ISUZU AXIOM 2002 Service Repair Manual

4A2±12DIFFERNTIAL (REAR)
3. By using the seal installer J±37263, install a new oil
seal (1) that has grease on seal lip.
425RS004
4. Install flange.
5. The pinion washer and a new nut while holding the
pinion flange with J±8614±01.

Tighten the nut until the pinion end play is just taken
up. Rotate the pinion while tightening the nut to seat
the bearings. Once there is not end play in the
pinion, the preload torque should be checked.

Remove J±8614±01. Using an inch-pound torque
wrench, check to make sure the pinion preload is
equal to or slightly over the reading recorded during
removal.
425RW018
6. Install propeller shaft to the frange.
7. Install bolt and nut. Tighten the bolt and nut to the
specified torque.
Torque: 63 N´m (46 lb ft)

DIFFERENTIAL (REAR)4A2±13
Differential Assembly
Disassembled View
420RW018
Legend
(1) ABS Speed Sensor
(2) Housing
(3) Outer Pinion Bearing (Cup and Cone)
(4) Outer Oil Slinger
(5) Oil Seal
(6) Companion Flange Assembly
(7) Pinion Nut Washer
(8) Pinion Nut
(9) Collapsible Spacer
(10) Baffle Plate
(11) Inner Pinion Bearing (Cup and Cone)
(12) Inner Oil Slinger
(13) Pinion gear adj. Shim-Selective (Position)
(14) Ring gear and Pinion Gear Assembly
(15) Exciter Ring
(16) Differential Case(17) Lock Pin
(18) Axle Vent
(19) Gasket
(20) Cover and Clip Assembly
(21) Fill Plug (with Magnet)
(22) Mounting Bracket
(23) Side Bearing Cap Bolt
(24) Side Bearing Cap
(25) Ring Gear Bolts
(26) Differential Adjustment Shims (Side Bearing
Preload and Ring Gear/Pinion Backlash)
(27) Side Bearing (Cup and Cone)
(28) Differential Shaft
(29) Differential Side Gears
(30) Side Gear Thrust Washer
(31) Pinion Mate Gears
(32) Thrustwasher-Differential Pinion Mate Gear

4A2±14DIFFERNTIAL (REAR)
Inspecting the Axle Before
Disassembly
1. Remove the axle cover from the rear axle and drain
the axle lubricant into a suitable container.
2. Check ring gear backlash. Refer to
Backlash
Adjustment
in this section. This information can be
used to determine the cause of the axle problem. It
will also help when setting up the shim packs for
locating and preloading the differential cage.
3. Check case for metal chips and shavings. Determine
where these chips and shavings come from, such as
a broken gear or bearing cage.

If possible, determine the cause of the axle problem
before disassembly.
Disassembly
1. Remove axle shafts.

Refer to
axle shaft replacement in this section.
2. Remove ABS sensor.
3. Remove bearing caps and bolts.

Mark the caps and the housing as left and right.
CAUTION: Be a ri n g c a p s a re machined with the
housing and must be assembled in the same
position as removed. Note the matched letter
stamped on the caps and carrier. When assembled,
the letters on the caps must agree in both the
hosizontal and vertical position with the letters on
the carrier.
420RW003
4. Remove Differential case.

Pry the case from the axle housing at the differential
ªwindowº.
420RW010
5. Remove side bearing outer races and shims.

Mark the races and shims as left and right, and
place them with the bearing cups.
6. Remove differential side bearings using remover
J±42379 and plug J±39830.

Select insert ; 303174 and collet halves ; 44801 in
remover kit J±42379.
415RW003
7. Remove ring gear bolts.

Ring gear bolts use right handed threads.
CAUTION: DO not pry the ring gear from the case.
This will damage the ring and the differential case.

DIFFERENTIAL (REAR)4A2±15
8. Remove ring gear from the differential.

Drive the ring gear off with a brass drift if necessary.

Check drive pinion bearing preload.
425RW018

Check the pinion assembly for looseness by
moving it back and forth. (Looseness indicates
excessive bearing wear.)
9. Remove pinion flange nut and washer.

Use flange holder J±8614±01 to hold the pinion
flange.
10. Remove pinion flange.

Use flange holder J±8614±01 to remove the pinion
flange.
415RS018
11. Remove pinion from the axle housing.

Thread the pinion nut halfway onto the pinion.

Drive the pinion out of the housing with a hammer
and a soft drift.

Remove the nut and then remove the pinion.12. Remove collapsible spacer(1).
415RW011
13. Remove outer seal, outer oil slinger and outer pinion
bearing.
14. Remove inner bearing, inner oil slinger and shim from
the pinion.

Press the bearing off the pinion using remover
J±42379.
415RW004

Select insert ; 303174 and collet halves ; 44801 in
remover kit J±42379.

Remove the shim.
15. Remove bearing cups and baffle plate from the axle
housing using a hammer and a punch.

Work the cups out of the housing evenly, moving the
punch back and forth between one side of the cup
and the other.

The baffle plate will be destroyed and should be
replaced with a new one.

4A2±16DIFFERNTIAL (REAR)
16. Remove exciter ring.

