front differential ISUZU AXIOM 2002 Service Repair Manual

SECTION TABLE OF CONTENTS
GENERAL INFORMATION
0AGeneral Information
0BMaintenance and Lubrication
WORKSHOP MANUAL
HEATING, VENTILATION AND AIR
CONDITIONING
1AHVAC System
STEERING
2APower-Assisted System
AXIOM
(UPR/S)SUSPENSION
3CFront Suspension
3DRear Suspension
3EWheel and Tire System
3FIntelligent Suspension System
DRIVELINE/AXLE
4A1Differential (Front)
4A2Differential (Rear)
4B1Driveline Control System
4B2Driveline Control System (TOD)
4CDrive Shaft System
4D2Transfer Case (TOD)
FOREWORD
This manual includes special notes, impor tant points, service data,
precautions, etc. That are needed for the maintenance, adjustments,
service, removal and installation of vehicle components.
All information, illustrations and specifications contained in this manual
are based on the latest product information available at the time of
publication.
All rights are reserved to make changes at any time without notice.
Arrangement of the material is shown in the table of contents on the
right-hand side of this page. A black spot on the first page of each
section can be seen on the edge of the book below each section title.
These point to a more detailed table of contents preceding each
section.BRAKE
5ABrake Control System
5BAnti-Lock Brake System
5CPower-Assisted Brake System
5D1Parking Brake System (4´4 model)
5D2Parking Brake System (4´2 model)
ENGINE
6AEngine Mechanical
6BEngine Cooling
6CEngine Fuel
6D1Engine Electrical
6D2Ignition System
6D3Starting and Charging System
6EDriveability and Emissions
6FEngine Exhaust
6GEngine Lubrication
6HEngine Speed Control System
6JInduction
TRANSMISSION
7AAutomatic Transmission
7A1Transmission Control System
BODY AND ACCESSORIES
8ALighting System
8BWiper/Washer System
This manual applies to 2002 models.8CEnter tainment
8DWiring System
8EMeter and Gauge
8FBody Structure
8GSeats
8HSecurity and Locks
8ISun Roof/Convertible Top
8JExterior/Interior Trim
RESTRAINTS
9ASeat Belt System
9JSupplemental Restraint System (Air Bag System)
9J1Restraint Control System
CONTROL SYSTEM
10ACruise Control System

0A±12
GENERAL INFORMATION
Abbreviations Charts
List of automotive abbreviations which may be used
in this manual
A Ð Ampere(s)
ABS Ð Antilock Brake System
AC Ð Alternating Current
A/C Ð Air Conditioning
ACCEL Ð Accelerator
ACC Ð Accessory
ACL Ð Air Cleaner
Adj Ð Adjust
A/F Ð Air Fuel Ratio
AIR Ð Secondary Air Injection System
Alt Ð Altitude
AMP Ð Ampere(s)
ANT Ð Antenna
ASM Ð Assembly
A/T Ð Automatic Transmission/Transaxle
ATDC Ð After Top Dead Center
ATF Ð Automatic Transmission Fluid
Auth Ð Authority
Auto Ð Automatic
BARO Ð Barometric Pressure
Bat Ð Battery
B+ Ð Battery Positive Voltage
Bbl Ð Barrel
BHP Ð Brake Horsepower
BPT Ð Backpressure Transducer
BTDC Ð Before Top Dead Center

C Ð Degrees Celsius
CAC Ð Charge Air Cooler
Calif Ð California
cc Ð Cubic Centimeter
CID Ð Cubic Inch Displacement
CKP Ð Crankshaft Position
CL Ð Closed Loop
CLCC Ð Closed Loop Carburetor Control
CMP Ð Camshaft Position
CO Ð Carbon Monoxide
Coax Ð Coaxial
Conn Ð Connector
Conv Ð Converter
Crank Ð Crankshaft
Cu. In. Ð Cubic Inch
CV Ð Constant Velocity
Cyl Ð Cylinder(s)
DI Ð Distributor Ignition
Diff Ð Differential
Dist Ð Distributor
DLC Ð Data Link Connector
DOHC Ð Double Overhead Camshaft
DTC Ð Diagnostic Trouble Code
DTM Ð Diagnostic Test Mode
DTT Ð Diagnostic Test Terminal
DVM Ð Digital Voltmeter (10 meg.)
DVOM Ð Digital Volt Ohmmeter
EBCM Ð Electronic Brake Control Module
ECM Ð Engine Control Module
ECT Ð Engine Coolant Temperature
EEPROM Ð Electronically Erasable Programmable
Read Only Memory
EGR Ð Exhaust Gas Recirculation
EI Ð Electronic Ignition
ETR Ð Electronically Tuned Receiver
EVAP Ð Evaporation EmissionExh Ð Exhaust

