torque ISUZU AXIOM 2002 Service Manual Online

4A1±15 DIFFERENTIAL (FRONT)
4. Place the shim on the drive pinion. Install the inner
bearing onto the pinion using an installer J±6133±01
and a press.
NOTE: Do not apply pressure to the roller cage and apply
pressure only to the inner race.
425RS024
5. Discard the used collapsible spacer and install a new
one.
6. Install pinion gear.
7. Install outer bearing.
8. Use oil seal installer J±24250 to install a new oil seal
that has been soaked in front axle lubricant.
NOTE: Take care to use a front differential oil seal, NOT
the rear differential oil seal.
415RS011
9. Install flange.
10. Install flange nut.
1. Apply lubricant to the pinion threads.
2. Tighten the nut to the specified torque using the
pinion flange holder J±8614±01.
Torque: 177±275N´m (130±203 lb ft)NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
415RW006
3. Adjust pinion bearing preload.
a. Measure the bearing preload by using a torque
meter. Note the scale reading required to
rotate the flange.
b. Continue tightening flange nut until the
specified starting torque is obtained.
Starting torque:
New bearing 0.7±1.1 N´m (5.64±9.98 lb in)
Used bearing 0.4±0.5 N´m (2.86±4.94 lb in)
NOTE: D o n o t t ighten the flange nut more than
678 N´m(500 lb ft).
425R200001
4. Using punch J±39209, stake the flange nut at two
points.

DIFFERENTIAL (FRONT) 4A1±18
16. Tighten the cap bolt to the specified torque.
Torque: 97 N´m (72 lb ft)
425RS036
Gear Tooth Contact Pattern Check and
Adjustment
1. Apply a thin coat of prussian blue or equivalent to
at least 7±8 ring gear teeth. Rotate the ring gear
and inspect the contact point of the impressions
and make the necessary adjustments as
described in the next page.
425RS038
Legend
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)
425RS039

4A1±19 DIFFERENTIAL (FRONT)
17. Install differential assembly.
1. Clean the faces of the front axle case and
differential carrier.
Apply Three Bond TB1215 or equivalent to the
sealing side of the axle case and the carrier.
2. Attach the differential case and the carrier
assembly to the front axle case and tighten the
nuts and bolts.
Torque: 25 N´m (19 lb ft)
415RS014
3. Fill the axle case with hypoid gear lubricant, up to
the base of the filler hole.
Lubricant capacity: 1.25 liter(1.32 US qt)
18. Install damper.
1. Clean the faces and bolt thread hole of differential
carrier.
2. Install the bracket with new bolts.
3. Install the damper to the bracket with new bolts.
Torque: 25 N´m (19 lb ft)
425RW042

4A1±21 DIFFERENTIAL (FRONT)
4. Remove the cross pin, using a soft metal rod and a
hammer.
425RS043
5. Remove pinion gear.
6. Remove side gear.
7. Remove 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.
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard used bolts and install new ones.
Torque: 108 N´m (80 lb ft)3. Tighten the fixing bolts in a diagonal sequence as
illustrated.
415RS016
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear with thrust washer by engaging
it with the side gears while turning both pinion gears
simultaneously in the same direction.
425RS048

DIFFERENTIAL (FRONT) 4A1±22
4. Install cross pin.

Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
425RS049
5. Install lock pin. After lock pin installation, stake the
cage to secure the lock pin.
6. Install ring gear and tighten the bolts in diagonal
sequence as illustrated.
Torque: 108 N´m (80 lb ft)
NOTE: Discard used bolts and install new ones.
415RS016

4A1±23 DIFFERENTIAL (FRONT)
Main Data and Specifications
General Specifications
Axle tube TypeIt consists of a duct, a cast iron housing
and an axle tube.
Gear typeHypoid
Gear ratio4.300
Differential typeTwo pinion
Oil capacityliter (US qt)1.25 (1.32) (Differential)
0.12 (0.13) (Actuator Housing: Shift on the fly)
Type of lubricantGL±5 (75W±90)
Axle shaft typeConstant velocity joint
(Birfield joint type and double offset joint)
Hub locking TypeRigid
Torque Specifications
412R200005

