2002 ISUZU AXIOM Service Repair Manual

2A±18
POWER±ASSISTED STEERING SYSTEM
Power Steering Unit
Power Steering Unit and Associated Parts
440R100001
Legend
(1) Bracket
(2) Transfer Gear Assembly(3) Universal Joint Assembly
(4) Power Steering Unit Assembly
(5) Crossmember
Removal
1. Remove the stone guard.
2. Remove the transfer gear assembly and universal
joint assembly.
Make a setting mark across the coupling flange and
transfer gear assembly to ensure reassembly of the
parts in the original position.
3. Drain power steering fluid.
4. Remove the tie rod end assembly from knuckle.
Use tie rod end remover J±29107.
433RW002

POWER±ASSISTED STEERING SYSTEM2A±19
5. Disconnect the feed line and return line from steering
unit.
Remove the clips on the crossmember and frame.
Wire the power steering line to frame.
NOTE: Take care to prevent foreign matter from entry
when disconnect the power steering line.
435RW001
4y4 model:
1. Remove the torsion bar. Refer to
Front Suspension in
Suspension
section.
2. Remove the lower control arm bolt (Frame side).
Refer to
Front Suspension in Suspension section.
3. Apply a setting mark across the crossmember and
frame so parts can be reassembled in their original
position.
431RX013
4. Remove the crossmember fixing bolt.
5. Remove the power steering unit with the
crossmember.6. Remove the power steering unit.
4y2 model:
1. Remove the power steering unit from the
crossmember.
Installation (4y2 Model)
1. Install power steering unit to crossmember.
Tighten fixing bolt to specified torque.
Torque: 116 N´m (85 lb ft)
2. Connect the feed line and return line.
Torque: 25 N´m (18 lb ft)
3. Install tie±rod end assembly to knuckle.
Torque: 118 N´m (87 lb ft)
4.
a. Align the setting marks made at removal.
Install the universal joint assembly to the transfer
gear assembly.
Temporary tighten the universal joint bolt.
b. Install the universal joint assembly to the power
steering unit assembly.
Temporary tighten the universal joint bolt.
c. Install the transfer gear assembly with the shim to
frame.
Torque: 54 N´m (40 lb ft)
d. Tighten the universal joint bolt to the specified
torque.
Torque: 31 N´m (23 lb ft)
5. Install the stone guard.
6. Bleed the system.
Refer to
Bleeding the Power Steering System in this
section.
Installation (4y4 Model)
1. Install power steering unit to crossmember.
Tighten fixing bolt to specified torque.
Torque: 116 N´m (85 lb ft)
2. Install power steering unit with crossmember to frame
by aligning the setting marks made when removing.
Tighten crossmember mounting bolt to specified
torque.
Torque: 173 N´m (128 lb ft)
3. Install lower control arm bolt.
Refer to
Front Suspension in Suspension section.
4. Install torsion bar.
Refer to
Front Suspension in Suspension section.
5. Connect the feed line and return line.
Torque: 25 N´m (18 lb ft)
6. Install tie±rod end assembly to knuckle.
Torque: 118 N´m (87 lb ft)

2A±20
POWER±ASSISTED STEERING SYSTEM
7.
a. Align the setting marks made at removal.
Install the universal joint assembly to the transfer
gear assembly.
Temporary tighten the universal joint bolt.
b. Install the universal joint assembly to the power
steering unit assembly.
Temporary tighten the universal joint bolt.
c. Install the transfer gear assembly with the shim to
frame.
Torque: 54 N´m (40 lb ft)
d. Tighten the universal joint bolt to the specified
torque.
Torque: 31 N´m (23 lb ft)8. Install the stone guard.
9. Bleed the system.
Refer to
Bleeding the Power Steering System in this
section.
Power Steering Unit Disassembled View
440R100002
Legend
(1) Tie-rod End
(2) Lock Nut
(3) Clip
(4) Bellows
(5) Band(6) Tie-rod Assembly
(7) Tab Washer
(8) Oil Line
(9) Valve Housing Assembly
(10) Mounting Rubber
(11) Dust Cover

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)

2A±22
POWER±ASSISTED STEERING SYSTEM
Main Data and Specifications
General Specifications
Power Steering unitTypeRack and pinion
Rack stroke152 mm (5.98 in)
Lock to lock3.64
Torque Specifications
440R100003
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
J±29107
Tie rod end remover

POWER±ASSISTED STEERING SYSTEM2A±23
Power Steering Pump
Power Steering Pump and Associated Parts
436RX001
Legend
(1) Pump Assembly
(2) Hose, Suction(3) Hose, Flexible
(4) Bolt
Removal
1. Remove the drive belt.
2. Place a drain pan below the pump.
3. Disconnect the suction hose.
4. Disconnect the flexible hose.
5. Remove the power steering fixing bolt and remove
the pump assembly.
Installation
1. Install the pump assembly to the pump braket, tighten
the fixing bolt to the specified torque.
Torque: 46 N´m (34 lb ft)
2. Install the flexible hose.
Tighten the eye bolt to specified torque.
Torque: 54 N´m (40 lb ft)
3. Install the drive belt.
4. Connect the suction hose, then fill and bleed system.
Refer to
Bleeding the Power Steering System in this
section.

2A±24
POWER±ASSISTED STEERING SYSTEM
Power Steering Pump Disassembled View
442RX001
Legend
(1) Bolt
(2) Suction Pipe
(3) O-ring
(4) Shaft Assembly
(5) Oil Seal
(6) Front Housing
(7) O-ring
(8) O-ring
(9) Side Plate
(10) Rotor and Vane
(11) Pin(12) Cam
(13) Pump Cartridge Assembly
(14) O-ring
(15) Snap Ring
(16) Rear Housing
(17) Bolt
(18) Spring
(19) Relief Valve
(20) O-ring
(21) Connector
(22) Pressure Switch Assembly
Disassembly
1. Clean the oil pump with solvent (plug the discharge
and suction ports to prevent the entry of solvent).
Be careful not to expose the oil seal of shaft assembly
to solvent.
2. Remove the bolt, suction pipe and O-ring.
3. Remove the connector, O-ring, relief valve and
spring.
4. Remove the pressure switch assembly.
5. Remove the bolt, rear housing and O-ring.
6. Remove the snap ring.7. Remove the shaft assembly.
8. Remove the oil seal.
CAUTION: When removing the oil seal, be careful
not to damage the housing.
9. Remove the pump cartridge assembly from the front
housing.
10. Remove two O-rings.

POWER±ASSISTED STEERING SYSTEM2A±25
Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.
Rotor
442RS002Check that the groove in the vane is free from excessive
wear and that the vane slides smoothly. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Vane
442RS003
Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip that contact with the
cam should be free from wear and distortion). When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Cam
The inner face of the arm should have a uniform contact
pattern without a sign of step wear. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger nail.
The parts with minor scores may be reused after lapping
the face.
Relief Valve
The sliding face of the valve must be free from burrs and
damage. The parts with minor scores may be reused after
smoothing with emery cloth (#800 or finer).
Shaft
Oil seal sliding faces must be free from a step wear which
can be felt by the finger nail. Bushing fitting face must be
free from damage and wear.
O-ring, Oil Seal, Snap Ring
Be sure to discard used parts, and always use new parts
for installation. Prior to installation, lubricate all seals and
rings with power steering fluid.
Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. If system
fails to function properly, disconnect connector at the
pressure switch and repeat system check while testing
continuity across disconnected SW connector.
Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts for
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.