Remove the exciter ring from the differential using a
mallet or a brass hammer if it is required.
NOTE: Discard the exciter ring after removal.
425RS097
Cleaning
Do not steam clean drive parts which have ground and
polished surfaces such as gears, bearings, and shafts.
These parts should be cleaned in a suitable solvent. All
parts should be disassembled before cleaning.
Parts should be thoroughly dried immediately after
cleaning. Use soft, clean, lintless rags. Parts may be dried
with cimpressed air. Do not allow the bearings to spin
while drying them with compressed air.
Inspection and Repair
It is very important to carefully and thoroughly inspect all
drive unit parts before reassembly.
Thorough inspection of the drive parts for wear or stress
and subsequent replacement of worn parts will eliminate
costly drive component repair after reassembly.
Axle Housing

The carrier bore for nicks or burrs that would prevent
the outer diameter of the pinion seal from sealing,
Remove any burrs that are found.

The bearing cap bores for nicks or burrs.
Remove any burrs that are found.

The housing for cracks. Replace the housing if any
cracks are found.

The housing for foreign material such as metal chips,
dirt, or rust.
Pinion and Ring Gear

Pinion and ring gear teeth for cracking, chipping,
scoring, or excessive wear.

Pinion splines for wear.

Pinion flange splines for wear.
The sealing surface of the pinion flange for nicks,
burrs, or rough tool marks which would cause
damage to the seal's inside diameter and result in an
oil leak.

Replace all worn or broken parts.

Ring and pinion gears are matched sets and are both
replaced anytime a replacement of either is
necessary.
Bearings

Bearings visually and by feel.

The bearings should feel smooth when oiled and
rotated while applying as much hand pressure as
possible.
The large end of the bearing rollers for wear.
This is where tapered roller bearing wear is most
evident.

Bearing cups for wear, cracks, brinelling and scoring.

Bearing and cups are only replaced as sets.

If the rear axle was operated for an extended period of
time with very loose bearings, the ring gear and drive
pinion will also require replacement.

Low mileage bearings may have minute scratches
and pits on the rollers and the bearing cups from the
initial pre-load. Do not replace a bearing for this
reason.

Bearing cups for cracks or chips.
Shims

Shims for cracks and chips. Damaged shims should
be replaced with an equally sized service shim.
Reassembly
1. Install pinion bearing races and baffle plate using
outer bearing race installer J±8611±01 / inner bearing
race installer J±42836 and drive handle J±8592.
NOTE: Baffle plate must be installed, when install the
inner pinion bearing race.
425RW019

DIFFERENTIAL (REAR)4A2±17
425RW020
2. Clean all the gauge parts.
3. Lubricate the outer and inner bearings with axle
lubricant.
4. Place the bearings into the pinion bearing races.
5. Place the inner oil slinger onto the inner pinion
bearing.
NOTE: The inner oil slinger must be placed between
gauge plate and inner pinion bearing when measuring the
pinion depth.
6. Install gauge plate J±39837±2, inner J±42827 stud
and nut J±21777±43 and outer pilot J±42824 to the
pinion bore.
420RW005
7. Hold the stud stationary at the flats of the stud (and).
Tighten the stud nut
Torque: 2.2 N´m (1.6 lb ft)
8. Rotate the gauge plate and bearings several
complete revolutions to seat the bearings.
9. Tighten the stud nut until a torque of 1.6 to 2.2 N´m
(1.2 to 1.6 lb ft.) is required to keep the gauge plate in
rotation.10. Assemble discs J±39837±1, arbor J±23597±1 and
dial indicator J±8001 to the side bearing bores.
NOTE: The bearing bores must be clean and burr-free.
420RW005
11. Install the side bearing caps and tighten the bolts to
the specified torque.
Torque: 108 N´m (80 lb ft)
12. Rotate the gauge plate until the gauging area is
parallel with the discs.
13. Position the arbor assembly in the carrier so that the
plunger is centered on the gauge area of the gauge
plate.

4A2±18DIFFERNTIAL (REAR)
14. Set the dial indicator to ª0º. Place it on the mounting
post of the gauging arbor with the contact button
touching the indicator pad.
Force the dial indicator downward until the needle has
made a half turn clockwise. Tighten down the dial
indicator in this position.
425RS020
Legend
(1) Dial Indicator
(2) Ganging Arbor
(3) Plunger
(4) Gaug Plate
15. Position the plunger on the gauge plate. Move the
gauging arbor slowly back and forth and locate the
position at which the dial indicator shows the greatest
defection. At this point, once again set the dial
indicator to ª0º.
Repeat the procedure to verify the ª0º setting.
425RS021
16. After the ZERO setting is obtained, rotate the gauging
arbor until the dial indicator rod does not touch the
gauging plate.
Record the number the dial indicator needle points to.
425RS022
Legend
(1) Example=Dial indicator reading of 0.085
17. Record the pinion depth code on the head of the drive
pinion.
The number indicates a necessary change in the
pinion mounting distance. A plus number indicates
the need for a greater mounting distance (which can
be achieved by decreasing the shim thickness). A
minus number indicates the need for a smaller
mounting distance (which can be achieved by
increasing the shim thickness). If examination
reveals pinion depth code ª0º, the pinion is ªnominalº.
425RS023

