ISUZU AXIOM 2002 Service Repair Manual

2A±50
POWER±ASSISTED STEERING SYSTEM
Supplemental Restraint System Steering Wheel & Column and
Associated Parts
Main Data and Specifications
Torque Specifications
430RY00002
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
J±29752
Steering wheel remover

FRONT SUSPENSION3C±1
AXIOM
SUSPENSION
CONTENTS
Front Suspension 3C±1. . . . . . . . . . . . . . . . . . . . . . .
Rear Suspension 3D±1. . . . . . . . . . . . . . . . . . . . . . . .
Wheel and Tire System 3E±1. . . . . . . . . . . . . . . . . . Intelligent Suspension Control 3F±1. . . . . . . . . . . .
FRONT SUSPENSION
CONTENTS
Service Precaution 3C±1. . . . . . . . . . . . . . . . . . . . . .
General Description 3C±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 3C±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber 3C±5. . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber and Associated Parts 3C±5. . . .
Removal 3C±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±5. . . . . . . . . . . . . . . . . .
Installation 3C±5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar 3C±6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar and Associated Parts 3C±6. . . . . .
Removal 3C±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±6. . . . . . . . . . . . . . . . . .
Installation 3C±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torsion Bar 3C±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torsion Bar and Associated Parts 3C±7. . . . . . . .
Removal 3C±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±8. . . . . . . . . . . . . . . . . .
Installation 3C±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle 3C±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knuckle and Associated Parts 3C±10. . . . . . . . . . .
Removal 3C±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±11. . . . . . . . . . . . . . . . . .
Installation 3C±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Control Arm 3C±13. . . . . . . . . . . . . . . . . . . . . .
Upper Control Arm and Associated Parts 3C±13.
Removal 3C±13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±14. . . . . . . . . . . . . . . . . .
Installation 3C±14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Control Arm 3C±16. . . . . . . . . . . . . . . . . . . . . .
Lower Control Arm and Associated Parts 3C±16.
Removal 3C±16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±17. . . . . . . . . . . . . . . . . .
Installation 3C±18. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Ball Joint 3C±19. . . . . . . . . . . . . . . . . . . . . . . . .
Upper Ball Joint and Associated Parts 3C±19. . . .
Removal 3C±19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±20. . . . . . . . . . . . . . . . . .
Installation 3C±20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Ball Joint 3C±21. . . . . . . . . . . . . . . . . . . . . . . . .
Lower Ball Joint and Associated Parts 3C±21. . . .
Removal 3C±21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3C±22. . . . . . . . . . . . . . . . . .
Installation 3C±22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 3C±23. . . . . . . . . . . . .
Special Tools 3C±25. . . . . . . . . . . . . . . . . . . . . . . . . . .
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.

3C±2FRONT SUSPENSION
General Description
The front suspension is designed to allow each wheel to
compensate for changes in the road surface level without
greatly affecting the opposite wheel. Each wheel is
independently connected to the frame by a steering
knuckle, ball joint assemblies, and upper and lower
control arms. The front wheels are held in proper
relationship to each other by two tie-rods which are
connected to steering arms on the knuckles, and to a
steering unit.
All models have a front suspension system consisting of
control arms, stabilizer bar, shock absorber and a torsion
bar. The front end of the torsion bar is attached to the
lower control arm. The rear of the torsion bar is mounted
into a height control arm at the crossmember. Vehicle trim
height is controlled by adjusting this arm.
Shock absorbers are mounted between the brackets on
the frame and the lower control arms. The lower portion ofeach shock absorber is attached to the lower control arm.
The upper portion of each shock absorber extends
through a frame bracket and is secured with two rubber
bushings, two retainers and a nut.
Ball joint assemblies are bolted to the outer end of the
upper and lower control arm and are attached to the
steering knuckle.
The inner ends of the upper control arm have pressed in
bushings. Bolts, passing through the bushing, attach the
control arm to the frame. The inner ends of the lower
control arm are attached to the frame by bolts passing
through the bushings.
Side roll of the front suspension is controlled by a spring
steel stabilizer bar. It is mounted in rubber bushings,
which are held to the frame by brackets. The ends of the
stabilizer bar are connected to the lower control arms by
links.
Diagnosis
ConditionPossible causeCorrection
Vehicle PullsMismatched or uneven tires.Replace tire.
Tires not adequately inflated.Adjust tire pressure.
Broken or sagging springs.Replace spring.
Radial tire lateral force.Replace tire.
Improper wheel alignment.Adjust wheel alignment.
Brake dragging in one wheel.Repair brake.
Loose, bent or broken front or rear
suspension parts.Tighten or replace the appropriate
suspension part(s).
Faulty shock absorbers.Replace shock absorber.
Parts in power steering valve
defective.Replace power steering unit.
Abnormal or Excessive Tire WearSagging or broken spring.Replace spring.
Tire out of balance.Balance or replace tire.
Improper wheel alignment.Check front end alignment.
Faulty shock absorber.Replace shock absorber.
Hard driving.Replace tire.
Overloaded vehicle.Replace tire and reduce load.
Tires not rotated periodically.Replace or rotate tire.
Worn or loose road wheel bearings.Replace wheel bearing.
Wobbly wheel or tires.Replace wheel or tire.
Tires not adequately inflated.Adjust the pressure.
Wheel HopBlister or bump on tire.Replace tire.
Improper shock absorber operation.Replace shock absorber.

