check oil ISUZU AXIOM 2002 Service Owner's Guide

4A2±10DIFFERNTIAL (REAR)
Pinion Oil Seal
Pinion Oil Seal and Associated Parts
420RW013
Legend
(1) Flange Nut and Washer
(2) Flange(3) Oil Seal
(4) Outer Oil Seal Slinger
(5) Outer Pinion Bearing (Cup and Cone)
Removal
1. Remove the rear propeller shaft. Refer to Rear
Propeller Shaft
in this section.
2. Drain the rear axle oil.
3. Check and record preload with an inch pound torque
wrench. This will give combined pinion bearing, seal,
carrier bearing, axle bearing and seal preload.
425RW018

DIFFERENTIAL (REAR)4A2±11
4. Remove flange nut and washer by using pinion flange
holder J±8614±01 after raising up its staked parts
completely.
425RW037
5. Remove flange by using SST J±8614±1 ~ 3.

Have a suitable container in place to catch
lubricant.
425RW038
6. Remove oil seal.
7. Remove pinion oil seal slinger.
8. Remove outer bearing by using remover J±39602.
425RS090
9. Remove collapsible spacer.
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. Seal surface of the flange.
2. Cage bore for burns.
Installation
1. Install collapsible spacer, discard the used collapsible
spacer and install a new one.
2. Install outer bearing.
NOTE: Do not drive in, but just temporarily set in the outer
bearing by hand, which should be indirectly pressed in
finally by tightening the flange nut.

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±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.

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.

DIFFERENTIAL (REAR)4A2±23
Backlash Adjustment
1. Install the differential case assembly and bearing
caps.
2. Rotate the case several times to seat the bearings.
3. Remove the spreader.
4. Install the side bearing cap bolts.
Tighten side bearing cap bolts
Torque: 108 N´m (80 lb ft)
5. Install a dial indicator to the case using a magnetic
base.
6. Place the indicator stem at the heel end of a tooth.

Set the dial indicator so that the stem is in line with
the gear rotation and perpendicular to the tooth
angle.
425RS087
7. Check and record the backlash at three points around
the ring gear.

The pinion must be held stationary when checking
backlash.

The backlash should be the same at each point
within 0.07 mm (0.003 in). If the backlash varies
more than 0.07 mm (0.003 in), check for burrs, a
distorted case flange, or uneven bolting conditions.
8. Backlash at the minimum lash point measured should
be between 0.13 and 0.20 mm (0.005 and 0.008 in)
for all new gear sets.
9. If the backlash is not within specifications, move the
ring gear in or out from the pinion by increasing the
thickness of one shims, and decreasing the thickness
of the other shim by the same amount.
This will maintain the correct rear axls side bearing
preload.

Moving 0.05 mm (0.002 in) worth of shim from one
side of the differential to the other will change the
backlash adjustment by 0.03 mm (0.001 in).
10. After obtaining correct tooth contact described in
later, install ABS speed sensor.11. Install the cover with sealant.
Torque: 40 N´m (30 lb ft)
12. Fill the axle lubricant.
Gear Tooth Pattern Check
Checking the ring gear to pinion tooth pattern is to be
done only after setting up the axle according to the
methods in this section. The pattern check is NEVER to
be used as an initial check, or instead of checking pinion
depth and backlash adjustments.
This check is only to be verify the correct adjustment of
the gear set after set up.
425RS038
Legend
(1) Heel
(2) Toe
(3) Concave Side (Coast)
(4) Convex Side (Drive)
1. Wipe all oil out of the carrier, and carefully clean each
tooth of the ring gear.
2. Use gear marking compound 1052351 or equivalent
and apply this mixture sparingly to all ring gear teeth,
using a medium-stiff brush. When properly used, the
area of pinion tooth contact will be visible when hand
load is applied.
3. Tighten the bearing cap bolts to the specified torque.
4. Expand the brake shoes until a torque of 54 to 68 N´m
(40 to 50 lb ft.) is required to turn the pinion. A test
made without loading the gears will not give a
satisfactory pattern. Turn the pinion flange with a
wrench so that the ring gear rotates one full
revolution, then reverse the rotation so that the ring
gear rotates one revolution in the opposite direction.
5. Observe the pattern on the ring gear teeth and
compare this with figure.

4A2±26DIFFERNTIAL (REAR)
Disassembly
1. Remove lock pin using a small drift.
425RS098
2. Remove the differential shaft by using a soft metal rod
and a hammer.
425RS043
3. Remove pinion mate gear and thrust washer.
4. Remove side gear and 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.

Ring gear, pinion gear

Bearing

Side gear, pinion mate gear, differential shaft

Differential case, carrier

Thrust washer

Oil seal
Reassembly
1. Install side gear with thrust washer.
2. Install the pinion mate gear with thrust washer by
engaging it with the side gears while turning both
pinion mate gears simultaneously in the same
direction.
425RS048
3. Install differential shaft.
1. Be sure to install the differential shaft so that it is in
alignment with the lock pin hole in the differential
case.
425RS049
4. Install lock pin.
After lock pin installation, stake the case to secure the
lock pin.

