torque ISUZU AXIOM 2002 Service Repair Manual

4B1±7
DRIVELINE CONTROL SYSTEM
Shift On The Fly Controller
Shift On The Fly Controller and Associated Parts
828RY00003
Legend
(1) Nut(2) SOF Controller
(3) Connector
Removal
1. Disconnect the battery ground cable.
2. Remove the front console assembly.
Refer to
Consoles in Body and Accessories section.
3. Disconnect the connector from the controller.
4. Remove the nut.
5. Remove the controller.
Installation
To install, follow the removal steps in the reverse order,
noting the following points.
Torque: Nut (1) 8 N´m (69 Ib in)

4B2±1
DRIVE LINE CONTROL SYSTEM (TOD)
AXIOM
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (TOD)
CONTENTS
Service Precaution 4B2±1. . . . . . . . . . . . . . . . . . . . . .
General Description 4B2±2. . . . . . . . . . . . . . . . . . . . .
Transfer Position and Drive Mode 4B2±2. . . . . . . .
TOD Control 4B2±3. . . . . . . . . . . . . . . . . . . . . . . . . .
TOD Indicator Control 4B2±3. . . . . . . . . . . . . . . . . .
Abbreviations 4B2±3. . . . . . . . . . . . . . . . . . . . . . . . .
System Components 4B2±4. . . . . . . . . . . . . . . . . . . .
Parts Location 4B2±4. . . . . . . . . . . . . . . . . . . . . . . .
Front and Rear Speed Sensors 4B2±5. . . . . . . . . .
Electromagnetic Coil 4B2±5. . . . . . . . . . . . . . . . . . .
Multi Plate Disk Clutch Pack 4B2±5. . . . . . . . . . . .
Mechanical Lock Sleeve 4B2±5. . . . . . . . . . . . . . . .
High-Low Planetary Gear Set 4B2±6. . . . . . . . . . .
4H and 4L Switch 4B2±6. . . . . . . . . . . . . . . . . . . . . .
Transfer Connector (12-pin type) 4B2±6. . . . . . . .
Transfer Connector (8-pin type) 4B2±6. . . . . . . . .
TOD Indicator Lamps
(on the instrument panel) 4B2±7. . . . . . . . . . . . . .
Check Lamp 4B2±7. . . . . . . . . . . . . . . . . . . . . . . . . .
TOD ECU 4B2±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Low Shift Motor 4B2±9. . . . . . . . . . . . . . . . . . .
Motor Position and Encoder Position Code 4B2±10
Encode Position Plate 4B2±10. . . . . . . . . . . . . . . . . .
Shift High Range and Low Range 4B2±10. . . . . . . . Functions of TOD Switch and Indicator
Lamp 4B2±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD Switch and Indication of Drive Mode 4B2±11.
Check Lamp 4B2±13. . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 4B2±14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information Diagnosis 4B2±14. . . . . . . . . .
Self-diagnosis 4B2±14. . . . . . . . . . . . . . . . . . . . . . . . .
Precautions on Diagnosis 4B2±16. . . . . . . . . . . . . . .
Basic Diagnostic Flow Chart 4B2±18. . . . . . . . . . . . . .
Parts Location 4B2±19. . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram 4B2±20. . . . . . . . . . . . . . . . . . . . . . . . .
Connector List 4B2±24. . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Failed Pin 4B2±26. . . . . . . . . . . . . . . . . . . . .
Connector Pin Assignment 4B2±26. . . . . . . . . . . . . .
Reference 4B2±28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Failed TOD Control Unit Pin 4B2±30. . . . .
Tech 2 Scan Tool 4B2±32. . . . . . . . . . . . . . . . . . . . . .
Getting Started 4B2±33. . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedure 4B2±33. . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes 4B2±35. . . . . . . . . . . . . . . .
Diagnosis from Trouble Codes 4B2±36. . . . . . . . . . . .
Trouble Diagnosis Depending on The Status
of TOD Indicator 4B2±67. . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis from Symptom 4B2±102. . . . . . . . . . . . . . . . .
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.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±2
General Description
412R200008
TOD (Torque on Demand) system is traction state control
system to vehicle.
Transfer Position and Drive Mode
Three drive modes can be selected through operation of
TOD switch and transfer lever.
Transfer Position
TOD SWITCHModeDrive mode
HIGH2HRWDRear wheel drive
TOD4WD
(HIGH)Electronically controlled torque split
four wheel drive
LOW4L4WD
(LOW)Low-speed mechanical lock-up four
wheel drive
The electronic control unit (ECU) judges the signals from
the TOD switch and controls the transfer drive mode and
shift-on-the-fly system status.