FRONT SUSPENSION3C±3
Condition CorrectionPossible cause
Shimmy, Shake or VibrationTire or wheel out of balance.Balance wheels or replace tire/or
wheel.
Loose wheel bearings.Replace wheel bearing.
Worn steering linkage ball joints.Replace ball joints.
Worn upper or lower end ball joints.Replace ball joints.
Excessive wheel runout.Repair or replace wheel and/or tire.
Blister or bump on tire.Replace tire.
Excessive loaded radial runout of
tire/wheel assembly.Replace tire or wheel.
Improper wheel alignment.Check wheel alignment.
Loose or worn steering linkage.Tighten or replace steering linkage.
Loose steering unit.Tighten steering unit.
Tires not adequately inflated.Adjust tire pressure.
Loose, bent or broken front or rear
suspension parts.Tighten or replace the appropriate
suspension parts.
Faulty shock absorber.Replace shock absorber.
Hub bearing preload misadjustment.Adjust preload.
Parts in power steering valve
defective.Replace power steering unit.
Hard SteeringBind in steering linkage ball studs,
upper or lower ball joint.Replace ball joint.
Improper wheel alignment.Check wheel alignment.
Tire not adequately inflated.Inflate tires to proper pressure.
Bind in steering column or shaft.Repair or replace.
Improper power steering system
operation.Repair or replace. Refer to Steering
section.
Too Much Play In SteeringWheel bearings worn.Replace wheel bearings.
Loose steering unit or linkage.Retighten or repair.
Worn or loose steering shaft
universal joint.Retighten or replace steering shaft.
Worn steering linkage ball joints.Replace ball joints.
Worn upper or lower end ball joints.Replace ball joints.
Poor Steering Wheel ReturnabilityBind in steering linkage ball joints.Replace ball joints.
Bind in upper or lower ball joints.Replace ball joints.
Bind in steering column and shaft.Repair or replace.
Bind in steering gear.Check and repair steering gear.
Improper wheel alignment.Adjust wheel alignment.
Tires not adequately inflated.Adjust pressure.
Loose steering wheel nut.Retighten.
Worn wheel bearing.Replace.

3C±4FRONT SUSPENSION
Condition CorrectionPossible cause
Abnormal NoiseWorn, sticky or loose upper or lower
ball joint, steering linkage ball joints
or drive axle joints.Replace.
Faulty shock absorbers.Replace.
Worn upper or lower control arm
bushing.Replace.
Loose stabilizer bar.Retighten bolts or replace bushings.
Loose wheel nuts.Tighten nuts. Check for elongated
wheel nut holes. Replace wheel if
required.
Loose suspension bolts or nuts.Retighten suspension bolts or nuts.
Broken or otherwise damaged wheel
bearings.Replace wheel bearing.
Broken suspension springs. Replace spring.
Loose steering unit. Retighten mounting bolt.
Faulty steering unit.Replace steering unit.
Wandering or Poor Steering StabilityMismatched or unevenly worn tires.Replace tire or inflate tires to proper
pressure.
Loose steering linkage ball joints.Replace ball joints.
Faulty shock absorbers.Replace shock absorber.
Loose stabilizer bar.Tighten or replace stabilizer bar or
bushings.
Broken or sagging springs.Replace spring (pairs).
Improper wheel alignment.Adjust wheel alignment.
Erratic Steering When BrakingWorn wheel bearings.Replace wheel bearings.
Broken or sagging springs.Replace spring (pairs).
Leaking caliper.Repair or replace caliper.
Warped discs.Replace brake disc.
Badly worn brake pads.Replace brake pads.
Tires are inflated unequally.Inflate tires to proper pressure.
Low or Uneven Trim HeightBroken or sagging springs.Replace springs (In pairs).
Vehicle overloaded.Reduce load.
Incorrect springs.Adjust or replace torsion bar.
Suspension BottomsVehicle overloaded. Reduce load.
Faulty shock absorber.Replace shock absorber.
Incorrect, broken or sagging springs.Replace springs.
Body LeansLoose stabilizer bar.Tighten stabilizer bar bolts or replace
bushings.
Faulty shock absorber, struts or
mounting.Replace shock absorber.
Broken or sagging springs.Replace springs (In pairs).
Vehicle overloaded.Reduce load.
Cupped TiresWorn wheel bearings.Replace wheel bearing.
Excessive tire or wheel run out.Replace tire or wheel.
Worn ball joints.Replace ball joints.
Tire out of balance.Adjust tire balance.