F Ð Degrees Fahrenheit
Fed Ð Federal (All States Except Calif.)
FF Ð Front Drive Front Engine
FL Ð Fusible Link
FLW Ð Fusible Link Wire
FP Ð Fuel Pump
FRT Ð Front
ft Ð Foot
FWD Ð Front Wheel Drive
4WD Ð Four Wheel Drive
4 x 4 Ð Four Wheel Drive
4 A/T Ð Four Speed Automatic Transmission/Transaxle
Gal Ð Gallon
GEN Ð Generator
GND Ð Ground
Gov Ð Governor
g Ð Gram
Harn Ð Harness
HC Ð Hydrocarbons
HD Ð Heavy Duty
Hg Ð Hydrargyrum (Mercury)
HiAlt Ð High Altitude
HO2S Ð Heated Oxygen Sensor
HVAC Ð Heater±Vent±Air±Conditioning
IAC Ð Idle Air Control
IAT Ð Intake Air Temperature
IC Ð Integrated Circuit / Ignition Control
ID Ð Identification / Inside Diameter
IGN Ð Ignition
INJ Ð Injection
IP Ð Instrument Panel
IPC Ð Instrument Panel Cluster
Int Ð Intake
ISC Ð Idle Speed Control
J/B Ð Junction Block
kg Ð Kilograms
km Ð Kilometers
km/h Ð Kilometer per Hour
kPa Ð Kilopascals
kV Ð Kilovolts (thousands of volts)
kW Ð Kilowatts
KS Ð Knock Sensor
L Ð Liter
lb ft Ð Foot Pounds
lb in Ð Inch Pounds
LF Ð Left Front
LH Ð Left Hand
LR ÐLeft Rear
LS Ð Left Side
LWB Ð Long Wheel Base
L±4 Ð In±Line Four Cylinder Engine
MAF Ð Mass Air Flow
MAN Ð Manual
MAP Ð Manifold Absolute Pressure
Max Ð Maximum
MC Ð Mixture Control
MFI Ð Multiport Fuel Injection
MIL Ð Malfunction Indicator Lamp
Min Ð Minimum
mm Ð Millimeter
MPG Ð Miles Per Gallon
MPH Ð Miles Per Hour
M/T Ð Manual Transmission/Transaxle
MV Ð Millivolt

0B±8MAINTENANCE AND LUBRICATION
Recommended Fluids and Lubricants
USAGEFLUID/LUBRICANT
EngineAPI SE, SF, SG, SH or ILSAC GF-1 Engine oil (See oil
chart on the following page for proper viscosity)
Engine coolantMixture of water and good quality ethylene glycol base
type antifreeze.
Brake systemDOT-3 hydraulic brake fluid.
Power steering systemDEXRON) -III Automatic transmission fluid.
Automatic transmissionDEXRON) -III Automatic transmission fluid.
TOD SYSTEM (TOD system model only)DEXRON) -IIE or DEXRON) -III Automatic transmis-
sion fluid.
Rear axle and front axleGL-5 gear lubricant (Standard differential)
GL-5 Limited slip differential gear lubricant together
with limited slip differential lubricant additive (Part No.
8-01052-358-0) or equivalent (If equipped with optional
limited slip differential) (See oil chart in this section for
proper viscosity)
Hood latch assembly
a. Pivots and spring anchorEngine oil
b. Release pawlChassis grease
Hood and door hingesEngine oil
Chassis lubricationChassis grease
Parking brake cablesChassis grease
Front wheel bearingsMultipurpose grease
Shift on the fly systemGL-5 gear lubricant (SAE 75W-90)
Body door hinge pins and linkage, fuel door hinge, rear
compartment lid hingesEngine oil
Windshield washer solventWasher fluid
Key lock cylinderSynthetic light weight engine oil (SAE 5W-30)
Accelerator linkageChassis grease