4B2±3
DRIVE LINE CONTROL SYSTEM (TOD)
TOD Control
The TOD position usually drives the rear wheels, and
transmits the torque to the front wheels with the help of
electronically controlled torque split mechanism
according to running conditions encountered. The driving
force is directly transmitted to the rear wheels. This force
is split by the transfer and delivered to the front wheels.
The magnitude of the torque transmitted to the front
wheels is controlled by changing the pressing force of the
multi plate disk clutch built in the transfer unit. The
pressing force of the clutch is controlled by changing the
duty ratio to the electromagnetic coil mounted to the rear
of the clutch. When the clutch is completely disengaged,
the rear wheels are driven. When the clutch is completely
engaged, a rigid four wheel drive mode is obtained. The
torque split status is controlled continuously between the
rear wheel and four wheel drive modes. This system
includes front and rear speed sensors, and receives
throttle position sensor and engine speed information
from the PCM, ABS control unit signal, brake switch
signal, and shift motor position information.
The control unit receives signals sent from these sensors
and changes the pressing force of the multi-plate disk
clutch to determine the torque distribution on the front and
rear wheels. Therefore, when the slip of the rear wheels is
increased against the current torque level in the normal
rear wheel drive mode, the control unit detects the slip
condition, determines the optimum torque based on the
feedback control logic, and increases the torque to the
front wheels.
The control unit uses the signal from the throttle position
sensor to predict the future vehicle condition and the
intention of the driver with respect to acceleration and
deceleration, and determines the initial torque distribution
using these data and the information from the speed
sensors.
In case of small circle turning in the parking lot, for
example, the control unit minimizes the clutch pressing
force to restrict a braking phenomenon. When the ABS
becomes active, the control unit optimizes the clutch
pressing force to ensure stable braking.
TOD Indicator Control
The TOD indicator on the instrument panel informs the
driver of the current working status of the transfer unit.
The information is the drive mode (2H, TOD, 4L,
transition). The indicator can display occasional errors
and corresponding error codes.
Abbreviations
ABS Anti-lock Brake System
ADC Axle Disconnect
(Shift on the fly system)
VB Battery Voltage
VIGN Ignition Voltage

4B2±5
DRIVE LINE CONTROL SYSTEM (TOD)
Front and Rear Speed Sensors
The sensors are built in the transfer case, and detect the
rotation of rotors directly coupled to the propeller shafts.
Thirty rectangular pulses are output per one rotation of
the propeller shaft.
261RW045
Electromagnetic Coil
Receives the duty signals from the TOD control unit and
controls the pressing force of the clutch pressure cam.
261RW044
Multi Plate Disk Clutch Pack
Transmits the torque determined by the clutch pressing
force to the front propeller shaft via the front drive chain.
262RW029
Mechanical Lock Sleeve
Couples the front and rear propeller shaft mechanically
when the transfer shaft is in the 4L position.
262RW028

4B2±11
DRIVE LINE CONTROL SYSTEM (TOD)
Functions of TOD Switch and
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
state
Drive modeTransfer shift conditionTransfer
position
detectionShift on the flyTOD indicator
state
4HSW4LSWAxle
SWADC circuit
2HRear-wheel
drive (RWD)Permissible during
driving (less than
100 km/h or 62 mph)OFFOFFOFFTurning on
electricity
TODElectronic
torque split
4WD (TOD)OFFOFFONTurning off
electricity
AT: Neutral
Brake: Applied
The car stops4LLow range
mechanical
direct 4WD
(4L)The car sto s
(less than 2 km/h or
1.2 mph and less than
1500 rpm)OFFONONTurning off
electricity
ADC: Shift on the fly
SW: Switch
TOD
Switch
TOD control unit terminal No.TOD indicator
stateSwitch
stateTOD indicatorTOD switchstate
state
7(Front)8(Rear)19(Auto)30(2H)43(4L)
2HOFFONOFFONOFF
TODONONONOFFOFF
4LONONOFFOFFON

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±106
Chart 2The TOD mode is not active.
Function of circuitÐ
Fail conditionThe rear wheels spin in the TOD mode, so the driving torque is not transmitted to the
front wheels. The indicator lamps will not show the 4L and TOD status.
D04R200021

