2002 ISUZU AXIOM Service Repair Manual

4A2±30DIFFERNTIAL (REAR)
9. While holding gears in place, insert LSD service
adapter J±39834 with long drive handle J±8592 in
differential shaft hole of case. Pull on long drive
handle J±8592 and rotate case, allowing gears to
turn. Make sure that holes in pinion mate gears align
with holes in case.
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It may be necessary to adjust tension on forcing
screw to rotate case.
10. Tighten forcing screw to compress the clutch packs,
to allow installation of spherical thrust washers.
11. Lubricate spherical thrust washers (2), and assemble
into case (1). Use a small screw driver to push
washers into place. Remove tools.
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12. Position differential shaft in case and drive in with
hammer. Be sure lock pin hole of differential shaft (5)
is properly aligned to allow installation of lock pin (3).
Be sure that thrust washers and differential pinion
mate gears are aligned with the differential case (4).
Install new lock pin to proper depth using a punch.
Stake metal of case over pin in two places, 180
degrees apart.
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DIFFERENTIAL (REAR)4A2±31
Main Data And Specifications
General Specifications
Rear axle
TypeSalisbury, Semi±floating
Rear axle Size226 mm (8.9 in)
Gear typeHypoid
Gear ratio4.300
Differential typeTwo pinion
Lubricant GradeGL±5: (Standard differential)
GL±5, LSD: (Limited slip differential)
Locking Differential Lubricant80W90 GL±5
(USE Limited Slip Differential Gear Lubricant or Friction
Modifier Organic Additive)
Capacity1.77 liter (1.87 US qt)
Torque Specifications
E04RX002

4A2±32DIFFERNTIAL (REAR)
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
J±8614±01
Pinion flange holder
J±37263
Installer; Pinion oil seal
J±42379
Remover; Bearing
J±39830
Adapter; Side bearing
plug
J±8611±01
Installer; Outer bearing
outer race
J±8592
Grip
ILLUSTRATIONTOOL NO.
TOOL NAME
J±42836
Installer; Inner bearing
outer race
J±42824
Pilot;Outer
J±21777±43
Nut & Stud
J±42827
Pilot;Inner
J±39837±2
Gauge plate
J±8001
Dial indicator

DIFFERENTIAL (REAR)4A2±33
ILLUSTRATIONTOOL NO.
TOOL NAME
J±39837±1
Disc (2 required)
J±23597±1
Arbor
J±42828
Installer; Pinion bearing
J±21784
Installer; Side bearing
J±39602
Remover; Outer bearing
J±24385±B
Spreader
ILLUSTRATIONTOOL NO.
TOOL NAME
J±39858
Clutch pack unloading
tool kit Includes
J±34174±1/J±34174±2
Screw cap and Cap
J±22342±15
Forcing screw
J±39834
Limited±slip differential
(LSD) service adapter
J±39824
Holder
J±39836
Side bearing preload
master bearings

4B1±1
DRIVELINE CONTROL SYSTEM
AXIOM
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM
CONTENTS
Service Precaution 4B1±1. . . . . . . . . . . . . . . . . . . . . .
Shift On The Fly System 4B1±2. . . . . . . . . . . . . . . . .
Outline of Shift on The Fly System 4B1±2. . . . . . . . .
Functions of Indicator Lamp 4B1±4. . . . . . . . . . . . . .
Shift On The Fly Electrical Equipment 4B1±5. . . . . .
Axle Shaft Connection and Disconnection 4B1±5. . Shift On The Fly Controller 4B1±7. . . . . . . . . . . . . . .
Shift On The Fly Controller and
Associated Parts 4B1±7. . . . . . . . . . . . . . . . . . . . . .
Removal 4B1±7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4B1±7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

4B1±2
DRIVELINE CONTROL SYSTEM
Shift On The Fly System
Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2WD) and 4 wheel drive (4WD) electronically by the
driver turning the TOD switch on the instrument panel.
This system will control the following operations. (Shifting
between ª4Hº and ª4Lº must be performed by TOD
switch.)
1. Transmitting the torque to the front propeller shaft.
2. Connecting front wheels to, and disconnecting them
from, the front axles by axle motor actuator.
3. Indicating on instrument panel.
4. 4WD out signal to other Electronic Brake Control
Module (EBCM).
System Diagrams
412R200008

4B1±3
DRIVELINE CONTROL SYSTEM
Normal Operation
The axle disconnect controller is driven by the signal from
TOD control unit and the axle motor actuator connects (or
disconnects when the 4WD switch is deactivated) the
front wheels to the front axles.
Time Chart of Shifting Under Normal Condition
F04R200002
4WD out signal to other Electronic Brake Control
Module : TOD Control Unit of shift on the fly sends 4WD
out signal to other Electronic Brake Control Module as
below.
4WD out signal
(Period)
Vehicle ConditionTransfer position switchFront axle switch
120 ms2WD2WD (Open)2WD (Open)
240 ms4WD4WD (Close)4WD (Close)

4B1±4
DRIVELINE CONTROL SYSTEM
Functions of Indicator Lamp
TOD Switch and Indication of Drive Mode
The TOD switch sends signals to the TOD control unit
which selects drive modes and controls the shift on the fly
system (axle disconnect : ADC).
TOD
switch
tt
Drive modeTransfer shift conditionTransfer posi-
tion detectionShift on the flyTOD indicator
state
state4HSW4LSWAxle
SWADC circuit
2HRear-wheel
drive (RWD)Permissible during
driving (less than
100 km/h or 62 mph)OFFOFFOFFTurning on
electricity
TODElectronic
torque split
4WD (HIGH)
OFFOFFONTurning off
electricity
4WD (HIGH)
(TOD)AT: Neutral
Brake: Applied
Th t (l4LLow range
mechanical
direct 4WD
(LOW) (4L)The car stops (less
than 2 km/h or
1.2 mph and less than
1500 rpm)OFFONONTurning off
electricity
ADC: Shift on the fly
SW: Switch
Bulb check :The bulb of indicator lamp is checked for 2
seconds when ignition key is turned on.
Bulb Check
When the starter switch is turned on, the TOD indicator
lamps comes on as shown below.
NOTE: Once the starter switch is turned on, all the TOD
indicator lamps are lit for two seconds even if the transfer
lever is in any position.
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