2002 ISUZU AXIOM suspension

INTELLIGENT SUSPENSION3F±35
Removal
1. Disconnect the battery ground cable.
2. Disconnect the connector from the harness and
remove the connector from the bracket.
3. Remove the clip.
View B
450RY00005
Legend
(1) Screw
(2) Actuator
(3) Nut
(4) Bracket
(5) Nut
(6) Washer
(7) Shock Absorber
1. Remove 2 screws.
2. Remove the actuator.
3. Remove the nut (3).
4. Disconnect bracket.
5. Remove the nut (5).
6. Disconnect the washer.
7. Remove the shock absorber.
Refer to
Shock Absorber in this section.
Inspection and Repair
Refer to shock Abosorber in this section.
Installation
1. Install the shock absorber.
Refer to
Shock Absorber in this section.
2. Install the washer and nut (5), then tighten it to the
specified torque.
Torque: 15 N´m (11 lb ft)
3. Install the bracket and nut (3), then tighten it to the
specified torque.
Torque: 39 N´m (29 lb ft)
NOTE: Fix the lower nut with wrench not to turn and
tighten upper nut.
4. Fit the top of the shock absorber rod in the connection
part of the actuator.
NOTE:
The mating section is width fitting across flats.
If these normally fit, the distance between the
actuator lower face and the bracket upper face is
about 1 mm.
5. Install 2 screws then tighten it to the specified torque.
3 N´m (26 lb in)
6. Connect the connector to the harness and insert the
connector to the bracket.
7. Connect the actuator harness with the clip.
8. Connect the battery ground cable.

3F±36INTELLIGENT SUSPENSION
Rear Shock Absorber
Rear Shock Absorber and Associated Parts
LH
461R100003
Legend
(1) Connector
(2) Clip
(3) Rear Shock Absorber
(4) Bracket
(5) Bolt(6) G-Sensor
(7) Front
(8) Upper
(9) Right
(10) Connector
(11) Gusset

INTELLIGENT SUSPENSION3F±37
Removal
1. Disconnect the battery ground cable.
2. Disconnect the connector (1) from the harness and
remove the connector (1) from the bracket (4).
3. Remove the clip (2).
4. Remove the rear shock absorber (3).
Refer to
Shock Absorber in this section.
5. Disconnect the connector (10) from the harness and
remove the connector (10) from the gusset (11).
6. Remove the 2 bolts (5).
7. Disconnect the G-sensor (6).
Inspection and Repair
Refer to Shock Absorber in this section.
Installation
1. Set the G-sensor on the gusset (11).
2. Install 2 bolts (5) then tighten it to the specified torque.
Torque: 7 N´m (61 lb in)
3. Connect the connector (10) to the harness and insert
the connector (10) to the gusset (11).
4. Install the rear shock absorber (3).
Refer to
Shock Absorber in this section.
5. Connect the connector (1) to the harness and insert
the connector (1) to the bracket (4).
6. Insert the clip (2) to the bracket (4).
7. Connect the battery ground cable.

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±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.

4A1±7 DIFFERENTIAL (FRONT)
3. Tighten the mounting bolts and nuts to the specified
torque.
Torque: 168 N´m (124 lb ft)
412R200004
4. Install the right side knuckle with lower control arm to
the upper control arm.
Refer to
Knuckle in Suspension section.
CAUTION: Carefully insert the drive shaft into the
knuckle, to avoid damaging the oil seal.
5. Align the bolt hole of the lower control arm, then install
the bolts and nuts.
NOTE: Adjust the buffer clearance before tightening the
bolts and nuts of the lower control arm.
6. Install the hose of the shift on the fly.
7. Install the actuator connector of the shift on the fly.
8. Install the tie-rod end of the power steering unit to the
knuckle, tighten the nut to the specified torque.
Torque: 118 N´m (87 lb ft)
9. Install lower bolts and nuts of the shock absorber,
tighten it to the specified torque.
Torque: 93 N´m (69 lb ft)
10. Install lower nuts of the stabilizer link, tighten it to the
specified torque.
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to
Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to
Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the
bearing preload.
Refer to
Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake
system.
16. Install the brake caliper. Tighten the bolt of the caliper
bracket to the specified torque.
Torque: 50 N´m (37 lb ft)
17. Install the stone guard.18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to
Trim Height Adjustment in Steering section.
20. Tighten the bolts and nuts of the lower control arm to
the specified torque.
Refer to
Lower Control Arm in Suspension section.

