light ISUZU AXIOM 2002 Service Service Manual

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±16
How to Clear The Trouble Code
The trouble codes saved to the control unit can be deleted
by the following procedure if the starter switch is being in
the OFF position.
1. Short-circuit terminal 8 of the self-diagnostic
connector to GND (terminal 4 or 5).
2. Turn on the starter switch while maintaining the state
of step1, and stop short-circuiting terminal 8 to GND
within five seconds.
826R200011
3. If the conditions shown in steps 1 and 2 are met, the
trouble codes saved to the control unit are cleared.
(After the codes are completely deleted, the code 12
that indicates the normal condition is continuously
displayed.)
Precautions on Diagnosis
Replacement of Control Unit
The control unit itself rarely fails. In most cases, the
harnesses have failed (i.e. short-circuit) to cause
secondary troubles. Other cases include that the cause
has been unknown due to intermittent occurrence of
troubles and the troubles are removed accidentally along
with replacement of control unit, resulting in misjudgment
of cause. Therefore, before replacing the control unit,
check the connector joints and whether the unspecified
current flows in the control unit due to short-circuit
between harnesses.
Trouble Intermittently Observed
Troubles intermittently observed are mostly attributable
to temporary imperfect connection of harnesses and
connectors.
When such troubles are found, check the associated
circuit according to the following procedure.
1. Check whether improper connectors are plugged in
or connector terminals are completely engaged.
2. Check whether the terminals are deformed or
damaged. If yes, remove the deformation or damage
and connect the terminals securely.3. It is likely that wires in the harness are falsely broken.
Therefore, in examination of failed harness circuit,
shake the harness for check to such extent that the
harness will not be damaged.
Test Run of Failed TOD Vehicle
If the TOD indicator lamps experienced faulty operation
even once in the past, the failed portion can be identified
by use of the procedure ªDiagnosis from Trouble Codesº
or ªTrouble Diagnosis Depending on the Status of TOD
Indicatorº. If the troubles that are only recognized as
abnormal phenomena of the vehicle by the driver are
observed, conduct the test run in the following procedure
to reproduce the faulty phenomena and diagnose the fault
for each phenomenon.
1. Start the engine, and check that the TOD indicator
lamps are turned on for about two seconds for initial
check; the CHECK lamp goes off; and the TOD
indicator lamps display the specified drive mode. (If
the CHECK lamp starts blinking, read the trouble
codes and identify the failed portion.)
2. While keeping the vehicle standstill, operate the TOD
switch to change the modes: 2H mode"TOD
mode"4L mode"TOD mode"2H mode. Check
that the TOD indicator lamps correctly display the
status whenever the mode is changed. If the
transition status is displayed during the shift
operation, run the vehicle a little to complete shifting.
3. Slowly start the vehicle in the TOD mode, and add the
power to accelerate to at least 40 km/h (25 mph)and
maintain the speed for about two minutes. Apply the
brake to completely stop the vehicle. Repeat this test
pattern at least three times.
4. Turn the steering to the right end (or left end) in the
TOD mode, and slowly start the vehicle and make a
circle five times. Next, conduct the same test in the 2H
mode.
5. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h (25 mph). Keep the
established speed, carefully change the mode in the
sequence ªTOD mode"2H mode "TOD modeº
while checking that the shift is complete in each mode
change. After the test, apply the brake to completely
stop the vehicle.
6. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h (25 mph). Apply the
brake strongly so that the ABS works, and completely
stop the vehicle.
7. Slowly start the vehicle in the 4L mode, and
accelerate to at least 20 km/h (13 mph). Apply the
brake to completely stop the vehicle.
If the CHECK lamp starts blinking during the test run, read
the trouble codes and give appropriate maintenance
according to the diagnostic procedure. If the TOD
indicator lamps are lit abnormally during the run, check
the lighting condition and give appropriate maintenance
according to the diagnostic procedure. Even if the
phenomena are not observed, try to reproduce the
abnormal state reported by the customer to the possible
extent.

