boot ISUZU AXIOM 2002 Service Repair Manual

POWER±ASSISTED STEERING SYSTEM2A±21
Disassembly
NOTE: The valve housing is made of aluminum and care
should be exercised when clamping in a vise, etc. to
prevent distortion or damage.
1. Loosen lock nut and remove tie±rod end.
2. Remove clip (3) and band (5), then remove bellows
(4).
3. Remove tie-rod assembly.
To remove, move the boot toward the tie-rod end,
then remove tab washer.
4. Remove oil line, mounting rubber and dust cover.
Inspection and Repair
Inspect the following parts for wear, damage or any
abnormal conditions.
Tie-rod End
If looseness or play is found when checked by moving the
end of ball joint at tie-rod end, replace tie-rod end.
Tie-rod Assembly
If the resistance is insufficient or play is felt when checked
by moving the ball on the tie-rod, replace the tie-rod
assembly.
Rubber Parts
If wear or damage is found through inspection, replace
with new ones.
Reassembly
1. Install mounting rubber and dust cover (If removed).
2. Install oil line.
Torque: 13 N´ m (113 lb in)
3. Install tie-rod assembly with tab washer.
Apply grease to ball joint, install tie-rod and tab
washer, then tighten to specified torque.
Torque: 83 N´m (61 lb ft)
After tightening, bend tab washer against width
across flat of inner ball joint.
4. Apply a thin coat of grease to the shaft for smooth
installation. Then install bellows.
5. Install band and clip.
6. Install tie-rod end and tighten lock nut.
Torque: 98 N´m (72 lb ft)

3C±6FRONT SUSPENSION
Stabilizer Bar
Stabilizer Bar and Associated Parts
410R200001
Legend
(1) Rubber Bushing
(2) Bracket and Bolt
(3) Link(4) Nut
(5) Stabilizer Bar
(6) Washer
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove the stone guard.
3. Remove wheel and tire assembly. Refer to
Wheel
Replacement in this section.
4. Remove nut.
CAUTION: Be careful not to break the ball joint boot.
5. Remove link.
6. Remove bracket.
7. Remove stabilizer bar.
8. Remove rubber bushing.
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 :

Stabilizer bar

Rubber bushing

Link ball joint
Installation
1. Install rubber bushing.
2. Install stabilizer bar.
3. Install bracket, then tighten it to the specified torque.
Torque: 25 N´m (18 lb ft)
4. Install link and Washer.
5. Install nut, then tighten it to the specified torque.
Torque: 50 N´m (37 lb ft)

FRONT SUSPENSION3C±11
9. Remove back plate.
10. Remove lower ball joint by using remover J±29107.
CAUTION: Be careful not to damage the ball joint
boot.
901RW163
11. Remove upper ball joint by using remover J±36831.
CAUTION: Be careful not to damage the ball joint
boot.
901RW162
12. Remove knuckle assembly.
13. Remove oil seal (Except 2WD model).
14. Remove washer (Except 2WD model).15. Remove needle bearing by using remover J±23907
(Except 2WD model).
901RW044
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:

Knuckle

Knuckle arm

Needle bearing

Thrust washer
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g) and install
needle bearing by using installer J±36838 and
J±8092 (Except 2WD model).
901RW045

3C±14FRONT SUSPENSION
CAUTION: Be careful not to damage the ball joint
boot.
901RW162
7. Remove upper ball joint.
8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and
number of shims.
11. Remove caster shims and note the positions and
number of shims.
12. Remove upper control arm assembly.
13. Remove nut.
14. Remove plate.
15. Remove bushing by using remover J±29755.
901RW161
901RW160
16. Remove fulcrum pin.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:

Upper control arm

Bushing

Fulcrum pin
Installation
1. Install fulcrum pin.
2. Install bushing by using installer J±29755 and
J±39376.
901RW164

3C±20FRONT SUSPENSION
3. Remove upper ball joint nut and cotter pin, then use
remover J±36831 to remove the upper ball joint from
the knuckle.
CAUTION: Be careful not to damage the ball joint
boot.
901RW162
4. Remove bolt and nut.
5. Remove upper ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.

Inspect the lower end boot for damage or grease leak.
Move the ball joint as shown in the figure to confirm its
normal movement.

Inspect screw/taper area of ball for damage.