4C±1 DRIVE SHAFT SYSTEM
AXIOM (Vehicles Produced Before July/31/2001)
DRIVELINE/AXLE
DRIVE SHAFT SYSTEM
CONTENTS
Service Precaution 4C±1. . . . . . . . . . . . . . . . . . . . . .
General Description 4C±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4C±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Hub and Disc (2WD Model) 4C±3. . . . . . . . .
Disassembled View 4C±3. . . . . . . . . . . . . . . . . . . .
Disassembly 4C±3. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4C±4. . . . . . . . . . . . . . . . . .
Reassembly 4C±5. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Hub and Disc (4WD Model) 4C±8. . . . . . . . .
Disassembled View 4C±8. . . . . . . . . . . . . . . . . . . .
Disassembly 4C±8. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4C±10. . . . . . . . . . . . . . . . . .
Reassembly 4C±10. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Shaft Joint 4C±13. . . . . . . . . . . . . . . . . . .
Front Drive Shaft Joints Replacement 4C±13. . . .
Front Axle Drive Shaft 4C±14. . . . . . . . . . . . . . . . . . .
Front Axle Drive Shaft and Associated
Parts 4C±14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 4C±15. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 4C±16. . . . . . . . . . . . . . . . . .
Bushing Replacement 4C±16. . . . . . . . . . . . . . . . . .
Reassembly 4C±17. . . . . . . . . . . . . . . . . . . . . . . . . .
Shift On The Fly System 4C±19. . . . . . . . . . . . . . . . .
Shift On The Fly System and Associated
Parts 4C±19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 4C±20. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 4C±21. . . . . . . . . . . . . . . . . .
Reassembly 4C±23. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4C±26. . . . . . . . . . .
Special Tools 4C±28. . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft 4C±29. . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 4C±29. . . . . . . . . . . . . . . . . . . .
Front Propeller Shaft 4C±30. . . . . . . . . . . . . . . . . . . . .
General Description 4C±30. . . . . . . . . . . . . . . . . . . .
Front Propeller Shaft and Associated Parts 4C±31
Removal 4C±31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4C±32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4C±35. . . . . . . . . . .
Rear Propeller Shaft 4C±36. . . . . . . . . . . . . . . . . . . . .
Rear Propeller Shaft and Associated Parts 4C±36
Removal 4C±36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4C±36. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slip Joint Disassembly 4C±37. . . . . . . . . . . . . . . . .
Universal Joint Disassembly 4C±38. . . . . . . . . . . .
Inspection 4C±40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Universal Joint Reassembly 4C±41. . . . . . . . . . . . .
Slip Joint Reassembly 4C±42. . . . . . . . . . . . . . . . . .
Main Data and Specifications 4C±43. . . . . . . . . . .
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.

4C±5 DRIVE SHAFT SYSTEM
Reassembly
1. Install wheel pin.

Place hub on a wood workbench or a block of wood
approx. 6º by 6º to protect the wheel stud ends and
threads.

Install wheel stud, using a hammer.
NOTE: Be sure wheel stud is started squarely and seats
completely.
411RS005
2. Align scribe marks(1) and attach the hub to disc then
tighten the bolts to the specified torque.
Torque: 103 N´m (76 lb ft)
411RS003
3. Install inner bearing.
Install the outer race by driving it into the hub by using
installer J±36829 and grip J±8092.
411RS023
4. Install outer bearing.
Install the outer race by driving it into the hub by using
installer J±36828 and grip J-8092.
901RW056

4C±6
DRIVE SHAFT SYSTEM
5. Install oil seal by using installer J±36830 and grip
J±8092.
Apply Multipurpose grease (NLGI No. 2 or equivalent)
to the lip portion.
901RW057
6. Inatall ABS sensor ring, then tigthen the bolts to the
specified torque.
Torque: 18 N´m (13 lb ft)
7. Install hub and disc assembly.

Apply grease in the hub.

Apply wheel bearing type grease (NLGI No.2 or
equivalent) to the outer and inner bearing.
Hub
35 g (1.23 oz)
Outer bearing10 g (0.35 oz)
Inner bearing15 g (0.53 oz)
8. Install hub nut.
Turn the place where there is a chamfer in the tapped
hole to the outer side, then attach the nut by using
front hub nut wrench J±36827.
901RW054
Preload Adjustment
1. Tighten the hub nut to 29.4 N´m (21.7 lb ft), then
fully loosen the nut.
2. Tighten the hub nut to the value given below,
using a spring scale on the wheel pin.
Bearing Preload
New bearing and New
oil seal
19.6 ± 24.5 N
(4.4 ± 5.5 lb)
Used bearing and New
oil seal11.8 ± 17.7 N
(2.6 ± 4.0 lb)
If the measured bearing preload is outside the
specifications, adjust it by loosening or tightening
the hub nut.
411RS011