2002 ISUZU AXIOM air condition

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.

DIFFERENTIAL (REAR)4A2±11
4. Remove flange nut and washer by using pinion flange
holder J±8614±01 after raising up its staked parts
completely.
425RW037
5. Remove flange by using SST J±8614±1 ~ 3.

Have a suitable container in place to catch
lubricant.
425RW038
6. Remove oil seal.
7. Remove pinion oil seal slinger.
8. Remove outer bearing by using remover J±39602.
425RS090
9. 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 flange.
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.

4A2±26DIFFERNTIAL (REAR)
Disassembly
1. Remove lock pin using a small drift.
425RS098
2. Remove the differential shaft by using a soft metal rod
and a hammer.
425RS043
3. Remove pinion mate gear and thrust washer.
4. Remove side gear and thrust washer.
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.

Ring gear, pinion gear

Bearing

Side gear, pinion mate gear, differential shaft

Differential case, carrier

Thrust washer

Oil seal
Reassembly
1. Install side gear with thrust washer.
2. Install the pinion mate gear with thrust washer by
engaging it with the side gears while turning both
pinion mate gears simultaneously in the same
direction.
425RS048
3. Install differential shaft.
1. Be sure to install the differential shaft so that it is in
alignment with the lock pin hole in the differential
case.
425RS049
4. Install lock pin.
After lock pin installation, stake the case to secure the
lock pin.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±62
StepActionYe sNo
11. Turn on the starter switch.
When the motor is not moving, is the voltage between the
terminals 35 and 47 8.0 ~ 14.5V?
Go to Step 2Go to Step 3
2When the motor is not moving, is the voltage between the terminal
48 and 47 8.0 ~ 14.5V?
Go to Step 5Go to Step 3
31. Turn off the starter switch.
2. Disconnect the ECU connector (C±37) and transfer connector
(A±2).
Is there the continuity between the connector terminal (C±37) 13
and (A±2) 7?
Go to Step 4
Repair the circuit.
Go to
Step 11
4Is there the continuity between the connector terminal (C±37) 26
and (A±2) 4?
Go to Step 5
Repair the circuit
Go to
Step 11
51. Connect the ECU connector (C±37) and transfer connector
(A±2).
2. Turn on the starter switch
Is the transfer shifted to the low range from the high range?
Go to Step 6Go to Step 7
61. Is the transfer shifted to the high range from the low range.The phenomenon
is not
reproduced.
Refer to
ªTrouble
intermittently
observedº.
Go to Step 8
71. After the starter switch is turned off, turn on the starter switch.
2. Right after the TOD switch is changed to the 4L position from
the TOD position, measure the voltage for 5 seconds.
Is the voltage between terminal 48 and 47 0V while the motor is
moving and 8.0 ~ 14.5V after the motor moving stops?
Go to Step 9
Replace the
ECU.
Go to
Step 11
81. After the starter switch is turned off, turn on the starter switch.
2. Right after the TOD switch is changed to the TOD position
from 4L position, measure the voltage for 5 seconds.
Is the voltage between terminals 35 and 47 0V while motor is
moving and 8.0 ~14.5V after the motor moving stops?
Go to Step 9
Replace the
ECU.
Go to
Step 11
91. Remove the motor asm with the connector (A±2) from the
transfer.
2. Connect the ECU connector (C±37).
3. Turn on the starter switch.
When the TOD switch is changed to the 4L position from the TOD
position, does the shaft in the motor asm rotate to the Low
direction?
Go to Step 10
Replace the
high-low motor
asm.
Go to
Step 11
10When the TOD switch is changed to the TOD position from the 4L
position, does the shaft in the motor asm rotate to the High
direction?
Repair the
transfer asm.
Go to
Step 11
Replace the
high±low motor
asm.
Go to
Step 11
111. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
Verify the repairReturn to Step 11
NOTE:

Confirm the operation conditions when changing high
and low range.
± The car stops. (less than 2 km/h or 1.2 mph and
engine speed less than 1500 rpm)± The AT selector position is neutral.
± The brake is applied (brake switch: ON)

Verify the completion of changing the high/low range
by the TOD indicator on the instrument panel.

4B2±63
DRIVE LINE CONTROL SYSTEM (TOD)
Check flowTrouble codePhenomenonStandard
1442 (P1773)Error operation was carried out
under high±low motor running.Ð
StepActionYe sNo
11. Clear the trouble code.
Is the transfer changed to the low range from the high range?
Go to Step 2Go to Step 3
2Is the transfer changed to the high range from the low range?The phenomenon
is not
reproduced.
Refer to
ªTrouble
intermittently
observedº.
Go to Step 3
3Is the trouble code memoried?
Go to Step 4
See ªDiagnosis
from Symptomº.
4Is the memory DTC42 (P1773)?
Go to Step 5
Remove the
trouble
associated with
codes except
DTC 42 first.
Confirm the DTC
again.
Go to
Step 5
51. Clear the trouble code.
2. Confirm the condition and operation of the transfer range
changing and check the state of the TOD indicator. Change
the transfer to the low from the high and vice versa.
Is the transfer changed to the low from the high and to the high
from the low?The transfer is
changed in both
ranges by the
correct operation.
Operate the
transfer
according to
ªOwner's
Manualº.
Go to Step 6
6Is the trouble code memoried?
Go to Step 7
See ªDiagnosis
from Symptomº.
7Is the memory DTC 42 (P1773)?
Replace the
ECU.
Go to
Step 8
Remove the
trouble
associated with
codes except
DTC 42 first.
Confirm the DTC
again.
Go to
Step 5
81. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
Verify the repair.Go to Step 8
NOTE:

Confirm the operation conditions when changing
high/low range.
± The car stops. (less than 2 km/h or 1.2 mph and
engine speed: less than 1500 rpm)
± The AT selector position is neutral.
± The brake is applied (brake switch: ON)
Verify the completion of changing the high/low range
by the TOD indicator on the instrument panel.

This code does not indicate the trouble of the transfer
or ECU, and is memoried when an error operation is
carried out under high-low motor running.
Therefore this code is not memoried if the transfer is
operated according to
ªOwner's Manualº.

4B2±65
DRIVE LINE CONTROL SYSTEM (TOD)
StepActionYe sNo
11. Turn on the starter switch.
Is the transfer changed to the low range from the high range?
Go to Step 2Go to Step 4
2Is the transfer changed to the high range from the low range?Go to Step 3Go to Step 5
31. Clear the trouble code.
2. Turn on the starter switch.
Is the memory DTC 55 (P1755)?
Go to Step 1
The phenomenon
is not
reproduced.
Refer to
ªTrouble
intermittently
observedº.
41. Turn off the starter switch.
2. Disconnect the ECU connector (C±37).
Is the continuity between the terminals ranged within the any case
(case1, 2 or 3) in the following table (1)?
Go to Step 8Go to Step 6
51. Turn off the starter switch.
2. Disconnect the ECU connector (C±37).
Does the continuity between the terminals comply with the
following table (2)?
Go to Step 8Go to Step 7
61. Turn off the starter switch.
2. Disconnect the transfer connector (A±2).
Is the continuity between the male terminals ranged within the any
case (case1, 2 or 3) in the following table (3)?
Go to Step 8
The encoder has
failed. Replace
the high-low
motor asm.
Go to
Step 9
71. Turn off the starter switch.
2. Disconnect the transfer connector (A-2).
Does the continuity between male terminals comply with the
following table (4)?
Go to Step 8
The encoder has
failed. Replace
the high-low
motor asm.
Go to
Step 9
81. Turn off the starter switch.
2. Disconnect the ECU connector (C±37) and transfer connector
(A±2).
Is there the continuity between connector terminal (C±37) 4 and
(A±2) 6, (C±37) 17 and (A±2) 1, (C±37) 3 and (A±2) 2, (C±37) 16
and (A±2) 3, and (C±37) 2 and (A±2) 5?
The encoder has
failed. Replace
the high-low
motor asm.
Go to
Step 9
The circuit in
which there is no
continuity is
broken. Repair
the circuit.
Go to
Step 9
91. Check that all the parts are mounted.
2. Clear the trouble code.
Is this step complete?
Verify the repair.Go to Step 9
NOTE:

Confirm the operation conditions when changing high
and low range.
± The car stops. (less than 2 km/h or 1.2 mph and
engine speed: less than 1500 rpm)
± The AT selector position is neutral.
± The brake is applied (brake switch: ON)

Verify the completion of changing the high/low range
by the TOD indicator on the instrument panel.

When changing high/low range, start the engine to
prevent the battery dead.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2±118
Chart 7The transfer does not change to low from high.
Function of circuitÐ
Fail conditionWhen the TOD switch is selected to the 4L position, the transfer does not change to the
low position. (The transfer stays neutral and the vehicle does not run.)
StepActionYe sNo
11. Turn on the starter switch.
2. Set the TOD switch to the any position.
Is the transfer changed to high or low?
Go to Step 2Go to Step 3
2Is the transfer changed to high from low and the low from high?The phenomenon
is not
reproduced.
Refer to
ªTrouble
intermittently
observedº.
Go to Step 3
3Is any of the trouble codes 41 (P1741), 42 (P1773), 43 (P1743),
and 55 (P1755) recorded?Examine the
trouble based on
ªDiagnosis from
Trouble Codesº.The transfer is
abnormal. Repair
the transfer.
Go to
Step 4
4Check that all the parts are mounted.
Is this step complete?
Verify the repair.Go to Step 4

4C±2
DRIVE SHAFT SYSTEM
General Description
This publication contains essential removal, installation,
adjustment and maintenance procedures.
The front axle utilizes a central disconnect type front
axle/transfer case system.The drive axles are completely flexible assemblies,
consisting of inner and outer constant velocity (CV) drive
shaft joints connected by an axle shaft.
For description of front propeller shaft and universal joint,
refer to
Front Propeller Shaft in this section.
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.