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
1A±61
Main Data and Specifications
General Specifications
COMPRESSOR
ModelDKV-14G
TypeVane rotary type
Number of vanes5
Rotor diameter64 mm (2.52 in.)
Stroke8.75 mm (0.34 in.)
Displacement140 cc (47.3 fl.oz.)
Maximum speed7,000 rpm (up to 8,400 rpm)
Direction of rotationClockwise (Front-side view)
Lubrication systemPressure differential type
LubricantR-134a Vane Rotary Type Compressor Oil
(AIPDN Part No.2-90188-301-0)
150 cc (5.0 fl.oz.)
RefrigerantRefrigerant-134a (R-134a), 700 g (1.54 lbs.)
Shaft sealLip type
Weight3.5 kg
MAGNETIC CLUTCH
TypeElectromagnetic single-plate dry clutch
Rated voltage12 Volts D.C.
Current consumption3.7 A
Starting torque49 N´m (36 lb´ft)
Direction of rotationClockwise (Front-side view)
Weight3.0 kg (6.6 lbs.)

4A1±1 DIFFERENTIAL (FRONT)
AXIOM
DRIVELINE/AXLE
CONTENTS
Differential (Front) 4A1. . . . . . . . . . . . . . . . . . . . . . .
Differential (Rear) 4A2. . . . . . . . . . . . . . . . . . . . . . .
Driveline Control System 4B1. . . . . . . . . . . . . . . . . Driveline Control System (TOD) 4B2. . . . . . . . . . .
Drive Shaft System 4C. . . . . . . . . . . . . . . . . . . . . .
Transfer Case (TOD) 4D2. . . . . . . . . . . . . . . . . . . .
Differential (Front)
CONTENTS
Service Precaution 4A1±1. . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle 4A1±2. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis 4A1±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal 4A1±3. . . . . . . . . . . . . . . . . . . . .
Pinion Shaft Oil Seal and Associated Parts 4A1±3
Removal 4A1±3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1±4. . . . . . . . . . . . . . . . . .
Installation 4A1±4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Axle Assembly 4A1±5. . . . . . . . . . . . . . .
Front Drive Axle Assembly and
Associated Parts 4A1±5. . . . . . . . . . . . . . . . . . . . . .
Removal 4A1±6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A1±6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Assembly 4A1±8. . . . . . . . . . . . . . . . . . . .
Disassembled View 4A1±8. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1±9. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 4A1±11. . . . . . . . . . . . . . . . . . . . . . . . . .
Differential Cage Assembly 4A1±20. . . . . . . . . . . . . . .
Disassembled View 4A1±20. . . . . . . . . . . . . . . . . . . .
Disassembly 4A1±20. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4A1±21. . . . . . . . . . . . . . . . . .
Reassembly 4A1±21. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4A1±23. . . . . . . . . . .
Special Tools 4A1±25. . . . . . . . . . . . . . . . . . . . . . . . . .
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.

DIFFERENTIAL (FRONT) 4A1±2
Front Drive Axle
Diagnosis
ConditionPossible causeCorrection
Oil Leak At Front AxleWorn or defective oil seal.Replace the oil seal.
Front axle housing cracked.Repair or replace.
Oil Leak At Pinion ShaftToo much gear oil.Correct the oil level.
Oil seal worn or defective.Replace the oil seal.
Pinion flange loose or damaged.Tighten or replace.
Noises In Front Axle Drive Shaft
JointBroken or worn drive shaft joints and
bellows (BJ and DOJ).Replace the drive shaft joints and
bellows.
ªClankº When Accelerating From
ªCoastºLoose drive shaft joint to output shaft
bolts.Tighten.
Damaged inner drive shaft joint.Replace.
Shudder or Vibration During
Acceleration
Excessive drive shaft joint angle.Repair.
AccelerationWorn or damaged drive shaft joints.Replace.
Sticking spider assembly (inner drive
shaft joint).Lubricate or replace.
Sticking joint assembly (outer drive
shaft joint).Lubricate or replace.
Vibration At Highway SpeedsOut of balance or out of round tires.Balance or replace.
Front end out of alignment.Align.
Noises in Front AxleInsufficient gear oil.Replenish the gear oil.
Wrong or poor grade gear oil.Replace the gear oil.
Drive pinion to ring gear backlash
incorrect.Adjust the backlash.
Worn or chipped ring gear, pinion
gear or side gear.Replace the ring gear, pinion gear or
side gear.
Pinion shaft bearing worn.Replace the pinion shaft bearing.
Wheel bearing worn.Replace the wheel bearing.
Differential bearing loose or worn.Tighten or replace.
Wanders and PullsWheel bearing preload too tight.Adjust the wheel bearing preload.
Incorrect front alignment.Adjust the front alignment.
Steering unit loose or worn.Tighten or replace.
Tire worn or improperly inflated.Adjust the inflation or replace.
Front or rear suspension parts loose
or broken.Tighten or replace.
Front Wheel ShimmyWheel bearing worn or improperly
adjusted.Adjust or replace.
Incorrect front alignment.Adjust the front alignment.
Worn ball joint or bush.Replace the ball joint or bush.
Steering unit loose or worn.Tighten or replace.
Tire worn or improperly inflated.Replace or adjust the inflation.
Shock absorber worn.Replace the shock absorber.

