ISUZU AXIOM 2002 Service Repair Manual

4D2±8
TRANSFER CASE (TOD)
TOD Control Unit
826R200006
Legend
(1) Bracket
(2) TOD Control Unit
Removal
1. Disconnect the battery ground cable.
2. Disconnect the harness connector from the TOD
control unit.
3. Remove the bracket retaining nuts (3 pieces) and the
bracket with TOD control unit.
4. Remove the TOD control unit from the bracket.
Installation
1. Install the TOD control unit to the bracket.
2. Install the bracket with TOD control unit to the
chassis.
3. Connect the harness connector to the TOD control
unit.
4. Connect the battery ground cable.

4D2±9 TRANSFER CASE (TOD)
Unit Repair
Disassembly and Reassembly of Major Components
266R200002
Legend
(1) Front Companion Flange, Oil Seal, Washer,
and End Nut
(2) 4H and 4L Switch
(3) Harness Assembly
(4) Harness Bracket
(5) Shift Motor Assembly
(6) Rear Companion Flange, Oil Seal, Washer and
End Nut(7) Speedometer Sensor and Driven Gear
(8) Plate and Bracket
(9) Connector Bracket
(10) Breather Hose
(11) Transfer Case Assembly
(12) Transfer Cover Assembly

4D2±10
TRANSFER CASE (TOD)
Disassembly
1. Remove the drain plug from the transfer case and
drain the oil.
2. Remove the speedometer sensor and driven gear.
3. Remove the front and rear speed sensor of the
harness assembly from the transfer cover assembly.
NOTE: Use care to prevent damage to speed sensor
when removing speed sensor.
4. Disconnect the clutch solenoid coil, 4H and 4L switch
harness connector.

Remove the harness bracket from the transfer
cover.
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5. Remove the connector bracket from the transfer
case.

Remove the harness assembly and shift motor
harness connector from the connector bracket.
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6. Remove the 4H and 4L switch from the transfer case.
7. Remove the shift motor assembly from the transfer
cover.
8. Using the flange holder J±8614±11, remove the end
nut.
Remove the washers, oil seals, front and rear
companion flange.
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9. Remove the transfer cover retaining bolts and the
transfer cover assembly from the transfer case
assembly.
NOTE: When removing the transfer cover assembly, use
care to prevent damage to oil seal.
10. Remove the breather hose from the transfer case.
Reassembly
1. Apply recommended liquid gasket (LOCTITE 598 or
its equivalent) uniformly to the transfer case and
cover fitting surface.
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4D2±11 TRANSFER CASE (TOD)
2. Install the plate, bracket, connector bracket and
ground cable of the harness assembly, and tighten
the transfer cover retaining bolts (16 pieces) to
specified torque.
Torque: 31 N´m (23 lb ft)
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3. Install the front and rear companion flange.
4. Install the oil seal and washer, and using the flange
holder J±8614±11, install the new end nut to the
specified torque.
Torque: 167 N´m (123 lb ft)5. Securely stake the end nut at one spot.
NOTE: Be sure to confirm that there is no clack at the
staked portion of the end nut after staking.
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4D2±12
TRANSFER CASE (TOD)
6. Apply recommended liquid gasket (LOCTITE 598 or
its equivalent) to the transfer cover and shift motor
assembly fitting surface.
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7. Install the shift motor assembly to the transfer cover
assembly.
Torque: 10 N´m (87 lb in)
8. Install the 4H and 4L switch.
Torque: 24 N´m (17 lb ft)
9. Install the harness assembly and shift motor harness
connector to the connector bracket.
10. Install the front and rear speed sensors to the transfer
cover.
Torque: 5 N´m (43 lb in)
11. Connect the harness assembly connector to the
clutch solenoid coil harness connector and 4H and 4L
switch.

