transmission ISUZU AXIOM 2002 Service User Guide

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.

1A±20
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
A condenser may malfunction in two ways: it may leak, or
it may be restricted. A condenser restriction will result in
excessive compressor discharge pressure. If a partial
restriction is present, the refrigerant expands after
passing through the restriction.
Thus, ice or frost may form immediately after the
restriction. If air flow through the condenser or radiator is
blocked, high discharge pressures will result. During
normal condenser operation, the refrigerant outlet line will
be slightly cooler than the inlet line.
The vehicle is equipped with the parallel flow type
condenser. A larger thermal transmission area on the
inner surface of the tube allows the radiant heat to
increase and the ventilation resistance to decrease.
The refrigerant line connection has a bolt at the block
joint, for easy servicing.
875R200015
Legend
(1) Pressure Switch
(2) Receiver Drier
(3) Condenser & Receiver Tank Assembly
(4) Condenser Fan
Receiver / Drier
The receiver/drier performs four functions:

As the quantity of refrigerant circulated varies
depending on the refrigeration cycle conditions,
sufficient refrigerant is stored for the refrigeration
cycle to operate smoothly in accordance with
fluctuations in the quantity circulated.

The liquefied refrigerant from the condenser is mixed
with refrigerant gas containing air bubbles. If
refrigerant containing air bubbles. If refrigerant
containing air bubbles is sent to the expansion valve,
the cooling capacity will decrease considerably.
Therefore, the liquid and air bubbles are separated
and only the liquid is sent to the expansion valve.

The receiver/drier utilizes a filter and drier to remove
the dirt and water mixed in the cycling refrigerant.A receiver/drier may fail due to a restriction inside the
body of the unit. A restriction at the inlet to the
receiver/drier will cause high pressure.
Outlet restrictions will be indicated by low pressure and
little or no cooling. An excessively cold receiver/drier
outlet may indicate a restriction.
The receiver/drier of this vehicle is made of aluminum
with a smaller tank. It has a 300cc refrigerant capacity.
The refrigerant line connection has a bolt at the block
joint, for easy servicing.
Triple Pressure Switch (V6, A/T)
Triple pressure switch is installed on the upper part of the
receiver/drier. This switch is constructed with a unitized
type of two switches. One of them is a low and high
pressure switch (Dual pressure switch) to switch ªONº or
ªOFFº the magnetic clutch as a result of irregularly
high±pressure or low pressure of the refrigerant. The
other one is a medium pressure switch (Cycling switch) to
switch ªONº or ªOFFº the condenser fan sensing the
condenser high side pressure.
Compressor
ON
(kPa/psi)OFF
(kPa/psi)
Low-pressure
control206.0+30.0
(29.8+4.3)176.5+24.5
(25.6+3.6)
High-pressure
control2353.6+196.1
(341.3+28.4)2942.0+196.1
(426.6+28.4)
Condenser fanON
(kPa/psi)OFF
(kPa/psi)
Medium-pressure
control1471.0+98.1
(213.3+14.2)1078.7+117.7
(156.4+17.1)
Expansion Valve
This expansion valve is an external pressure type and it is
installed at the evaporator intake port.
The expansion valve converts the high pressure liquid
refrigerant sent from the receiver/drier to a low pressure
liquid refrigerant by forcing it through a tiny port before
sending it to the evaporator.
This type of expansion valve consists of a temperature
sensor, diaphragm, ball valve, ball seat, spring
adjustment screw, etc.
The temperature sensor contacts the evaporator outlet
pipe, and converts changes in temperature to pressure. It
then transmits these to the top chamber of the
diaphragm.
The refrigerant pressure is transmitted to the diaphragm's
bottom chamber through the external equalizing pressure
tube.
The ball valve is connected to the diaphragm. The
opening angle of the expansion valve is determined by
the force acting on the diaphragm and the spring
pressure.

INTELLIGENT SUSPENSION3F±23
DTC5 Vehicle Speed Sensor Open Circuit or Short
Circuit Description
Output speed information is provided to the control unit by
the vehicle speed sensor. The vehicle speed sensor
produces a pulsing AC voltage. The AC voltage level and
number of pulses increases as the speed of the vehicle
increases. The control unit then converts the pulsing
voltage to vehicle speed.
Diagnostic Aids

Inspect the wiring for poor electrical connections
between the control unit 48 way connector and the
speed sensor connectors. Look for possible bent,
backed out, deformed, or damaged terminals. Check
for weak terminal tension as well.
Also check for a chafed wire that could short to bare
metal or other wiring. Inspect for a broken wire inside
the insulation.

