2002 ISUZU AXIOM axle shaft

4B1±5
DRIVELINE CONTROL SYSTEM
Shift On The Fly Electrical Equipment
Axle Shaft Connection and Disconnection
412R200006
Actuator Assembly
412RY00004
Axle Disconnect Controller
828RY00009

4B2±109
DRIVE LINE CONTROL SYSTEM (TOD)
StepActionYe sNo
1Do the indicator lamps show the correct status?
Go to Step 2
Examine the
trouble based on
ªTrouble
Diagnosis
Depending on the
Status of TOD
Indicatorº.
2Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762)
recorded?Examine the
trouble based on
ªDiagnosis from
Trouble Codesº.
Go to Step 3
3Turn on the starter switch.
Is the battery voltage observed between terminals 14 and 47?
Go to Step 4Go to Step 5
4When the TOD Switch is selected to the 2H position, are the front
axle gears correctly disengaged (and when the left front tire is
jacked up and turned, is the front propeller shaft standstill)?The phenomenon
is not
reproduced.
Refer to
ªTrouble
intermittently
observedº
.
The shift on the
fly system is
failed (refer to
Section 4B1 and
4C
).
5Does the battery voltage maintain the correct level?
Repair the battery
circuit.
Go to
Step 6
Repair the battery
and charging
system.
Go to
Step 6
6Check that all the parts are mounted.
Is this step complete?
Verify the repair.Go to Step 6

4C±1 DRIVE SHAFT SYSTEM
AXIOM (Vehicles Produced Before July/31/2001)
DRIVELINE/AXLE
DRIVE SHAFT SYSTEM
CONTENTS
Service Precaution 4C±1. . . . . . . . . . . . . . . . . . . . . .
General Description 4C±2. . . . . . . . . . . . . . . . . . . . .
Diagnosis 4C±2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Hub and Disc (2WD Model) 4C±3. . . . . . . . .
Disassembled View 4C±3. . . . . . . . . . . . . . . . . . . .
Disassembly 4C±3. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4C±4. . . . . . . . . . . . . . . . . .
Reassembly 4C±5. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Hub and Disc (4WD Model) 4C±8. . . . . . . . .
Disassembled View 4C±8. . . . . . . . . . . . . . . . . . . .
Disassembly 4C±8. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair 4C±10. . . . . . . . . . . . . . . . . .
Reassembly 4C±10. . . . . . . . . . . . . . . . . . . . . . . . . .
Front Drive Shaft Joint 4C±13. . . . . . . . . . . . . . . . . . .
Front Drive Shaft Joints Replacement 4C±13. . . .
Front Axle Drive Shaft 4C±14. . . . . . . . . . . . . . . . . . .
Front Axle Drive Shaft and Associated
Parts 4C±14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 4C±15. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 4C±16. . . . . . . . . . . . . . . . . .
Bushing Replacement 4C±16. . . . . . . . . . . . . . . . . .
Reassembly 4C±17. . . . . . . . . . . . . . . . . . . . . . . . . .
Shift On The Fly System 4C±19. . . . . . . . . . . . . . . . .
Shift On The Fly System and Associated
Parts 4C±19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 4C±20. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection And Repair 4C±21. . . . . . . . . . . . . . . . . .
Reassembly 4C±23. . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4C±26. . . . . . . . . . .
Special Tools 4C±28. . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft 4C±29. . . . . . . . . . . . . . . . . . . . . . . . . .
General Description 4C±29. . . . . . . . . . . . . . . . . . . .
Front Propeller Shaft 4C±30. . . . . . . . . . . . . . . . . . . . .
General Description 4C±30. . . . . . . . . . . . . . . . . . . .
Front Propeller Shaft and Associated Parts 4C±31
Removal 4C±31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4C±32. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications 4C±35. . . . . . . . . . .
Rear Propeller Shaft 4C±36. . . . . . . . . . . . . . . . . . . . .
Rear Propeller Shaft and Associated Parts 4C±36
Removal 4C±36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4C±36. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slip Joint Disassembly 4C±37. . . . . . . . . . . . . . . . .
Universal Joint Disassembly 4C±38. . . . . . . . . . . .
Inspection 4C±40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Universal Joint Reassembly 4C±41. . . . . . . . . . . . .
Slip Joint Reassembly 4C±42. . . . . . . . . . . . . . . . . .
Main Data and Specifications 4C±43. . . . . . . . . . .
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.

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.

4C±13 DRIVE SHAFT SYSTEM
Front Drive Shaft Joint
Front Drive Shaft Joints
Replacement

Refer to Front Drive Axle Assembly Replacement in
this section, and refer to
Front Hub and Disc Overhaul
in Suspension
section.
Front Hub Bearing Preload Check
Check the hub bearing preload at the wheel pin.
New bearing and New oil seal:
19.6 ± 24.5 N (4.4 ± 5.5 lb)
Used bearing and New oil seal:
11.8 ± 17.7 N(2.6 ± 4.0 lb)
411RS011
Inspection Of Shift On The Fly System
Gear Oil
412RY00008
1. Open filler plug and make sure that the oil up to the
plug port.
If the oil is short, replenish with gear oil GL±5 grade.
2. Tighten the filler plug to specified torque.
Torque: 78 N´m (58 lb in)

4C±14
DRIVE SHAFT SYSTEM
Front Axle Drive Shaft
Front Axle Drive Shaft and Associated Parts
412RY00036
Legend
(1) Axle Case and Differential
(2) Snap Ring
(3) Bearing
(4) Snap Ring
(5) Oil Seal
(6) Bracket
(7) DOJ Case
(8) Circlip
(9) Bolt
(10) Drive Shaft Joint Assembly
(11) Ball(12) Snap Ring
(13) Ball Retainer
(14) Ball Guide
(15) Band
(16) Bellows
(17) Band
(18) Band
(19) Bellows
(20) Band
(21) BJ Shaft
(22) Dust Seal

4C±16
DRIVE SHAFT SYSTEM
7. Remove ball retainer, ball guide and bellows.
8. Raise the hooked end of the band with a screwdriver
or equivalent.
412RS014
9. Remove band(1).
10. Remove bellows.
11. Remove dust seal.
12. Remove BJ shaft assembly.
13. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
14. Remove snap ring and bearing.
15. Remove snap ring and oil seal.
16. Remove bracket.
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. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal
Bushing Replacement

Remove the bushings using a remover J±39378±1
and hammer.
412RS015

By using installer J±39378±2 and base J±39378±3,
press fit the bushings into the bracket.
412RS016

4C±17 DRIVE SHAFT SYSTEM
Reassembly
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
3. Install bearing and fix snap ring.
4. Install bracket to axle case. Tighten the bracket bolt to
the specified torque.
Torque: 116 N´m (85 lb ft)
5. Apply 150g of the specified grease in BJ.
6. Install dust seal.
7. Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
8. Install band. Note the setting direction. After
installation, check that the bellows is free from
distortion.
412RS017
9. Install another bellows and fix band.
10. Install the ball guide with the smaller diameter side
ahead onto the shaft.
11. Install ball retainer.
12. Using snap ring pliers, install the snap ring (1)
securing the ball retainer to the shaft.
412RS013
13. Align the track on the ball (1) retainer with the window
in the cage, and install the six balls into position.
412RS018
14. Pack 150g of the specified grease in DOJ case, then
install drive shaft joint assembly. After reassembly,
move the DOJ longitudinally several times to get to fit.