Fix the harness with harness bracket.
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12. Install the driven gear and speedometer sensor to the
transfer case.
Torque: 25 N´m (19 lb ft)
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13. Remove the filler plug and fill the transfer case with
ATF DEXRON)±II or III.
14. Wind the sealing tape around the filler plug thread and
tighten the plug to the specified torque.
Torque: 25 N´m (19 lb ft)
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15. Install the breather hose to the transfer case.

4D2±13 TRANSFER CASE (TOD)
Transfer Cover Assembly
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Legend
(1) Coil Assembly
(2) Snap Ring
(3) Ball Bearing(4) Speed Gear and Tone Wheel
(5) Ball Bearing
(6) Transfer Cover (With Oil Seal)
(7) Oil Drain Plug and Oil Filler Plug
Disassembly
1. Using a precision screwdriver or a suitable tool, push
down the lock to unlatch the terminal for the coil
assembly, and pull the terminal out.
NOTE: Use care to prevent damage to harness terminal
and connector.
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4D2±14
TRANSFER CASE (TOD)
2. Remove the coil assembly set nuts (3 pieces) and coil
assembly from the transfer cover.
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3. Using snap ring pliers, remove the snap ring from the
transfer cover.
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4. Strike the speed gear and tone wheel with a rod or
other appropriate tool from the rear side of the
transfer cover assembly, and remove the ball bearing,
speed gear and tone wheel.
NOTE: Use care to prevent damage to the speed gear
teeth.
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5. Using the bearing remover J±42805 and slide
hammer J±2619±01, remove the ball bearing of the
front output shaft from the transfer cover.
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Inspection and Repair
Refer to ªInspection and Repair (Transfer Case
Assembly)º in this section.

4D2±15 TRANSFER CASE (TOD)
Reassembly
Transfer cover oil seal replacement
1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to the circumference of the new oil seal and
fill the lip with grease (BESCO L2 or its equivalent).
3. Using the oil seal installer J±42804, install the oil seal
to the transfer cover assembly.
261RY00017Shift shaft oil seal replacement
4. Remove the oil seal from the transfer cover assembly.
5. Apply oil the circumference of the new oil seal.
6. Using the oil seal installer J±33951, install the oil seal
to the transfer cover assembly.
The drive in depth must be 9.4 ~ 10.4 mm (0.370 ~
0.409 in). The knurled end of the installer (indicated
by the arrow) must be flush with the oil seal
installation surface.
NOTE: Use care to prevent tilt to oil seal when installing
oil seal to the case.
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7. Install the ball bearing of the front output shaft to the
transfer cover.
8. Install the speed gear and tone wheel.
9. Install the ball bearing to the transfer cover.
10. Using snap ring pliers, install the snap ring to the
transfer cover.
NOTE: The snap ring must be fully inserted into the
transfer cover snap ring groove.
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11. Install the coil assembly to the transfer cover and
tighten the set nuts (3 pieces) to the specified torque.
Torque: 10 N´m (87 lb in)
12. Install the connector to the harness terminal of the coil
assembly.
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4D2±16
TRANSFER CASE (TOD)
Clutch Pack and Clutch Cam (Transfer Case Assembly)
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Legend
(1) Transfer Case Assembly
(2) Snap Ring
(3) Wave Spring
(4) Cam Pulley
(5) Cam Ball(6) Cam and Coil Housing Assembly
(7) Thrust Bearing
(8) Armature Plate
(9) Insulator Washer
(10) Clutch Pack Assembly
(11) Lockup Fork Spring
Disassembly
1. Remove the lockup fork spring.
2. Remove the thrust bearing and cam and coil housing
assembly from the output shaft.
NOTE: When the cam and coil housing assembly is
removed, the cam balls may be detached together with
the housing. Pay attention not to lose the ball.
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4D2±17 TRANSFER CASE (TOD)
3. Remove the cam ball (3 pieces).
4. Remove the cam pulley.
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5. Remove the wave spring.
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6. Using snap ring pliers, remove the snap ring.
NOTE: Use care to prevent damage to snap ring.
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7. Remove the armature plate, insulator washer and
clutch pack assembly as a package.
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