2002 ISUZU AXIOM front differential

4A1±13 DIFFERENTIAL (FRONT)
6. After the ZERO setting is obtained, rotate the
gauging arbor until the dial indicator rod does not
touch the gauging plate.
Record the number the dial indicator needle
points to.
425RS022
Legend
(1) Example=Dial indicator reading of 0.085
7. Record the pinion depth code on the head of the
drive pinion.
The number indicates a necessary change in the
pinion mounting distance. A plus number indi-
cates the need for a greater mounting distance
(which can be achieved by decreasing the shim
thickness). A minus number indicates the need
for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If ex-
amination reveals pinion depth code ª0º, the pin-
ion is ªnominalº.
425RS023

DIFFERENTIAL (FRONT) 4A1±14
8. Select the shim using chart;
Pinion
marking
Dial
indicator
reading
(Inches)+7+6+5+4+3+2+10±1±2±3±4±5±6±7
0.0230.030
0.0240.0300.030
0.0250.0300.0300.032
0.0260.0300.0300.0320.032
0.0270.0300.0300.0320.0320.034
0.0280.0300.0300.0320.0320.0340.034
0.0290.0300.0300.0320.0320.0340.0340.036
0.0300.0300.0300.0320.0320.0340.0340.0360.036
0.0310.0300.0300.0320.0320.0340.0340.0360.0360.038
0.0320.0300.0300.0320.0320.0340.0340.0360.0360.0380.038
0.0330.0300.0300.0320.0320.0340.0340.0360.0360.0380.0380.040
0.0340.0300.0300.0320.0320.0340.0340.0360.0360.0380.0380.0400.040
0.0350.0300.0300.0320.0320.0340.0340.0360.0360.0380.0380.0400.0400.042
0.0360.0300.0300.0320.0320.0340.0340.0360.0360.0380.0380.0400.0400.0420.042
0.0370.0300.0300.0320.0320.0340.0340.0360.0360.0380.0380.0400.0400.0420.0420.044
0.0380.0300.0320.0320.0340.0340.0360.0360.0380.0380.0400.0400.0420.0420.0440.044
0.0390.0320.0320.0340.0340.0360.0360.0380.0380.0400.0400.0420.0420.0440.0440.046
0.0400.0320.0340.0340.0360.0360.0380.0380.0400.0400.0420.0420.0440.0440.0460.046
0.0410.0340.0340.0360.0360.0380.0380.0400.0400.0420.0420.0440.0440.0460.0460.048
0.0420.0340.0360.0360.0380.0380.0400.0400.0420.0420.0440.0440.0460.0460.0480.048
0.0430.0360.0360.0380.0380.0400.0400.0420.0420.0440.0440.0460.0460.0480.0480.050
0.0440.0360.0380.0380.0400.0400.0420.0420.0440.0440.0460.0460.0480.0480.0500.050
0.0450.0380.0380.0400.0400.0420.0420.0440.0440.0460.0460.0480.0480.0500.0500.052
0.0460.0380.0400.0400.0420.0420.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0470.0400.0400.0420.0420.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0480.0400.0420.0420.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0490.0420.0420.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0500.0420.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0510.0440.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0520.0440.0460.0460.0480.0480.0500.0500.0520.052
0.0530.0460.0460.0480.0480.0500.0500.0520.052
0.0540.0460.0480.0480.0500.0500.0520.052
0.0550.0480.0480.0500.0500.0520.052
0.0560.0480.0500.0500.0520.052
0.0570.0500.0500.0520.052
0.0580.0500.0520.052
0.0590.0520.052
0.0600.052

