD indicator
state
state4HSW4LSWAxle
SWADC circuit
2HRear-wheel
drive (RWD)Permissible during
driving (less than
100 km/h or 62 mph)OFFOFFOFFTurning on
electricity
TODElectronic
torque split
4WD (HIGH)
OFFOFFONTurning off
electricity
4WD (HIGH)
(TOD)AT: Neutral
Brake: Applied
Th t (l4LLow range
mechanical
direct 4WD
(LOW) (4L)The car stops (less
than 2 km/h or
1.2 mph and less than
1500 rpm)OFFONONTurning off
electricity
ADC: Shift on the fly
SW: Switch
Bulb check :The bulb of indicator lamp is checked for 2
seconds when ignition key is turned on.
Bulb Check
When the starter switch is turned on, the TOD indicator
lamps comes on as shown below.
NOTE: Once the starter switch is turned on, all the TOD
indicator lamps are lit for two seconds even if the transfer
lever is in any position.
C07RW016