4A1±3 DIFFERENTIAL (FRONT)
Pinion Shaft Oil Seal
Pinion Shaft Oil Seal and Associated Parts
415R200001
Legend
(1) Flange Nut
(2) Flange(3) Oil Seal
(4) Outer Bearing
(5) Collapsible Spacer
Removal
1. Raise the vehicle and support it at the frame.
The hoist must remain under the front axle housing.
2. Drain the front axle oil by loosening the drain plug(1).
412RS001

DIFFERENTIAL (FRONT) 4A1±4
3. Remove the front propeller shaft. Refer to Front
Propeller Shaft
in this section.
4. Remove flange nut by using pinion flange holder
J±8614±01.
415RS018
5. Remove flange.
6. Remove oil seal.
7. Remove outer bearing by using remover J±39602.
415RS001
8. Remove collapsible spacer.
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. Seal surface of the pinion.
2. Cage bore for burns.
Installation
1. Install collapsible spacer. Discard the used
collapsible spacer and install a new one.
2. Install outer bearing.
NOTE: Do not drive in, but just temporarily set in the outer
bearing by hand, which should be indirectly pressed in
finally by tightening the flange nut.
3. Install oil seal, use oil seal installer J±24250 to install a
new oil seal that has been soaked in axle lubricant.
415RS002
4. Install flange.
5. Install flange nut, refer to
Differential Assembly
Overhaul for flange nut reassembly
in this section.
NOTE: Discard the used nut and install a new one.

4A1±5 DIFFERENTIAL (FRONT)
Front Drive Axle Assembly
Front Drive Axle Assembly and Associated Parts
412R200003
Legend
(1) Propeller Shaft
(2) Mounting Nut
(3) Front Axle Case Assembly and Front Drive
Shaft Assembly
(4) Washer(5) Mounting Bolt
(6) Tie±rod End; Power Steering Unit
(7) Knuckle and Back Plate
(8) Hub and Disc Assembly
(9) Suspension Crossmember

DIFFERENTIAL (FRONT) 4A1±6
Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
3. Remove the stone guard.
4. Remove the brake caliper fixing bolt and hang the
caliper. Refer to
Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to
Front Wheel Speed Sensor in Brake section.
6. Remove the hub and disc assembly.
Refer to
Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to
Front Propeller
Shaft
in this section.
8. Loosen the height control arm of the torsion bar, then
remove the torsion bar from lower control arm.
Refer to
Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock
absorber.
412RW057
12. Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering Section.
13. Disconnect the hose of the shift on the fly.
14. Disconnect the actuator connector.
15. Remove the bolts and nuts of the lower control arm
(Frame side), then disconnect the lower control arm
from frame.
16. Disconnect between the right side upper control arm
and the knuckle, then remove the knuckle with lower
control arm.CAUTION: When removing the knuckle, be careful
not to damage the oil seal inside of the knuckle.
410RW008
17. Support the differential case by the jack.
18. Remove the front axle mounting bolts and nuts, lower
the jack slowly. Remove the left side drive shaft end
from the knuckle, then lower the axle assembly from
the vehicle.
CAUTION:
1. Make sure the axle assembly is supported
securely when performing repairs.
2. Do not damage the power steering unit when
performing the repairs.
3. Do not damage the shift±on±the fly hose bracket
when performing the repairs.
Installation
1. Support the differential case with a jack.
2. Jack up the front drive axle assembly, install the left
side drive shaft to the knuckle, then install the mount
bolts and nuts.
CAUTION:
1. Do not damage the power steering unit when
performing the repairs.
2. Do not damage the shift±on±the fly hose bracket
when performing the repairs.
3. When installing the drive shaft to the knuckle, be
careful not to damage the oil seal inside of the
knuckle.