4B2±27
DRIVE LINE CONTROL SYSTEM (TOD)
No. CONTENTSNAME
26MTR POS1Shift Motor Position 1
27POSCAT Position C
28POSAAT Position A
29DIAGDiagnostic Input
30TOD SW ATOD Switch A (2H)
314H SW4H Switch Input
32FT. SIGFront Speed Signal
33ABS INABS In
34VBPower Bat
35MTR H-LPower Shift Motor H-L
364WD OUT4WD Signal Output
37BRAKE SWBrake Switch Input
38MTR POS4Shift Motor Position 4
39MTR POS2Shift Motor Position 2
40LIGHTING SWLighting Switch Input
41POSBAT Position B
42AXLE SWAxle Switch Input
43TOD SWBTOD Switch B (4L)
444L SW4L Switch Input
45RR. SIGRear Speed Signal
46GND. 1ECU Ground 1
47GND. 2ECU Ground 2
48MTR L-HPower Shift Motor L-H

4B2±31
DRIVE LINE CONTROL SYSTEM (TOD)
Check
Pin
No.Note Standard Value Measure
between
Pin No. Unit
Scale/
Range Engine
State Ignition
Switch
Position Circuit to be
tested
364WD
OUTOFFSTOP
36, 477 ~12 k
Disconnect battery GND terminal
11EMC(+)OFFSTOP
11, 221.0 ~5.0
Disconnect battery GND terminal
30TOD SW
AONSTOPDCV30 (+), 47
(±)SW: TOD, 4L: 0
V
SW:2H:8.0 ~
14.5 V
43TOD
SWBONSTOPDCV43 (+), 47
(±)SW: 2H,
TOD:0V
SW: 4L: 8.0 ~
14.5V
40LIGHTONSTOPDCV40 (+), 47
(±)SW OFF : 0 V
SW ON : 8.0 ~
14.5 V
19IND BONSTOPDCV19 (+), 47
(±)8.0 ~14.5 VWhen the indicator lamp is turned
off
8IND CONSTOPDCV8 (+), 47
(±)8.0 ~ 14.5 VWhen the indicator lamp is turned
off
27AT POSCONSTOPDCV27 (+), 47
(±)ON:D, 3, 2, 1
OFF:PRNON:8.0 ~ 14.5 V
OFF:0V
41AT POSBONSTOPDCV41 (+), 47
(±)ON:R, N, D, 3
OFF:P, 2, 1ON:8.0 ~ 14.5 V
OFF:0V
28AT POSAONSTOPDCV28 (+), 47
(±)ON:P, R, 3, 2
OFF:N, D, 1ON:8.0 ~ 14.5 V
OFF:0V
2ENG REVONRUNms2, 47Waveform
(PWM)50 ms (1000 rpm)

4B2±67
DRIVE LINE CONTROL SYSTEM (TOD)
Trouble Diagnosis Depending on The
Status of TOD Indicator
Functional check with TOD indicator light is conducted
prior to check on Charts A±H.

After the starter is switched on, check and see if the
status has become as tabulated below.
C04R200003

If the status is as tabulated above, there is no
problem. If not as tabulated above, inspect the
harness.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±100
Chart HLighting switch circuit
Function of circuitReads in the status of lighting switch, and reduces the indicator at night.
Fail conditionEven if the lighting switch is pressed on and off, brightness does not change.
Indicator lamp state
TOD switch positionAll position (exsample TOD mode)
D04R200009

4B2±101
DRIVE LINE CONTROL SYSTEM (TOD)
StepActionYe sNo
11. Turn on the starter switch.
2. Turn off the lighting switch.
Is 0V observed between the EUC terminal 40 and 47?
Go to Step 2
Lighting switch
battery circuit
short. Repair the
circuit.
Go to
Step 4
2Turn lighting switch ªONº.
Is the battery voltage observed between ECU terminal 40 and 47?
Go to Step 3
Wires are broken
in lighting switch
circuit. Repair the
circuit.
Go to
Step 4
3While the lighting switch is pressed on and off, does the
brightness of the indicator change?The phenomenon
is not
reproduced.
Refer to
ªTroubles
intermittently
observedº
The ECU has
failed. Replace
the ECU.
Go to
Step 4
4Check that all the parts are mounted.
Is this step complete?
Verify the repair.Go to Step 4

4C±39 DRIVE SHAFT SYSTEM
1. Apply alignment marks on the yokes of the universal
joint, then remove the snap ring.
401RW024If the snap ring is stuck in position, remove paint from
the hole in the yoke or tap around the edge of the
bearing lightly with a soft drift.
401RW025
2. Set the yoke in the arbor press with a piece of tube
stock beneath it.
Place a solid plug on the upper bearing and press it
through to release the lower bearing.
401RW027
3. If the bearing will not pull out by hand after pressing,
tap the base of the lug near the bearing to dislodge it.
4. To remove the opposite bearing, turn the yoke over
and straighten the spider in the open spider hole.
Then carefully press on the end of the spider so the
remaining bearing moves straight out of the bearing
spider hole. If the spider or bearing are cocked, the
bearing will score the walls of the spider hole and ruin
it.
401RW026