If any defects are found by the above inspections,
replace the ball joint assembly with a new one.
450RS023

After moving the ball joint 4 or 5 times, attach nut then
measure the preload.
Starting torque: 0.5 ±3.2 N´m (0.4±2.4 lb ft)
450RS024If the above limits specified are exceeded, replace the ball
joint assembly.
Installation
1. Install upper ball joint.
2. Install bolt and nut, then tighten them to the specified
torque.
Torque: 57 N´m (42 lb ft)
3. Install nut and cotter pin, then tighten the nut to the
specified torque with just enough additional torque to
align cotter pin holes. Install new cotter pin.
Torque: 98 N´m (72 lb ft)

FRONT SUSPENSION3C±21
Lower Ball Joint
Lower Ball Joint and Associated Parts
450RW011
Legend
(1) Bolt
(2) Lower Ball Joint(3) Nut
(4) Nut and Cotter Pin
Removal
1. Raise the vehicle and support the frame with suitable
safety stands.
2. Remove wheel and tire assembly. Refer to
Wheel in
this section.
3. Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle driving
shaft to release the shaft from hub(Except 2WD
model). Refer to
Front Hub and Disc in Driveline/Axle
section.
5. Support lower control arm with a jack.
6. Remove lower ball joint nut and cotter pin, then use
remover J±29107 to remove the lower ball joint from
the knuckle.
CAUTION: Be careful not to damage the ball joint
boot.
901RW163

3C±22FRONT SUSPENSION
7. Remove nut.
8. Remove bolt.
9. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found
through inspection.

Inspect the lower end boot for damage or grease leak.
Move the ball joint as shown in the figure to confirm its
normal movement .

Inspect screw/taper area of ball for damage.

If any defects are found by the above inspections,
replace the ball joint assembly with a new one.
450RS026

After moving the ball joint 4 or 5 times, attach nut the
measure the preload.
Starting torque: 0.5±6.4 N´m (0.4±4.7 lb ft)
450RS024

If the above limits specified are exceeded, replace the
ball joint assembly.
Installation
1. Install lower ball joint.
2. Install bolt.
3. Install nut and tighten it to the specified torque.
Torque: 116 N´m (85 lb ft)
4. Install ball joint nut, then tighten it to the specified
torque with just enough additional torque to align
cotter pin holes. Install new cotter pin.
Torque: 147 N´m (108 lb ft)

4C±32
DRIVE SHAFT SYSTEM
401RW053
401RW052
4. Remove bolt, nut and washer (Front axle side).
5. Remove bolt, nut and washer (Transfer side).
6. Remove front propeller shaft.
NOTE: When removing, installing or carring the front
propeller shaft, be sure to wrap a piece of cloth around the
part of the boot with which fittings may interfere so that the
boot can be protected. The boot may be damaged if
bending force is applied to the constant velocity joint of
the shaft.
401RW051
Installation
NOTE: Never install the shaft assembly backwards.
Completely remove the black paint from the connecting
surface of flange coupling on each end of propeller shaft.
Clean so that no foreign matter will be caught in between.
1. Align the mark which was applied at removal. Install
front propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 N´m (46 lb ft)
2. Install the exhaust and transfer protectors.
Constant Velocity Joint
NOTE: L J a n d B J constant velocity joints are
unremovable types. Check the joint for play and the boot
for damage, wear, and leak of grease. If abnormality is
found, replace propeller shaft as an assembly.

4C±33 DRIVE SHAFT SYSTEM
Play in Constant Velocity Joint
Position the shaft in a vise between two pieces of wood,
then secure.
Test for shaft movement by attempting to move back and
forth, and side to side.
Secure as needed.
401RW050
401RW049
Boot of Constant Velocity Joint
Check the following: boot (2) for crack, damage and
grease leakage, the boot band (1) for looseness and
damage, and both sides of the joint for gease leakage
coming from the cover press-in parts (3).
401RW048
401RW047

4C±37 DRIVE SHAFT SYSTEM
Slip Joint Disassembly
401RX00001
Legend
(1) Spline Yoke and Universal Joint Assembly
(2) Clamp(3) Boot
(4) Clamp
(5) Tube and Universal Joint Assembly
1. Lay the shaft horizontally on a bench and secure.
2. Indicate the original assembled position by marking
the phasing of the shaft prior to disassembly.
3. Using the flat blade of a screwdriver, pry the loose end
of the boot clamp upwards and away from the
propeller shaft boot. Be careful not to damage the
boot.4. When boot clamps becomes loose, remove by hand.
5. Repeat for the other boot clamp.
6. Remove the slip yoke assembly from the driveshaft,
by securing the boot with one hand and pulling on the
slip yoke.
7. Remove the boot from the shaft assembly.