2002 ISUZU AXIOM wheel

4D2±2
TRANSFER CASE (TOD)
General Description
A04R200003
The Torque-On-Demand (TOD) is an
electronically-controlled torque-split 4-wheel drive
system with the following features.
Shifting Between High and Low Ranges
The shifting mechanism consists of the cam and shaft rail
assembly, the high/low shift motor and the encoder. The
encoder is built-in to the motor.
The encoder senses high/low range shift motor rotation
position and sends this data to the TOD control unit.
Based on this data, the TOD control unit adjusts motor
rotation speed or stops the motor.
The shifting between the high and low ranges using the
TOD switch only is possible. The vehicle must be stopped
or nearly stopped (vehicle speed less than 2 km/h (1.2
mph) and engine speed less than 1,500 rpm), the
automatic transmission selector level must be in the
neutral (N) position, and the brakes must be applied.
Electronically-controlled Wet-type Multiple
Disc Clutch
The clutch automatically provides the optimum drive
power to the front wheels of the vehicle in response to
varying road surface conditions when the vehicle is
operated in the TOD mode. The delivered power ranges
from 0% to 100% of power train output. Superior
operational stability is maintained over a wide range of
operating conditions.
Front Output Drive
Front output drive is provided by a chain. This reduces the
loud noise associated with 4-wheel drive operation.
Oil Pump Lubrication
An oil pump is used to lubricate the transfer. This ensures
stable multiple-disc clutch operation and maintains the
lubricating oil at a constant temperature.

4D2±13 TRANSFER CASE (TOD)
Transfer Cover Assembly
261RY00032
Legend
(1) Coil Assembly
(2) Snap Ring
(3) Ball Bearing(4) Speed Gear and Tone Wheel
(5) Ball Bearing
(6) Transfer Cover (With Oil Seal)
(7) Oil Drain Plug and Oil Filler Plug
Disassembly
1. Using a precision screwdriver or a suitable tool, push
down the lock to unlatch the terminal for the coil
assembly, and pull the terminal out.
NOTE: Use care to prevent damage to harness terminal
and connector.
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4D2±14
TRANSFER CASE (TOD)
2. Remove the coil assembly set nuts (3 pieces) and coil
assembly from the transfer cover.
261RW030
3. Using snap ring pliers, remove the snap ring from the
transfer cover.
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4. Strike the speed gear and tone wheel with a rod or
other appropriate tool from the rear side of the
transfer cover assembly, and remove the ball bearing,
speed gear and tone wheel.
NOTE: Use care to prevent damage to the speed gear
teeth.
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5. Using the bearing remover J±42805 and slide
hammer J±2619±01, remove the ball bearing of the
front output shaft from the transfer cover.
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Inspection and Repair
Refer to ªInspection and Repair (Transfer Case
Assembly)º in this section.

4D2±15 TRANSFER CASE (TOD)
Reassembly
Transfer cover oil seal replacement
1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to the circumference of the new oil seal and
fill the lip with grease (BESCO L2 or its equivalent).
3. Using the oil seal installer J±42804, install the oil seal
to the transfer cover assembly.
261RY00017Shift shaft oil seal replacement
4. Remove the oil seal from the transfer cover assembly.
5. Apply oil the circumference of the new oil seal.
6. Using the oil seal installer J±33951, install the oil seal
to the transfer cover assembly.
The drive in depth must be 9.4 ~ 10.4 mm (0.370 ~
0.409 in). The knurled end of the installer (indicated
by the arrow) must be flush with the oil seal
installation surface.
NOTE: Use care to prevent tilt to oil seal when installing
oil seal to the case.
261R200009
7. Install the ball bearing of the front output shaft to the
transfer cover.
8. Install the speed gear and tone wheel.
9. Install the ball bearing to the transfer cover.
10. Using snap ring pliers, install the snap ring to the
transfer cover.
NOTE: The snap ring must be fully inserted into the
transfer cover snap ring groove.
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11. Install the coil assembly to the transfer cover and
tighten the set nuts (3 pieces) to the specified torque.
Torque: 10 N´m (87 lb in)
12. Install the connector to the harness terminal of the coil
assembly.
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4D2±20
TRANSFER CASE (TOD)
Chain, Sprocket and Mechanical Lock (Transfer Case Assembly)
262RY00021
Legend
(1) Transfer Case Assembly
(2) Cam and Shaft Rail Assembly
(3) Front Output Shaft
(4) Chain
(5) Lower Drive Sprocket
(6) Front Tone Wheel
(7) Drive Sprocket
(8) Spacer
(9) Shift Fork and Rail Assembly
(10) Lockup Rail(11) Spring Pin
(12) Shift Fork Assembly
(13) Lockup Fork
(14) Lockup Fork Spring
(15) Reduction Hub
(16) Rear Output Shaft
(17) Oil Pump Assembly (with Strainer)
(18) Thrust Washer
(19) Lockup Hub
(20) Lockup Collar Assembly
(21) Magnet

4D2±21 TRANSFER CASE (TOD)
Disassembly
1. Remove the spacer.
2. Remove the front tone wheel, lower drive sprocket,
drive sprocket and chain together from the front and
rear output shaft.
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3. Remove the lockup collar assembly and lockup fork
together.
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4. Remove the lockup hub.
5. Remove the thrust washer.6. Remove the magnet from the strainer set position
together with the oil pump assembly.
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7. Remove the output shaft.
8. Remove the cam and shaft rail assembly.
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9. Remove the shift fork and rail assembly, and
reduction hub.
10. Remove the spring pin from the shift fork and rail
assembly.
11. Remove the shift fork assembly from the lockup rail.
12. Remove the front output shaft from the transfer case.

4D2±23 TRANSFER CASE (TOD)
11. Apply ATF to the chain and engage it to both
sprockets.
12. Mount the chain and sprocket assembly to both
output shafts.
NOTE: When installing chain, the copper colored ring of
the chain (indicated by the arrow) to be installed in
direction of rear.
13. Install the front torn wheel to the front output shaft.
14. Install the spacer to the drive sprocket assembly.
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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