ISUZU AXIOM 2002 Service Repair Manual

DIFFERENTIAL (FRONT) 4A1±18
16. Tighten the cap bolt to the specified torque.
Torque: 97 N´m (72 lb ft)
425RS036
Gear Tooth Contact Pattern Check and
Adjustment
1. Apply a thin coat of prussian blue or equivalent to
at least 7±8 ring gear teeth. Rotate the ring gear
and inspect the contact point of the impressions
and make the necessary adjustments as
described in the next page.
425RS038
Legend
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)
425RS039

4A1±19 DIFFERENTIAL (FRONT)
17. Install differential assembly.
1. Clean the faces of the front axle case and
differential carrier.
Apply Three Bond TB1215 or equivalent to the
sealing side of the axle case and the carrier.
2. Attach the differential case and the carrier
assembly to the front axle case and tighten the
nuts and bolts.
Torque: 25 N´m (19 lb ft)
415RS014
3. Fill the axle case with hypoid gear lubricant, up to
the base of the filler hole.
Lubricant capacity: 1.25 liter(1.32 US qt)
18. Install damper.
1. Clean the faces and bolt thread hole of differential
carrier.
2. Install the bracket with new bolts.
3. Install the damper to the bracket with new bolts.
Torque: 25 N´m (19 lb ft)
425RW042

DIFFERENTIAL (FRONT) 4A1±20
Differential Cage Assembly
Disassembled View
415R200005
Legend
(1) Pinion Gear
(2) Thrust Washer
(3) Side Gear
(4) Cross Pin(5) Ring Gear
(6) Bolt
(7) Differential Cage
(8) Lock Pin
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin.
425RS042

4A1±21 DIFFERENTIAL (FRONT)
4. Remove the cross pin, using a soft metal rod and a
hammer.
425RS043
5. Remove pinion gear.
6. Remove side gear.
7. Remove thrust 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.
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard used bolts and install new ones.
Torque: 108 N´m (80 lb ft)3. Tighten the fixing bolts in a diagonal sequence as
illustrated.
415RS016
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear with thrust washer by engaging
it with the side gears while turning both pinion gears
simultaneously in the same direction.
425RS048

DIFFERENTIAL (FRONT) 4A1±22
4. Install cross pin.

Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
425RS049
5. Install lock pin. After lock pin installation, stake the
cage to secure the lock pin.
6. Install ring gear and tighten the bolts in diagonal
sequence as illustrated.
Torque: 108 N´m (80 lb ft)
NOTE: Discard used bolts and install new ones.
415RS016

4A1±23 DIFFERENTIAL (FRONT)
Main Data and Specifications
General Specifications
Axle tube TypeIt consists of a duct, a cast iron housing
and an axle tube.
Gear typeHypoid
Gear ratio4.300
Differential typeTwo pinion
Oil capacityliter (US qt)1.25 (1.32) (Differential)
0.12 (0.13) (Actuator Housing: Shift on the fly)
Type of lubricantGL±5 (75W±90)
Axle shaft typeConstant velocity joint
(Birfield joint type and double offset joint)
Hub locking TypeRigid
Torque Specifications
412R200005

DIFFERENTIAL (FRONT) 4A1±24
415R200003

4A1±25 DIFFERENTIAL (FRONT)
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
J±8614±01
Holder; Pinion flange
J±24250
Installer; Oil seal
J±37264
Differential holding
fixture
(Use with J±3289±20
base)
J±3289±20
Holding fixture base
J±42379
Remover; Side/Pinion
bearing
J±8107±2
Adapter; Side bearing
plug
ILLUSTRATIONTOOL NO.
TOOL NAME
J±7817
Installer; Outer bearing
outer race
J±7818
Installer; Inner bearing
outer race
J±8092
Driver handle
J±21777±42
Pilot
J±21777±43
Nut and stud
J±42479±1
Gauge plate

DIFFERENTIAL (FRONT) 4A1±26
ILLUSTRATIONTOOL NO.
TOOL NAME
J±8001
Dial indicator
J±23597±8
Disc
J±23597±1
Arbor
J±6133±01
Installer; Pinion bearing
J±24244
Installer; Side bearing
J±39602
Remover; Outer bearing
ILLUSTRATIONTOOL NO.
TOOL NAME
J±42479±2
Pilot
J±39209
Punch; End nut lock

DIFFERENTIAL (REAR)4A2±1
AXIOM
DRIVELINE/AXLE
Differential (Rear)
CONTENTS
Service Precaution 4A2±1. . . . . . . . . . . . . . . . . . . . . .
General Description 4A2±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing 4A2±5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts 4A2±5. . . . . .
Removal 4A2±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A2±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Shaft, Oil Seal and Bearing 4A2±7. . . . . . . . . .
Axle Shaft and Associated Parts 4A2±7. . . . . . . . .
Removal 4A2±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 4A2±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A2±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal 4A2±10. . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts 4A2±10. . . . .
Removal 4A2±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2±11. . . . . . . . . . . . . . . . . .
Installation 4A2±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A2±13. . . . . . . . . . . . . . . . . . . .
Disassembled View 4A2±13. . . . . . . . . . . . . . . . . . . .
Inspecting the Axle Before Disassembly 4A2±14. .
Disassembly 4A2±14. . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 4A2±16. . . . . . . . . . . . . . . . . .
Reassembly 4A2±16. . . . . . . . . . . . . . . . . . . . . . . . . .
Side Bearing Preload Adjustment 4A2±20. . . . . . . .
Pinion Installation 4A2±21. . . . . . . . . . . . . . . . . . . . . .
Determination of Backlash & Preload Shims 4A2±22
Backlash Adjustment 4A2±23. . . . . . . . . . . . . . . . . . .
Gear Tooth Pattern Check 4A2±23. . . . . . . . . . . . . .
Adjustments Affecting Tooth Contact 4A2±24. . . . .
Differential Case Assembly 4A2±25. . . . . . . . . . . . . . .
Disassembled View 4A2±25. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2±26. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2±26. . . . . . . . . . . . . . . . . .
Reassembly 4A2±26. . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Slip Differential Assembly 4A2±27. . . . . . . . .
Disassembled View 4A2±27. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2±27. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2±29. . . . . . . . . . . . . . . . . .
Reassembly 4A2±29. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data And Specifications 4A2±31. . . . . . . . . . . . .
Special Tools 4A2±32. . . . . . . . . . . . . . . . . . . . . . . . . . .
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 REFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFOMATION. 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 specification. Following these
instructions can help you avoid damage to parts and
systems.