When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
DTC5 Vehicle Speed Sensor Open Circuit or Short
StepActionValue(s)Ye sNo
11. Jack up and support the rear axle on the stand.
2. Change the transfer mode to 2WD, using TOD
switch on instrument panel.
3. Shift the transmission lever in a forward position
and rotate the rear wheels.
Does the speedo-meter operate?
ÐGo to Step 2Go to Step 3
21. Open the throttle and rev up engine speed.
2. Using a volt meter, measure the voltage between
the meter B connector I±23 terminals 7 and 16
(GND).
Does the voltage change alternately at the specified
values?
0V and 12VGo to Step 7Go to Step 5
31. Turn off the starter switch and disconnect the
control connectors C±46 and C±44.
2. Check the continuity between the vehicle speed
sensor connector terminal 3 and meter B connector
I±23 terminal 7.
Is there continuity?
ÐGo to Step 4Go to Step 6
41. Check the continuity between the control unit
connector C±46 terminal 1 and control unit
connector C±44 terminal 48.
Is there continuity?
ÐGo to Step 5Go to Step 6
5Repair or replace the vehicle speed sensor.
ÐGo to Step 8Ð
6Repair the circuit between the vehicle speed sensor
connector terminal 3 and the meter B connector I±23
terminal 7 or the circuit between the control unit
connector C±44 terminal 48 and the speed sensor
connector terminal 3.
ÐGo to Step 8Ð

DIFFERENTIAL (REAR)4A2±3
Diagnosis
Many noises that seem to come from the rear axle
actually originate from other sources such as tires, road
surface, wheel bearings, engine, transmission, muffler, or
body drumming. Investigate to find the source of the
noise before disassembling the rear axle. Rear axles, like
any other mechanical device, are not absolutely quiet but
should be considered quiet unless some abnormal noise
is present.
To make a systematic check for axle noise, observe the
following:
1. Select a level asphalt road to reduce tire noise and
body drumming.
2. Check rear axle lubricant level to assure correct level,
and then drive the vehicle far enough to thoroughly
warm up the rear axle lubricant.
3. Note the speed at which noise occurs. Stop the
vehicle and put the transmission in neutral. Run the
engine speed slowly up and down to determine if the
noise is caused by exhaust, muffler noise, or other
engine conditions.
4. Tire noise changes with different road surfaces; axle
noises do not. Temporarily inflate all tires to 344 kPa
(50 psi) (for test purposes only). This will change
noise caused by tires but will not affect noise caused
by the rear axle.
Rear axle nose usually stops when coasting at
speeds under 48 km/h (30 mph); however, tire noise
continues with a lower tone. Rear axle noise usually
changes when comparing pull and coast, but tire
noise stays about the same.
Distinguish between tire noise and rear axle noise by
noting if the noise changes with various speeds or
sudden acceleration and deceleration. Exhaust and
axle noise vary under these conditions, while tire
noise remains constant and is more pronounced at
speeds of 32 to 48 km/h (20 to 30 mph). Further check
for tire noise by driving the vehicle over smooth
pavements or dirt roads (not gravel) with the tires at
normal pressure. If the noise is caused by tires, it will
change noticeably with changes in road surface.
5. Loose or rough front wheel bearings will cause noise
which may be confused with rear axle noise; however,
front wheel bearing noise does not change when
comparing drive and coast. Light application of the
brake while holding vehicle speed steady will often
cause wheel bearing noise to diminish. Front wheel
bearings may be checked for noise by jacking up the
wheels and spinning them or by shaking the wheels to
determine if bearings are loose.
6. Rear suspension rubber bushings and spring
insulators dampen out rear axle noise when correctly
installed. Check to see that there is no link or rod
loosened or metal±to±metal contact.7. Make sure that there is no metal±to±metal contact
between the floor and the frame.
After the noise has been determined to be in the axle, the
type of axle noise should be determined, in order to make
any necessary repairs.
Gear Noise
Gear noise (whine) is audible from 32 to 89 km/h (20 to 55
mph) under four driving conditions.
1. In drive under acceleration or heavy pull.
2. Driving under load or under constant speed.
3. When using enough throttle to keep the vehicle from
driving the engine while the vehicle slows down
gradually (engine still pulls slightly).
4. When coasting with the vehicle in gear and the throttle
closed. The gear noise is usually more noticeable
between 48 and 64 km/h (30 and 40 mph) and 80 and
89 km/h (50 and 55 mph).
Bearing Noise
Bad bearings generally produce a rough growl or grating
sound, rather than the whine typical of gear noise.
Bearing noise frequently ªwow±wowsº at bearing rpm,
indicating a bad pinion or rear axle side bearing. This
noise can be confused with rear wheel bearing noise.
Rear Wheel Bearing Noise
Rear wheel bearing noise continues to be heard while
coasting at low speed with transmission in the neutral.
Noise may diminish by gentle braking. Jack up the rear
wheels, spin them by hand and listen for noise at the
hubs. Replace any faulty wheel bearings.
Knock At Low Speeds
Low speed knock can be caused by worn universal joints
or a side gear hub counter bore in the cage that is worn
oversize. Inspect and replace universal joints or cage and
side gears as required.
Backlash Clunk
Excessive clunk on acceleration and deceleration can be
caused by a worn rear axle pinion shaft, a worn cage,
excessive clearance between the axle and the side gear
splines, excessive clearance between the side gear hub
and the counterbore in the cage, worn pinion and side
gear teeth, worn thrust washers, or excessive drive pinion
and ring gear backlash. Remove worn parts and replace
as required. Select close±fitting parts when possible.
Adjust pinion and ring gear backlash.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±6
High-Low Planetary Gear Set
Establishes an auxiliary transmission mechanism. When
the TOD switch is set to the 2H or TOD position, the
reduction gear ratio is 1.000 and the corresponding
driving force is generated. When the TOD switch is set to
the 4L position, the reduction gear ratio is 2.480 and the
corresponding driving force is generated.
262RW030
4H and 4L Switch
Detects the shift position of the transfer from the
movement of the shift rod and outputs signals to the TOD
control unit.
261RW002
Transfer Connector (12-pin type)
Transmits the input and output signals of the speed
sensors, electromagnetic coil, and 4H and 4L switche to
the vehicle harness. A waterproof 12-pin type is used.
261RW046
Transfer Connector (8-pin type)
Transmits the output signals of the shift motor position to
the vehicle harness and power for the shift motor to the
transfer. A waterproof 8-pin type is used.
261RY00039

