2002 ISUZU AXIOM axle shaft

4C±19 DRIVE SHAFT SYSTEM
Shift On The Fly System
Shift On The Fly System and Associated Parts
412RY00007
Legend
(1) Filler Plug
(2) Bolt
(3) Oil Seal
(4) Snap Ring(External)
(5) Inner Shaft Bearing
(6) Snap Ring(Internal)
(7) Inner Shaft(8) Needle Bearing
(9) Clutch Gear
(10) Sleeve
(11) Housing
(12) Front Axle Drive Shaft(LH side) with Bracket
(13) Bolt
(14) Actuator Assembly
(15) Bolt

4C±20
DRIVE SHAFT SYSTEM
Disassembly
1. Remove filler plug and gasket, drain oil.
2. Loosen mounting bracket fitting bolts and remove
front axle drive shaft from front axle case.
3. Remove actuator assembly and draw out actuator
ASM.
4. Remove housing.
5. Remove sleeve.
6. Remove clutch gear.
7. Remove snap ring from front axle case by using snap
ring pliers.
412RW017
8. Take out inner shaft from front axle case.
9. Remove snap ring from inner shaft by using snap ring
pliers.
412RW016
10. Remove inner shaft bearing.
NOTE: Be careful not to damage the shaft.
412RW015
11. Remove needle bearing from inner shaft by using a
remover J±26941 and sliding hammer J±2619±01.
412RS045
12. Remove oil seal from front axle case.
NOTE: Be careful not to damage the front axle case.

4C±24
DRIVE SHAFT SYSTEM
2. Install a new needle bearing into inner shaft by using a
Installer J±41694 and grip J±8092.
412RS051
3. Place a new snap ring(internal) in inner shaft.
Install a new inner shaft bearing into the inner shaft.
412RS044
4. Install snap ring(external).
NOTE: Be careful not to damage the inner shaft.
5. Clean the housing contact surface of the front axle
case and insert inner shaft assembly into the front
axle case.
NOTE: Be careful not to damage seal.
6. Install snap ring internal in the groove of front axle
case.NOTE: Be sure to install the snap ring properly.
412RW017
7. Apply differential gear oil to clutch gear, then install
clutch gear.
8. Apply differential gear oil to sleeve, then install
sleeve.
9. Clean contact surface with the front axle and actuator
mounting surface. Apply liquid gasket to the contact
surface on the front axle case, then install in the
housing.
412RW023
10. Tighten bolts to specified torque.
Torque: 75N´m(55 lb ft)
11. Clean the actuator contact surface with the housing
then Install and tighten shift position switch to
specified torque.
Torque: 39N´m (29 lb ft)

4C±25 DRIVE SHAFT SYSTEM
12. Apply liquid gasket to the contact surface on the
actuator side.
412RW012
13. Align shift arm with the groove of sleeve and install the
actuator.
14. Tighten bolts to specified torque.
Torque: 9N´m(78 lb in)
15. Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified torque.
Torque: 116N´m (85 lb ft)
16. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity: 1.4lit (1.48US qt)
Actuator Housing
Oil Capacity: 0.12lit(0.13US qt)
17. Install filler plug through gasket and tighten to
specified torque.
Torque: 78N´m (58lb ft)

4C±26
DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
Front drive axle oil capacity1.25 liter (1.32 US qt)(Differential)
0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly)
Type of lubricantGL±5 (75W±90) Refer to chart in General Information
Axle shaft typeConstant velocity joint(Birfield joint type and double offset joint)
Torque Specifications
412RY00040

4C±28
DRIVE SHAFT SYSTEM
Special Tools
ILLUSTRATIONTOOL NO.
TOOL NAME
J±39378
Remover and Installer;
Front Axle mount
bushing
J± 26941
Remover; Bearing
needle
J±2619±01
Hammer; Sliding
J±41693
Installer; Oil seal
J±41694
Installer; Bearing needle
J±8092
Grip
ILLUSTRATIONTOOL NO.
TOOL NAME
J±36827
Wrench; Hub nut
J±36829
Installer; Inner bearing
J±36828
Installer; Outer bearing
J±36830
Installer; Oil seal

4C±29 DRIVE SHAFT SYSTEM
Propeller Shaft
General Description
401R200001
Legend
(1) Front Propeller Shaft
(2) Rear Propeller Shaft;
Aluminum Tube with Flange Yoke Type (for
4y2 model)
(3) Rear Propeller Shaft;
Steel Tube Type (for 4y4 model)
Torque is transmitted from the transmission to the axle
through the propeller shaft and universal joint assembles.
All propeller shafts are the balanced tubular type. A
splined slip joint is provided in some drivelines.

Since the propeller shaft is balanced carefully,
welding or any other modification is not permitted.

Alignment marks should be applied to each propeller
shaft before removal.
Park, turn the engine off and apply the parking brake
to secure the vehicle.

Carefully attach the propeller shaft to the vise, do not
overtighten the vise when securing the propeller
shaft, this may cause deformation.

4C±31 DRIVE SHAFT SYSTEM
Front Propeller Shaft and Associated Parts
401R200006
Legend
(1) Bolt, and Washer (Front Axle Side)
(2) Front Propeller Shaft (with TOD)(3) Bolt and Washer (Transfer Side)
(4) BJ Constant Velocity Joint
(5) LJ Constant Velocity Joint
Removal
1. Jack up the vehicle and support it on the chassis
stands.
2. Gear shift lever should be placed in neutral position
and parking brake released.
3. Remove the exhaust and transfer protectors.
NOTE: Apply alignment marks on the flange at the front
propeller shaft both front and rear side.
401RS020