DIFFERENTIAL (REAR)4A2±1
AXIOM
DRIVELINE/AXLE
Differential (Rear)
CONTENTS
Service Precaution 4A2±1. . . . . . . . . . . . . . . . . . . . . .
General Description 4A2±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A2±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing 4A2±5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Housing and Associated Parts 4A2±5. . . . . .
Removal 4A2±5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A2±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle Shaft, Oil Seal and Bearing 4A2±7. . . . . . . . . .
Axle Shaft and Associated Parts 4A2±7. . . . . . . . .
Removal 4A2±8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 4A2±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A2±8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal 4A2±10. . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Oil Seal and Associated Parts 4A2±10. . . . .
Removal 4A2±10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2±11. . . . . . . . . . . . . . . . . .
Installation 4A2±11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A2±13. . . . . . . . . . . . . . . . . . . .
Disassembled View 4A2±13. . . . . . . . . . . . . . . . . . . .
Inspecting the Axle Before Disassembly 4A2±14. .
Disassembly 4A2±14. . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair 4A2±16. . . . . . . . . . . . . . . . . .
Reassembly 4A2±16. . . . . . . . . . . . . . . . . . . . . . . . . .
Side Bearing Preload Adjustment 4A2±20. . . . . . . .
Pinion Installation 4A2±21. . . . . . . . . . . . . . . . . . . . . .
Determination of Backlash & Preload Shims 4A2±22
Backlash Adjustment 4A2±23. . . . . . . . . . . . . . . . . . .
Gear Tooth Pattern Check 4A2±23. . . . . . . . . . . . . .
Adjustments Affecting Tooth Contact 4A2±24. . . . .
Differential Case Assembly 4A2±25. . . . . . . . . . . . . . .
Disassembled View 4A2±25. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2±26. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2±26. . . . . . . . . . . . . . . . . .
Reassembly 4A2±26. . . . . . . . . . . . . . . . . . . . . . . . . .
Limited Slip Differential Assembly 4A2±27. . . . . . . . .
Disassembled View 4A2±27. . . . . . . . . . . . . . . . . . . .
Disassembly 4A2±27. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A2±29. . . . . . . . . . . . . . . . . .
Reassembly 4A2±29. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data And Specifications 4A2±31. . . . . . . . . . . . .
Special Tools 4A2±32. . . . . . . . . . . . . . . . . . . . . . . . . . .
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 REFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFOMATION. 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 specification. Following these
instructions can help you avoid damage to parts and
systems.

4A2±2DIFFERNTIAL (REAR)
General Description
The rear axle assembly is of the semi±floating type in
which the vehicle weight is carried on the axle housing .
The center line of the pinion gear is below the center line
of the ring gear (hypoid drive).
All parts necessary to transmit power from the propeller
shaft to the rear wheels are enclosed in a salisbury type
axle housing (a carrier casting with tubes pressed and
welded into the carrier). A removable aluminum cover at
the rear of the axle housing permits rear axle service
without removal of the entire assembly from the vehicle.
The 8.9 inch ring gear rear axle uses a conventional ring
and pinion gear set to transmit the driving force of the
engine to the rear wheels. This gear set transfers this
driving force at a 90 degree angle from the propeller shaft
to the drive shafts.
The axle shafts are supported at the wheel end of the
shaft by a roller bearing.
The pinion gear is supported by two tapered roller
bearings. The pinion depth is set by a shim pack located
between the gear end of the pinion and the roller bearing
that is pressed onto the pinion. The pinion bearing
preload is set by crushing a collapsible spacer between
the bearings in the axle housing.
The ring gear is bolted onto the differential case with 10
bolts.
The differential case is supported in the axle housing by
two tapered roller bearings. The differential and ring gear
are located in relationship to the pinion by using selective
shims and spacers between the bearing and the
differential case. To move the ring gear, shims are deleted
from one side and an equal amount are added to the other
side. These shims are also used to preload the bearings
which are pressed onto the differential case. Two bearing
caps are used to hold the differential into the rear axle
housing.
The differential is used to allow the wheels to turn at
different rates of speed while the rear axle continues to
transmit the driving force. This prevents tire scuffing
when going around corners and prevents premature wear
on internal axle parts.
The rear axle is sealed with a pinion seal, a seal at each
axle shaft end, and by a liquid gasket between the rear
cover and the axle housing.
Limited Slip Differential (LSD)
The axle assembly may be equipped with an limited slip
differential (LSD). It is similar to the standard differential
except that part of the torque from the ring gear is
transmitted through clutch packs between the side gears
and differential case.
The LSD construction permits differential action when
required for turning corners and transmits equal torque to
both wheels when driving straight ahead. However, when
one wheel tries to spin due to a patch of ice, etc., the
clutch packs automatically provide more torque to the
wheel which is not trying to spin.
In diagnosing customer complaints, it is important to
recognize two things:
1. If, both wheels slip, with unequal traction, the LSD
has done all it can possibly do.
2. In extreame cases of differences in traction, the
wheel with the least traction may spin after the LSD
has transferred as much torque as possible to the
non-slipping wheel.
Limited Slip Differntials impose additional requirements
on lubricants, and require a special lubricant or lubricant
additive. Use 80W90 GL±5 LSD lubricant.
Rear Axle Identification
The Bill of Material and build date information(1) is
stamped on the right axle tube on the rearward side.
The axle ratio is identified by a tag(3) which is secured by
a cover bolt. If the axle has limited-slip differntial, it also
will be identified with a tag(2) secured by a cover bolt.
425RX001

DIFFERENTIAL (REAR)4A2±9
3. Install oil seal. Note direction.
4. Install bearing assembly, using installer and press.
420RS030
NOTE: Install bearing with cup towards inboard side.
420RS031
5. Install retainer ring, using installer and press.
420RS033
6. Install snap ring.
7. Install axle shaft assembly into housing.
8. Install bolts, lockwashers, and nuts.
Tighten the retainer nuts to the specified torque.
Torque : 75 N´m (55 lb ft)

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