4C±40
DRIVE SHAFT SYSTEM
5. Repeat this procedure on the remaining bearing to
remove the spider from the yoke.
Inspection

Propeller shaft for run-out Aluminum tube type.
Static run-out limit : 1.0 mm(0.04 in)
TIR full length of tubing maximum.
(TIR : Total Indicator Reading)

Propeller shaft for runout (Steel tube type).
Static runout limit : 0.13 mm(0.005 in)
TIR on the neck of the slip tube shaft (with a
boot).
0.25 mm(0.010 in)
TIR on the ends of the tubing 3 inch from the
welds.
0.38 mm(0.015 in)
TIR at the linear center of the tube.
0.38 mm(0.015 in)
TIR for the full length of tube with 30º or less of
tubing.
(TIR: Total Indicator Reading)
401RW017

Play in universal joint.
Limit: Less than 0.15 mm(0.006 in)

Spider pin should be smooth and free from fretting or
galling.
Visible signs of needle presence is normal, but wear
should not be felt.
401RW028

Preload of the universal joint.
Preload should be 0 to 49 N (0 to 11.0 lb).
Joints should rotate smoothly and freely and should
exhibit no rough or ratchety movement.
401RW019

Inspect splines of slip joint for wear.
The nylon-coated spline should be free from nicks
and dings and the underlying steel spline should not
be visible.
After cleaning the nylon coating spline, the coating
should exhibit only slight indication of wear.
Grease volume is approximately 10 grams of grease
in total. Grease should be evenly applied to both the
female and the male slip splines using a small brush.
After assembly of the slip joint, the sliding joint should
be fully worked from the full collapsed to the full
extended position.

4C±76
DRIVE SHAFT SYSTEM
Spline
The nylon-coated spline should be free from nicks and
dings and the underlying steel spline should not be visible.
After cleaning the nylon coating spline, the coating should
exhibit only slight indicator of wear.
Grease volume is approximately 10 grams of grease in
total. Grease should be evenly applied to both the female
and the male slip splines using a small brush. After
assembly of the slip joint, the sliding joint should be fully
worked from the full collapsed to the full extended
position.
Play in the universal joint
Limit: Less than 0.15 mm (0.006 in)
401RW023
Preload of the universal joint
Preload should be 0 to 49 N(0 to11.0 lb). Joints should
rotate smoothly and freely and should exhibit no rough or
ratchety movement.
401RW019
Universal Joint Reassembly
1. Install spider to flange yoke. Be sure to install the
spider by aligning the setting marks made during
disassembly.
2. Pack the four grease cavities of the spider with a high
quality, extreme pressure N.L.G.I. Grade 2 grease.
Do not add additional grease to the bearing cup
assembly.
3. Move one end of the spider to cause a trunnion to
project through the spider hole beyond the outer
machined face of the yoke lug. Place a bearing over
the trunnion diameter and align it to the spider hole.
Using an arbor press, hold the trunnion in alignment
with the spider hole and place a solid plug on the
upper bearing. Press the bearing into the spider hole
enough to install a snap ring.
401RW020
4. Install a snap ring.
Be sure the snap rings are properly seated in the
grooves.
5. Repeat steps 3 and 4 to install the opposite bearing. If
the joint is stiff, strike the yoke ears with a soft
hammer to seat needle bearings.

4C±82
DRIVE SHAFT SYSTEM
1. Apply alignment marks on the yokes of the universal
joint, then remove the snap ring.
401RW024If the snap ring is stuck in position, remove paint from
the hole in the yoke or tap around the edge of the
bearing lightly with a soft drift.
401RW025
2. Set the yoke in the arbor press with a piece of tube
stock beneath it.
Place a solid plug on the upper bearing and press it
through to release the lower bearing.
401RW027
3. If the bearing will not pull out by hand after pressing,
tap the base of the lug near the bearing to dislodge it.
4. To remove the opposite bearing, turn the yoke over
and straighten the spider in the open spider hole.
Then carefully press on the end of the spider so the
remaining bearing moves straight out of the bearing
spider hole. If the spider or bearing are cocked, the
bearing will score the walls of the spider hole and ruin
it.
401RW026
5. Repeat this procedure on the remaining bearing to
remove the spider from the yoke.