DIFFERENTIAL (REAR)4A2±19
18. Select the shim using the chart;
Dial Indicator
ReadingMarking (inches)Reading
(inches)
+3+2+10±1±2±3
0.027 0.030
0.028 0.0300.031
0.029 0.0300.0310.032
0.030 0.0300.0310.0320.033
0.031 0.0300.0310.0320.0330.034
0.032 0.0300.0310.0320.0330.0340.035
0.0330.0300.0310.0320.0330.0340.0350.036
0.0340.0310.0320.0330.0340.0350.0360.037
0.0350.0320.0330.0340.0350.0360.0370.038
0.0360.0330.0340.0350.0360.0370.0380.039
0.0370.0340.0350.0360.0370.0380.0390.040
0.0380.0350.0360.0370.0380.0390.0400.041
0.0390.0360.0370.0380.0390.0400.0410.042
0.0400.0370.0380.0390.0400.0410.0420.043
0.0410.0380.0390.0400.0410.0420.0430.044
0.0420.0390.0400.0410.0420.0430.0440.045
0.0430.0400.0410.0420.0430.0440.0450.046
0.0440.0410.0420.0430.0440.0450.0460.047
0.0450.0420.0430.0440.0450.0460.0470.048
0.0460.0430.0440.0450.0460.0470.0480.049
0.0470.0440.0450.0460.0470.0480.0490.050
0.0480.0450.0460.0470.0480.0490.0500.051
0.0490.0460.0470.0480.0490.0500.0510.052
0.0500.0470.0480.0490.0500.0510.0520.053
0.0510.0480.0490.0500.0510.0520.053
0.0520.0490.0500.0510.0520.053
0.0530.0500.0510.0520.053
0.0540.0510.0520.053
0.0550.0520.053
0.0560.053

4A2±20DIFFERNTIAL (REAR)
19. Remove bearing caps and depth gauging tools.
20. Install the correct pinion shim and inner oil slinger
onto pinion.
NOTE: Do not install pinion gear into housing at this time.
21. If the exciter ring was removed, install the new exciter
ring onto the differential case by pressing using the
ring gear as a pilot.
425RS047
22. Install ring gear(1) to the differential case(2)
425RW021
23. Install new ring gear bolts.

Tighten the ring gear bolts alternately in stages,
gradually pulling the ring gear onto the differential
case.
Tighten the ring gear bolts in sequence
Torque: 108 N´m (80 lb ft)
NOTE: Discard used bolts and install new ones.
415RS016
Side Bearing Preload Adjustment
1. The side bearing preload adjustment must be made
before installing the pinion.
2. The side bearing preload is adjusted by changing the
thickness of both the left and right shims equally. This
maintain the original backlash.
3. Install master side bearings J±39836 onto the case.
Remove all nicks, burrs, dirt etc., from the hubs to
allow the master bearings to rotate freely.
425RW026

DIFFERENTIAL (REAR)4A2±21
4. Assemble the differential case into the housing (less
pinion). Install bearing caps and finger tight bolts.
Mount a dial indicator with a magnetic base to the
housing and indicate on the flange or head of screw.
Force the differential assembly as far as possible in
the dirction towards the indicator.
With force still applied, set indicator at zero(0).
NOTE: Dial indicator set should be capable of a minimum
travel of 5.08 mm (0.2 in).
425RS107
5. Force the differetial assembly as far as it will go in the
opposite direction. Repeat these steps until the same
reading is obtained.
6. RECORD THE READING OF THE INDICATOR.
This amount, in shims, will be included in the final
assembly shim stack to establish side bearing
preload and ring gear and pinion backlash.
7. After marking sure the readings are correct, remove
the indicator and differetial assembly from the
housing.
Pinion Installation

The bearing cups should have been installed in Pinion
Depth Adjustment in this section.
1. Place the shim(1) and inner oil slinger(2) on the pinion
gear, then install the pinion inner bearing(3) using
installer J±42828.
425RW023

Drive the bearing until the bearing cone seats on the
pinion shims.
2. Install a new collapsible spacer.

Lubracate the pinion bearings with axle lublicant.
3. Install pinion to the axle housing.
4. Install outer pinion bearing onto the pinion.

Hold the pinion forward from inside the case while
driving the bearing onto the pinion.
5. Install oil seal slinger.
6. Install pinion oil seal using installer J±37263.
7. Install the pinion flange to the pinion by tapping it with
a rawhide hammer until a few threads show through
the pinion flange.
8. Install pinion washer and a new nut while holding the
pinion flange with flange holder J±8614±01.

Tighten the nut until the pinion end play is just taken
up. Rotate the pinion while tightening the nut to seat
the bearings.
Torque:217-678 N´m (160-500 lb ft)
Once there is no end play in the pinion, the preload
torque should be checked.

Remove flange holder J±8614±01. Using an
inch-pound torque wrench, check the pinion
preload by rotating the pinion with the wrench.