ISUZU AXIOM 2002 Service Repair Manual

4D2±28
TRANSFER CASE (TOD)
13. Install the snap ring of the input shaft bearing to the
transfer case.
265RY00003
14. Using snap ring pliers, open the snap ring from the
gap on the carrier assembly.
While opening the snap ring, securely attach the input
shaft and carrier assembly to the transfer case.
265RY00002
Inspection and Repair (Transfer Case
Assembly)
When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all the parts with clean detergent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or residual
detergent.
Chain

Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.

If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that a
skipped engagement occurs between the chain and
sprocket, replace the chain.
Sprocket

Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.

If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.
Gear

Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.
Thickness of Reduction Hub

Measure the thickness with a micrometer.

If the measurement exceeds the limit, replace the
reduction hub.
Standard : 3.05±3.30 mm (0.120±0.130 in)
Allowable limit : 2.5 mm (0.098 in)
265RW005

4D2±29 TRANSFER CASE (TOD)
Lockup Collar Assembly

Install the lockup hub, drive sprocket assembly, and
lockup collar assembly to the output shaft.

If the lockup collar assembly does not move
smoothly, replace the lockup collar assembly.
NOTE: Apply ATF to the rear engaging the gear.
Width of Lockup Collar

Using calipers, measure the lockup collar groove for
width of wear.

If the measurement exceeds the limit, replace the
lockup collar assembly.
Standard : 7.16±7.32 mm (0.282±0.288 in)
Allowable limit : 7.9 mm (0.311 in)
262RY00018
Shift Fork and Rail Assembly
Check the shift fork and rail for wear, distortion, and
scratches. If defects are observed, replace the parts.
Thickness of Shift Fork

If the measurement exceeds the limit, replace the
shift fork.
Standard : 3.41±3.79 mm (0.134±0.149 in)
Allowable limit : 4.4 mm (0.173 in)
262RY00016
Lockup Fork and Rail

Check the lockup fork and rail for wear, distortion, and
scratches. If defects are observed, replace the parts.
Thickness Lockup Fork
If the measurement exceeds the limit, replace the lockup
fork.
Standard : 6.99±7.09 mm (0.275±0.279 in)
Allowable limit : 6.3 mm (0.248 in)
262RY00017

4D2±30
TRANSFER CASE (TOD)
Bearing
Check the profile of the needle, roller, ball, and thrust
bearings. Wash the bearings with clean detergent
completely, and dry with air.
NOTE: If the bearing is rotated excessively, the rollers
may be damaged. So, rotate the bearing slowly with your
hand. Apply grease to the bearing, and check the
smoothness of the bearing while slowly rotating the race
with your hand.
Allowable limit : 0.23 mm (0.009 in)
226RW143
Lockup Fork Spring
Check the lockup fork spring for distortion, cracking, and
wear. If defects are observed, replace the part.
Multi Plate Disk Clutch

If the burned, mirror-surfaced clutch facing, or
scraping is observed on the clutch plates, clutch
housing, armature plate, and insulator washer,
replace the parts.
266R200003
Legend
(1) Clutch Housing
(2) Clutch Plate
(3) Insulator Washer
(4) Armature Plate
Coil Assembly

Check the resistance of the coil with a tester. If
defects are observed, replace the coil assembly.
Standard : 1.7+0.3
(at ordinary temperature)
Allowable limit : 1.0~5.0

261RY00022
Cam Pulley, Cam Ball, and Cam & Coil
Housing

Check the cam balls and cam for excessive wear or
damage. If defective, replace the parts.
266RW016

4D2±31 TRANSFER CASE (TOD)
4H and 4L Switch

Check the continuity of 4H and 4L switch.
If defects are observed, replace the 4H and 4L switch.
261R200006
261RW049
Switch
Stroke4H Switch
Signal4L Switch
SignalThe
correspon-
ding
Terminal 2 to
Switch BodyTerminal
1 to 3
g
position of
TOD
switch
1OpenOpen2H, TOD
2OpenClose4L
3CloseCloseNeutral
Shift Motor Assembly

Check the resistance of the shift motor assembly
(between terminal 4 to 7) with a tester.
If defects are observed, replace the shift motor
assembly.
Standard : 0.63+0.2
(at ordinary temperature)
8±6
261RY00023
Oil Pump

Remove foreign materials from the strainer. If the
strainer is damaged, replace it.