4C±29 DRIVE SHAFT SYSTEM
Propeller Shaft
General Description
401R200001
Legend
(1) Front Propeller Shaft
(2) Rear Propeller Shaft;
Aluminum Tube with Flange Yoke Type (for
4y2 model)
(3) Rear Propeller Shaft;
Steel Tube Type (for 4y4 model)
Torque is transmitted from the transmission to the axle
through the propeller shaft and universal joint assembles.
All propeller shafts are the balanced tubular type. A
splined slip joint is provided in some drivelines.

Since the propeller shaft is balanced carefully,
welding or any other modification is not permitted.

Alignment marks should be applied to each propeller
shaft before removal.
Park, turn the engine off and apply the parking brake
to secure the vehicle.

Carefully attach the propeller shaft to the vise, do not
overtighten the vise when securing the propeller
shaft, this may cause deformation.

4C±35 DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
Engine6VE1(3.5 L)
TransmissionA/T with TOD
ConstructionHollow steel tube with constant velocty joints.
Outside diameter40.0 mm (1.57 in)
Length597 mm (23.50 in)
Torque Specifications
401R200005

4C±36
DRIVE SHAFT SYSTEM
Rear Propeller Shaft
Rear Propeller Shaft and Associated Parts
401R200002
Legend
(1) Bolt, Nut and Washer (Transfer Side)(2) Rear Propeller Shaft
(3) Bolt, Nut and Washer (Rear Axle Side)
Removal
1. Raise the vehicle on a hoist.
NOTE: Apply alignment marks on the flange at the rear
propeller shaft both front and rear side.
2. Remove transfer side bolt, nut and washer (except
spline yoke type).
3. Remove rear axle side bolt, nut and washer.
4. Remove rear propeller shaft.
NOTE: Plug the hole of the transmission rear end to
prevent oil leakage (spline yoke type only).
Installation
NOTE: Never install the shaft assembly backwards.
Never insert bar between yoke lugs when tightening or re-
moving bolts.
Completely remove the dust or foreign matter from the
connecting surface of flange coupling on each end of the
propeller shaft.
1. Align the mark which is applied at removal.
2. Install rear propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 N´m(46 lb ft)

4C±43 DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
2WD Model4WD Model
Engine6VD16VD1
TransmissionA/TA/T
Type (See illustration)12
Length
between two spiders center)1323.0mm
(52.09in)1030.0mm
(40.55in)
Universal joint typeCardan type
Torque Specifications
401R200007

4C±69 DRIVE SHAFT SYSTEM
Propeller Shaft
General Description
401RX002
Legend
(1) Front Propeller Shaft
(2) Rear Propeller Shaft;
Aluminum Tube with Spline Yoke Type(3) Rear Propeller Shaft;
Aluminum Tube with Flange Yoke Type
(4) Rear Propeller Shaft;
Steel Tube Type (for 4y4, 6VD1, A/T model)
Torque is transmitted from the transmission to the axle
through the propeller shaft and universal joint assembles.
All propeller shafts are the balanced tubular type. A
splined slip joint is provided in some drivelines.

Since the propeller shaft is balanced carefully,
welding or any other modification is not permitted.
Alignment marks should be applied to each propeller
shaft before removal.

Park, turn the engine off and apply the parking brake
to secure the vehicle.

Carefully attach the propeller shaft to the vise, do not
overtighten the vise when securing the propeller
shaft, this may cause deformation.