2002 ISUZU AXIOM Service Repair Manual

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

4A1±21 DIFFERENTIAL (FRONT)
4. Remove the cross pin, using a soft metal rod and a
hammer.
425RS043
5. Remove pinion gear.
6. Remove side gear.
7. Remove 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.
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard used bolts and install new ones.
Torque: 108 N´m (80 lb ft)3. Tighten the fixing bolts in a diagonal sequence as
illustrated.
415RS016
Reassembly
1. Install thrust washer.
2. Install side gear.
3. Install the pinion gear with thrust washer by engaging
it with the side gears while turning both pinion gears
simultaneously in the same direction.
425RS048

DIFFERENTIAL (FRONT) 4A1±22
4. Install cross pin.

Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
cage.
425RS049
5. Install lock pin. After lock pin installation, stake the
cage to secure the lock pin.
6. Install ring gear and tighten the bolts in diagonal
sequence as illustrated.
Torque: 108 N´m (80 lb ft)
NOTE: Discard used bolts and install new ones.
415RS016

4A1±23 DIFFERENTIAL (FRONT)
Main Data and Specifications
General Specifications
Axle tube TypeIt consists of a duct, a cast iron housing
and an axle tube.
Gear typeHypoid
Gear ratio4.300
Differential typeTwo pinion
Oil capacityliter (US qt)1.25 (1.32) (Differential)
0.12 (0.13) (Actuator Housing: Shift on the fly)
Type of lubricantGL±5 (75W±90)
Axle shaft typeConstant velocity joint
(Birfield joint type and double offset joint)
Hub locking TypeRigid
Torque Specifications
412R200005