FRONT SUSPENSION3C±5
Shock Absorber
Shock Absorber and Associated Parts
450R200001
Legend
(1) Nut
(2) Rubber Bushing and Washer
(3) Bolt and Nut
(4) Shock Absorber(5) Rubber Bushing and Washer
(6) Actuator Bracket
(7) Actuator
(8) Screw
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove wheel and tire assembly. Refer to
Wheel
Replacement in this section.
3. Remove bolt and nut.
4. Remove ISC Actuator and Bracket. Refer to
Intelligent Suspension.
5. Remove nut.
6. Remove rubber bushing and washer.
7. Remove shock absorber.
8. Remove rubber bushing and washer.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts :
Shock absorber

Rubber bushing
Installation
1. Install rubber bushing and washer.
2. Install shock absorber.
3. Install rubber bushing and washer.
4. Install nut, then tighten it to the specified torque.
Torque: 20 N´m (14 lb ft)
5. Install ISC Actuator and Bracket. Refer to
Intelligent
Suspension.
6. Install bolt and nut, then tighten to the specified
torque.
Torque: 93 N´m (69 lb ft)

3C±6FRONT SUSPENSION
Stabilizer Bar
Stabilizer Bar and Associated Parts
410R200001
Legend
(1) Rubber Bushing
(2) Bracket and Bolt
(3) Link(4) Nut
(5) Stabilizer Bar
(6) Washer
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove the stone guard.
3. Remove wheel and tire assembly. Refer to
Wheel
Replacement in this section.
4. Remove nut.
CAUTION: Be careful not to break the ball joint boot.
5. Remove link.
6. Remove bracket.
7. Remove stabilizer bar.
8. Remove rubber bushing.
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.Check the following parts :

Stabilizer bar

Rubber bushing

Link ball joint
Installation
1. Install rubber bushing.
2. Install stabilizer bar.
3. Install bracket, then tighten it to the specified torque.
Torque: 25 N´m (18 lb ft)
4. Install link and Washer.
5. Install nut, then tighten it to the specified torque.
Torque: 50 N´m (37 lb ft)

FRONT SUSPENSION3C±7
Torsion Bar
Torsion Bar and Associated Parts
410RS003
Legend
(1) Adjust Bolt, End Piece and Seat(2) Height Control Arm
(3) Torsion Bar
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Apply the setting marks(1) to the adjust bolt and end
piece, then remove adjust bolt, end piece and seat.
410RS004

3C±8FRONT SUSPENSION
3. Apply the setting marks(2) to the height control arm
and torsion bar, then remove height control arm.
410RS005
4. Apply the setting marks(3) to the torsion bar and
lower control arm, then remove torsion bar.
410RS006
Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found through inspection.
Check the following parts:

Torsion bar

Height control arm

Adjust bolt

Rubber seat
Installation
1. Apply grease to the serrated portions, then install
torsion bar. Make sure the bars are on their correct
respective sides and align the setting marks(3).
410RS007
410RS006

FRONT SUSPENSION3C±9
2. Apply grease to the portion that fits into the bracket
then install height control arm and align the setting
marks(2).
410RS005
3. Apply grease to the bolt portion of the end piece(4).
Apply grease to the portion of the seat(5) that fits into
the bracket.
410RS008
4. Apply grease to the serrated portions.
5. Install adjust bolt and seat, then turn the adjust bolt to
the setting mark(1) applied during disassembly.
NOTE: A d j u s t t h e t r i m h e ight. Refer to
Front End
Alignment Inspection and Adjustment in Steering section.
410RS004