If the area into which the shaft is inserted is
excessively worn or damaged, replace the oil pump
assembly.

4D2±32
TRANSFER CASE (TOD)
Main Data and Specification
General Specification
TypeElectronically controlled torque split four wheel drive with two wheel
drive.
2WD: Rear two wheel drive
TOD: Electronically controlled torque split four wheel drive.
4L: Low speed mechanical lockup four wheel drive.
Rear drive: Direct drive
Front drive: Chain drive
Low range deceleration: Planetary gear drive
Control systemSwitch control
Gear ratioHigh: 1.000
Low: 2.480
Lubrication systemBuilt-in oil pump
Forced lubrication
Type of lubricantATF DEXRON)±II or III
Oil capacity1.35 liters. (1.43 US.quart)
Clutch discs number13
Planetary gear teeth numberSun gear: 58
Pinion gear: 15
Ring gear: 86

4D2±33 TRANSFER CASE (TOD)
Torque Specifications
E04R200001

4D2±34
TRANSFER CASE (TOD)
Torque Specifications (Cont'd)
E04R200002

4D2±35 TRANSFER CASE (TOD)
Torque Specifications (Cont'd)
E04R200003

4D2±36
TRANSFER CASE (TOD)
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
J±8614±11
Flange Holder
J±42804
Rear Oil Seal Installer
J±33951
Shift Shaft Oil Seal
Installer
J±42805
Bearing Remover
J±2619±01
Slide Hammer
J±22912±01
Bearing Remover
ILLUSTRATIONTOOL NO.
TOOL NAME
J±42806
Ring Gear Remover
J±42807
Front Output Shaft Oil
Seal Installer
J±42808
Input Shaft Oil Seal
Installer
J±42809
Ring Gear Installer