4A1±15 DIFFERENTIAL (FRONT)
4. Place the shim on the drive pinion. Install the inner
bearing onto the pinion using an installer J±6133±01
and a press.
NOTE: Do not apply pressure to the roller cage and apply
pressure only to the inner race.
425RS024
5. Discard the used collapsible spacer and install a new
one.
6. Install pinion gear.
7. Install outer bearing.
8. Use oil seal installer J±24250 to install a new oil seal
that has been soaked in front axle lubricant.
NOTE: Take care to use a front differential oil seal, NOT
the rear differential oil seal.
415RS011
9. Install flange.
10. Install flange nut.
1. Apply lubricant to the pinion threads.
2. Tighten the nut to the specified torque using the
pinion flange holder J±8614±01.
Torque: 177±275N´m (130±203 lb ft)NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
415RW006
3. Adjust pinion bearing preload.
a. Measure the bearing preload by using a torque
meter. Note the scale reading required to
rotate the flange.
b. Continue tightening flange nut until the
specified starting torque is obtained.
Starting torque:
New bearing 0.7±1.1 N´m (5.64±9.98 lb in)
Used bearing 0.4±0.5 N´m (2.86±4.94 lb in)
NOTE: D o n o t t ighten the flange nut more than
678 N´m(500 lb ft).
425R200001
4. Using punch J±39209, stake the flange nut at two
points.

DIFFERENTIAL (FRONT) 4A1±16
NOTE: When staking, be sure to turn the nut to insure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3.
415R200004
11. Install adjust shim.
1. Attach the side bearing to the differential
assembly without shims. Support the opposite
side using a pilot to prevent bearing damage.
425RS029
Legend
(1) Drive handle:J±8092
(2) Installer:J±24244
(3) Pilot:J±8107±2
2. Insert the differential cage assembly with bearing
outer races into the side bearing bores of the
carrier.
425RS030
3. Using two sets of feeler gauges, insert a feeler
stock of sufficient thickness between each
bearing outer race and the carrier to remove all
end play. Make certain the feeler stock is pushed
to the bottom of the bearing bores.
Mount the dial indicator J±8001 on the carrier so
that the indicator stem is at right angles to a tooth
on the ring gear.
425RS031

4A1±17 DIFFERENTIAL (FRONT)
4. Adjust feeler gauge thickness from side to side
until ring gear backlash is in the specified range.
Backlash: 0.13±0.20 mm(0.005 ±0.008 in)
425RS032With zero end play and correct backlash estab-
lished, remove the feeler gauge packs, determine
the thickness of the shims required and add 0.025
mm (0.001 in) to each shim pack to provide side
bearing preload. Always use new shims.
5. Use bearing remover J±42379 and pilot
J±8107±2 to remove side bearing.

Select insert; 303173 and collet halves;44801
in remover kit J±42379.
415RW003
12. Install the side bearings together with the selected
shims.
425RS029
Legend
(1) Drive Handle:J±8092
(2) Installer: J±24244
(3) Pilot: J±8107±2
13. Install side bearing outer race.
14. Install differential cage assembly.
15. Install bearing cap then align the setting marks(1)
applied at disassembly.
425RS035

DIFFERENTIAL (FRONT) 4A1±18
16. Tighten the cap bolt to the specified torque.
Torque: 97 N´m (72 lb ft)
425RS036
Gear Tooth Contact Pattern Check and
Adjustment
1. Apply a thin coat of prussian blue or equivalent to
at least 7±8 ring gear teeth. Rotate the ring gear
and inspect the contact point of the impressions
and make the necessary adjustments as
described in the next page.
425RS038
Legend
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)
425RS039

4A1±19 DIFFERENTIAL (FRONT)
17. Install differential assembly.
1. Clean the faces of the front axle case and
differential carrier.
Apply Three Bond TB1215 or equivalent to the
sealing side of the axle case and the carrier.
2. Attach the differential case and the carrier
assembly to the front axle case and tighten the
nuts and bolts.
Torque: 25 N´m (19 lb ft)
415RS014
3. Fill the axle case with hypoid gear lubricant, up to
the base of the filler hole.
Lubricant capacity: 1.25 liter(1.32 US qt)
18. Install damper.
1. Clean the faces and bolt thread hole of differential
carrier.
2. Install the bracket with new bolts.
3. Install the damper to the bracket with new bolts.
Torque: 25 N´m (19 lb ft)
425RW042

DIFFERENTIAL (FRONT) 4A1±20
Differential Cage Assembly
Disassembled View
415R200005
Legend
(1) Pinion Gear
(2) Thrust Washer
(3) Side Gear
(4) Cross Pin(5) Ring Gear
(6) Bolt
(7) Differential Cage
(8) Lock Pin
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin.
425RS042