DIFFERENTIAL (REAR)4A2±3
Diagnosis
Many noises that seem to come from the rear axle
actually originate from other sources such as tires, road
surface, wheel bearings, engine, transmission, muffler, or
body drumming. Investigate to find the source of the
noise before disassembling the rear axle. Rear axles, like
any other mechanical device, are not absolutely quiet but
should be considered quiet unless some abnormal noise
is present.
To make a systematic check for axle noise, observe the
following:
1. Select a level asphalt road to reduce tire noise and
body drumming.
2. Check rear axle lubricant level to assure correct level,
and then drive the vehicle far enough to thoroughly
warm up the rear axle lubricant.
3. Note the speed at which noise occurs. Stop the
vehicle and put the transmission in neutral. Run the
engine speed slowly up and down to determine if the
noise is caused by exhaust, muffler noise, or other
engine conditions.
4. Tire noise changes with different road surfaces; axle
noises do not. Temporarily inflate all tires to 344 kPa
(50 psi) (for test purposes only). This will change
noise caused by tires but will not affect noise caused
by the rear axle.
Rear axle nose usually stops when coasting at
speeds under 48 km/h (30 mph); however, tire noise
continues with a lower tone. Rear axle noise usually
changes when comparing pull and coast, but tire
noise stays about the same.
Distinguish between tire noise and rear axle noise by
noting if the noise changes with various speeds or
sudden acceleration and deceleration. Exhaust and
axle noise vary under these conditions, while tire
noise remains constant and is more pronounced at
speeds of 32 to 48 km/h (20 to 30 mph). Further check
for tire noise by driving the vehicle over smooth
pavements or dirt roads (not gravel) with the tires at
normal pressure. If the noise is caused by tires, it will
change noticeably with changes in road surface.
5. Loose or rough front wheel bearings will cause noise
which may be confused with rear axle noise; however,
front wheel bearing noise does not change when
comparing drive and coast. Light application of the
brake while holding vehicle speed steady will often
cause wheel bearing noise to diminish. Front wheel
bearings may be checked for noise by jacking up the
wheels and spinning them or by shaking the wheels to
determine if bearings are loose.
6. Rear suspension rubber bushings and spring
insulators dampen out rear axle noise when correctly
installed. Check to see that there is no link or rod
loosened or metal±to±metal contact.7. Make sure that there is no metal±to±metal contact
between the floor and the frame.
After the noise has been determined to be in the axle, the
type of axle noise should be determined, in order to make
any necessary repairs.
Gear Noise
Gear noise (whine) is audible from 32 to 89 km/h (20 to 55
mph) under four driving conditions.
1. In drive under acceleration or heavy pull.
2. Driving under load or under constant speed.
3. When using enough throttle to keep the vehicle from
driving the engine while the vehicle slows down
gradually (engine still pulls slightly).
4. When coasting with the vehicle in gear and the throttle
closed. The gear noise is usually more noticeable
between 48 and 64 km/h (30 and 40 mph) and 80 and
89 km/h (50 and 55 mph).
Bearing Noise
Bad bearings generally produce a rough growl or grating
sound, rather than the whine typical of gear noise.
Bearing noise frequently ªwow±wowsº at bearing rpm,
indicating a bad pinion or rear axle side bearing. This
noise can be confused with rear wheel bearing noise.
Rear Wheel Bearing Noise
Rear wheel bearing noise continues to be heard while
coasting at low speed with transmission in the neutral.
Noise may diminish by gentle braking. Jack up the rear
wheels, spin them by hand and listen for noise at the
hubs. Replace any faulty wheel bearings.
Knock At Low Speeds
Low speed knock can be caused by worn universal joints
or a side gear hub counter bore in the cage that is worn
oversize. Inspect and replace universal joints or cage and
side gears as required.
Backlash Clunk
Excessive clunk on acceleration and deceleration can be
caused by a worn rear axle pinion shaft, a worn cage,
excessive clearance between the axle and the side gear
splines, excessive clearance between the side gear hub
and the counterbore in the cage, worn pinion and side
gear teeth, worn thrust washers, or excessive drive pinion
and ring gear backlash. Remove worn parts and replace
as required. Select close±fitting parts when possible.
Adjust pinion and ring gear backlash.