5A±1
BRAKE CONTROL SYSTEM
AXIOM
BRAKES
CONTENTS
Brake Control System 5A±1. . . . . . . . . . . . . . . . . . . .
Anti±lock Brake System 5B±1. . . . . . . . . . . . . . . . . .
Power±assisted Brake System 5C±1. . . . . . . . . . . .
Parking Brakes (4x4 Model) 5D1±1. . . . . . . . . . . . . .
Parking Brakes (4x2 Model) 5D2±1. . . . . . . . . . . . . .
Brake Control System
CONTENTS
Service Precaution 5A±2. . . . . . . . . . . . . . . . . . . . . .
General Description 5A±3. . . . . . . . . . . . . . . . . . . . .
Functional Description 5A±4. . . . . . . . . . . . . . . . .
System Components 5A±10. . . . . . . . . . . . . . . . . . .
Electronic Hydraulic Control Unit (EHCU) 5A±10.
ABS Warning Light 5A±10. . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor 5A±10. . . . . . . . . . . . . . . . . .
G-Sensor 5A±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal and Anti-lock Braking 5A±10. . . . . . . . . . .
Brake Pedal Travel 5A±10. . . . . . . . . . . . . . . . . . . .
Acronyms and Abbreviations 5A±11. . . . . . . . . . . .
General Diagnosis 5A±11. . . . . . . . . . . . . . . . . . . . . . .
General Information 5A±11. . . . . . . . . . . . . . . . . . . .
ABS Service Precautions 5A±11. . . . . . . . . . . . . . .
Computer System Service Precautions 5A±11. . .
General Service Precautions 5A±11. . . . . . . . . . . .
Note on Intermittents 5A±11. . . . . . . . . . . . . . . . . . .
Test Driving ABS Complaint Vehicles 5A±12. . . . .
ªABSº Warning Light 5A±12. . . . . . . . . . . . . . . . . . .
Normal Operation 5A±12. . . . . . . . . . . . . . . . . . . . .
Tech 2 Scan Tool 5A±13. . . . . . . . . . . . . . . . . . . . . .
DATA LIST 5A±16. . . . . . . . . . . . . . . . . . . . . . . . . . .
ACTUATOR TEST 5A±17. . . . . . . . . . . . . . . . . . . . .
Tech 2 Service Bleed 5A±21. . . . . . . . . . . . . . . . . .
Basic Diagnostic Flow Chart 5A±22. . . . . . . . . . . .
Basic Inspection Procedure 5A±23. . . . . . . . . . . . .
EHCU Connector Pin-out Checks 5A±24. . . . . . . . .
Circuit Diagram 5A±25. . . . . . . . . . . . . . . . . . . . . . .
Connector List 5A±28. . . . . . . . . . . . . . . . . . . . . . . .
Part Location 5A±29. . . . . . . . . . . . . . . . . . . . . . . . .
Symptom Diagnosis 5A±30. . . . . . . . . . . . . . . . . . . . .
Chart A-1 ABS Works Frequently But
Vehicle Does Not Decelerate 5A±30. . . . . . . . . . .
Chart TA-1 ABS Works Frequently But
Vehicle Does Not Decelerate
(Use TECH 2) 5A±31. . . . . . . . . . . . . . . . . . . . . . . .
Chart A-2 Uneven Braking Occurs While
ABS Works 5A±31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart TA-2 Uneven Braking Occurs While
ABS Works (Use TECH 2) 5A±31. . . . . . . . . . . . . Chart A-3, TA-3 The Wheels Are Locked 5A±32.
Chart A-4 Brake Pedal Feed Is Abnormal 5A±32.
Chart A-5, TA-5 Braking Sound
(From EHCU) Is Heard While Not Braking 5A±33
Diagnostic Trouble Codes 5A±34. . . . . . . . . . . . . . . .
Diagnosis By ªABSº Warning Light
Illumination Pattern 5A±36. . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Codes (DTCs) 5A±37. . . . . . .
Chart B-1 With the key in the ON position
(Before starting the engine). Warning light
(W/L) is not activated. 5A±39. . . . . . . . . . . . . . . . .
Chart B-2 CPU Error (DTC 14 (Flash out) /
C0271, C0272, C0273, C0284 (Serial
communications)) 5A±39. . . . . . . . . . . . . . . . . . . . .
Chart B-3 Low or High Ignition Voltage
(DTC 15 (Flash out) / C0277, 0278 (Serial
communications)) 5A±40. . . . . . . . . . . . . . . . . . . . .
Chart B-4 Excessive Dump Time (DTC 17
(Flash out) / C0269 (Serial
communications)) 5A±40. . . . . . . . . . . . . . . . . . . . .
Chart B-5 Excessive Isolation Time
(DTC 18 (Flash out) / C0274
(Serial communications)) 5A±40. . . . . . . . . . . . . . .
Chart B-6 G-Sensor Output Failure
(DTC 21 (Flash out) / C0276
(Serial communications)) 5A±41. . . . . . . . . . . . . . .
Chart B-7 Brake Switch Failure
(DTC 22 (Flash out) / C0281
(Serial communications)) 5A±41. . . . . . . . . . . . . . .
Chart B-8 2WD Controller in 4WD Vehicle
Controller (DTC 13 (Flash out) / C0285
(Serial communications)), 4WD State Input
Signal Failure (DTC 24 (Flash out) / C0282
(Serial communications)) 5A±42. . . . . . . . . . . . . . .
Chart B-9 Pump Motor Failure
(DTC 32 (Flash out) / C0267, C0268
(Serial communications)) 5A±42. . . . . . . . . . . . . . .
Chart B-10 EHCU Valve Relay Failure
(DTC 35 (Flash out) / C0265, C0266
(Serial communications)) 5A±43. . . . . . . . . . . . . . .
Chart B-11 FL Isolation Solenoid Coil Failure
(DTC 41 (Flash out) / C0245, C0247
(Serial communications)) 5A±43. . . . . . . . . . . . . . .
Chart B-12 FL Dump Solenoid Coil Failure
(DTC 42 (Flash out) / C0246, C0248
(Serial communications)) 5A±43. . . . . . . . . . . . . . .