4B2±1
DRIVE LINE CONTROL SYSTEM (TOD)
AXIOM
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (TOD)
CONTENTS
Service Precaution 4B2±1. . . . . . . . . . . . . . . . . . . . . .
General Description 4B2±2. . . . . . . . . . . . . . . . . . . . .
Transfer Position and Drive Mode 4B2±2. . . . . . . .
TOD Control 4B2±3. . . . . . . . . . . . . . . . . . . . . . . . . .
TOD Indicator Control 4B2±3. . . . . . . . . . . . . . . . . .
Abbreviations 4B2±3. . . . . . . . . . . . . . . . . . . . . . . . .
System Components 4B2±4. . . . . . . . . . . . . . . . . . . .
Parts Location 4B2±4. . . . . . . . . . . . . . . . . . . . . . . .
Front and Rear Speed Sensors 4B2±5. . . . . . . . . .
Electromagnetic Coil 4B2±5. . . . . . . . . . . . . . . . . . .
Multi Plate Disk Clutch Pack 4B2±5. . . . . . . . . . . .
Mechanical Lock Sleeve 4B2±5. . . . . . . . . . . . . . . .
High-Low Planetary Gear Set 4B2±6. . . . . . . . . . .
4H and 4L Switch 4B2±6. . . . . . . . . . . . . . . . . . . . . .
Transfer Connector (12-pin type) 4B2±6. . . . . . . .
Transfer Connector (8-pin type) 4B2±6. . . . . . . . .
TOD Indicator Lamps
(on the instrument panel) 4B2±7. . . . . . . . . . . . . .
Check Lamp 4B2±7. . . . . . . . . . . . . . . . . . . . . . . . . .
TOD ECU 4B2±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Low Shift Motor 4B2±9. . . . . . . . . . . . . . . . . . .
Motor Position and Encoder Position Code 4B2±10
Encode Position Plate 4B2±10. . . . . . . . . . . . . . . . . .
Shift High Range and Low Range 4B2±10. . . . . . . . Functions of TOD Switch and Indicator
Lamp 4B2±11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD Switch and Indication of Drive Mode 4B2±11.
Check Lamp 4B2±13. . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 4B2±14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information Diagnosis 4B2±14. . . . . . . . . .
Self-diagnosis 4B2±14. . . . . . . . . . . . . . . . . . . . . . . . .
Precautions on Diagnosis 4B2±16. . . . . . . . . . . . . . .
Basic Diagnostic Flow Chart 4B2±18. . . . . . . . . . . . . .
Parts Location 4B2±19. . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagram 4B2±20. . . . . . . . . . . . . . . . . . . . . . . . .
Connector List 4B2±24. . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Failed Pin 4B2±26. . . . . . . . . . . . . . . . . . . . .
Connector Pin Assignment 4B2±26. . . . . . . . . . . . . .
Reference 4B2±28. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Failed TOD Control Unit Pin 4B2±30. . . . .
Tech 2 Scan Tool 4B2±32. . . . . . . . . . . . . . . . . . . . . .
Getting Started 4B2±33. . . . . . . . . . . . . . . . . . . . . . . .
Operating Procedure 4B2±33. . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes 4B2±35. . . . . . . . . . . . . . . .
Diagnosis from Trouble Codes 4B2±36. . . . . . . . . . . .
Trouble Diagnosis Depending on The Status
of TOD Indicator 4B2±67. . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis from Symptom 4B2±102. . . . . . . . . . . . . . . . .
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.

4B2±35
DRIVE LINE CONTROL SYSTEM (TOD)
Diagnostic Trouble Codes
CodeTech 2 code
(P code)ItemDiagnosisCheck flow No.
12ÐStart codeNormalÐ
13P1735RefShorted GND6
14P1731Front speed sensorInput abnormality (open, sig or com)2
15P1736RefShorted VB6
16P1737Front speed sensorInput abnormality4
17P1774Inhibitor switchInput abnormality8
21P1716TPSShorted or disconnected wiring,
abnormality in input7
23ÐECUCPU abnormality1
24P1733Rear speed sensorInput abnormality (open, sig or com)3
27P1738Rear speed sensorInput abnormality5
28P1760ADC (+) & AXLE SWOutput abnormality10
31P1721EMC (+)Shorted VB, disconnected coil/wiring or
shorted GND9
32P1761ADC (+)Shorted VB or disconnected wiring11
33P1762ADC (+)Shorted GND12
36ÐECUCPU abnormality1
37P1712ECUCPU abnormality1
38P1714ECUCPU abnormality1
41P1741Hight-Low shift motorShorted GND or disconnected wiring13
42P1773Hight-Low shift motorUser operation error (not failure)14
43P1743Hight-Low shift motorMotor moving more than 5s15
55P1755Hight-Low shift motorInput abnormality of motor position signal16
TPS : Throttle Position Sensor
EMC : Electromagnetic coil
ADC : Shift on the fly (Axle Dis Connect)

4B2±53
DRIVE LINE CONTROL SYSTEM (TOD)
Check flowTrouble codePhenomenonStandard
931 (P1721)The electromagnetic coil is broken
or shorted to the battery or GND.Ð
D04R200005