ISUZU AXIOM 2002 Service Repair Manual

REAR SUSPENSION3D±15
Installation
1. Install rubber bushing.
2. Install bracket to axle housing and tighten to the
specified torque.
Torque: 25 N´m (19 lb ft)
3. Install link.
4. Install bolt and nut, then tighten the nut to the
specified torque.
Torque: 31 N´m (27 lb ft)
460RW010

3D±16REAR SUSPENSION
Main Data and Specifications
General Specifications
Rear suspensionType5±Link, coil spring type with stabilizer bar.
Coil springFree length370.5 mm (14.59 in)
Spring diameter12.4 mm (0.49 in)
Coil diameter
(inner)105 mm (4.13 in)
Effective No. of
turns5.21
Total No. of turns6.71
Shock absorberTypeHydraulic, double acting, telescopic
Piston diameter30 mm (1.18 in)
Stroke159 mm (6.26 in)
Extended length518 mm (20.39 in)
Compressed
length359 mm (14.13 in)
Stabilizer barDiameter18 mm (0.71 in)

REAR SUSPENSION3D±17
Torque Specifications
E03R200002

3D±18REAR SUSPENSION
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
J±39214
Remover and Installer;
Trailing link bushing
J±43008
Remover and Installer;
Upper link bushing
J±39792
Remover and Installer;
Lateral rod bushing
(Axle side)
J±39215
Remover and Installer;
Lateral rod bushing
(Frame side)

REAR SUSPENSION3D±19
AXIOM (Vehicles Produced After Aug./1/2001)
REAR SUSPENSION
CONTENTS
Service Precaution 3D±19. . . . . . . . . . . . . . . . . . . . . .
General Description 3D±19. . . . . . . . . . . . . . . . . . . . .
Diagnosis 3D±20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Spring 3D±23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Spring and Associated Parts 3D±23. . . . . . . .
Removal 3D±23. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3D±24. . . . . . . . . . . . . . . . . .
Installation 3D±24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber 3D±25. . . . . . . . . . . . . . . . . . . . . . . . .
Shock Absorber and Associated Parts 3D±25. . . .
Removal 3D±25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3D±25. . . . . . . . . . . . . . . . . .
Installation 3D±25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Link 3D±26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailing Link and Associated Parts 3D±26. . . . . . .
Removal 3D±26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3D±26. . . . . . . . . . . . . . . . . .
Installation 3D±27. . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Link 3D±28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Link and Associated Parts 3D±28. . . . . . . .
Removal 3D±28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3D±28. . . . . . . . . . . . . . . . . .
Installation 3D±29. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lateral Rod 3D±30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lateral Rod and Associated Parts 3D±30. . . . . . .
Removal 3D±30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3D±30. . . . . . . . . . . . . . . . . .
Installation 3D±31. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar 3D±32. . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar and Associated Parts 3D±32. . . . . .
Removal 3D±32. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 3D±32. . . . . . . . . . . . . . . . . .
Installation 3D±33. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 3D±34. . . . . . . . . . . . .
Special Tools 3D±36. . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
General Description
The rear suspension is a 5-link, coil spring type
suspension with a stabilizer bar, consisting of two trailing
links, two upper links, lateral rod, shock absorber, and
stabilizer. In this suspension, the links are specially
arranged to enable the rear axle to move freely, thereby
expanding suspension stroke, reducing friction, and
improving lateral rigidity and roll control. All these result in
improved stability, riding comfort, and rough road
maneuverability.
Each link connects the axle housing with the frame
through a runner bushing. The axle housing is supported
by the trailing links and upper links longitudinally and by
the lateral rod latitudinally.

3D±20REAR SUSPENSION
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.
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.

REAR SUSPENSION3D±21
Condition CorrectionPossible cause
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.
Misassemble Transfer Gear ASMReassemble Transfer Gear to proper
portion
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.

3D±22REAR SUSPENSION
Condition CorrectionPossible cause
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.
Trim Height out of specAdjust Trim height
Suspension BottomsVehicle overloaded. Reduce load.
Faulty shock absorber.Replace shock absorber.
Incorrect, broken or sagging springs.Replace springs.
Body LeansTrim Height out of specAdjust Trim height
Loose 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.

REAR SUSPENSION3D±23
Coil Spring
Coil Spring and Associated Parts
460R200004
Legend
(1) Stabilizer Bar
(2) Upper Link Fixing Bolt and Nut
(3) Rubber Plate(4) Coil Spring
(5) Insulator
(6) Shock Absorber
(7) Breather Hose
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Support the rear axle case with a jack.
3. Disconnect brake hose at the crossmember.
4. Remove breather hose.
5. Remove upper link fixing bolt, nut and rubber plate on
the rear axle case (left-side only).6. Disconnect the stabilizer bar at the stabilizer link.
7. Remove the shock absorber from the axle case.
8. Remove spring insulator.
9. Remove the insulator and coil spring while lowering
the rear axle case.
CAUTION: Be sure not to let the brake hose, parking
brake cable, and breather hose extend to their full
length.

3D±24REAR SUSPENSION
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:

Coil spring

Insulator
Installation
1. Install coil spring and make sure that the coil spring is
installed in the proper position. Paint mark(1) should
be downward.
460RW001
2. Fit the end of the coil spring to the coil spring seat and
mount the coil spring on the rear axle case.
460RW004
3. Install the insulator on the coil spring. Jack up the axle
case gently with the top of the coil spring set to the
spring seat on the frame side.
460RW013
4. Install shock absorber and tighten the nut lightly, then
retighten it to the specified torque after the vehicle is
at curb height.
NOTE: When mounting shock absorber, be sure not to
use grease on bushings or any other nearby part.
Torque: 78 N´m (58 lb ft)
5. Install stabilizer bar at the stabilizer link.
Torque: 31 N´m (23 lb ft)
6. Install upper link with rubber plate and tighten fixing
bolt.
Torque: 137 N´m (101 lb ft)
7. Install breather hose.
8. Connect brake hose and bleed the brake system.
Refer to
Bleeding the Brake Hydraulic System in
Brake
section.