Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Service manual — part 146
4C–84
DRIVE SHAFT SYSTEM
D
Aluminum tube type only: Inspect the aluminum
tubing for surface scratches and dents. These
scratches may not exceed 0.2 mm (0.008 in) in depth.
401RW022
D
Aluminum tube type only: Visually inspect the circle
welds and fittings for any signs of cracks or signs of
deterioration. If there are any cracks that exceed 0.2
mm (0.008 in) in depth, the assembly must be
replaced.
D
Aluminum tube type only: Check to be sure there are
no missing balance weights. If balance weights are
missing and void has occurred in the aluminum tubing
greater than 0.2 mm (0.008 in), the assembly must be
replaced.
Universal Joint Reassembly
1. Pack the four grease cavities of the spider with a high
quality, extreme pressure N.L.G.I. Grade 2 grease.
Do not add additional grease to bearing cup
assembly.
2. Move one end of the spider to cause a trunnion to
project through the spider hole beyond the outer
machined face of the yoke lug. Place a bearing over
the trunnion diameter and align it to the spider hole.
Using an arbor press, hold the trunnion in alignment
with the spider hole and place a solid plug on the
upper bearing. Press the bearing into the spider hole
enough to install snap ring.
401RW026
3. Install a snap ring.
NOTE: Be sure the snap rings are properly seated in the
grooves.
4. Repeat steps 2 and 3 to install the opposite bearing. If
the joint is stiff, strike the yoke ears with a soft
hammer to seat the bearing.
5. Align the setting marks and join the yokes.
4C–85
DRIVE SHAFT SYSTEM
Slip Joint Reassembly
401RX00001
Legend
(1) Spline Yoke and Universal Joint Assembly
(2) Clamp
(3) Boot
(4) Clamp
(5) Tube and Universal Joint Assembly
1. Apply grease evenly to both the female and male
splines.
2. Apply a small amount of grease by finger to the outer
lips of the boot.
3. Slide the boot (smaller diameter side) onto the spline
yoke shaft being careful not to damage the spline
coating or boot.
4. Insert the spline yoke shaft spline into the tube
assembly being careful to maintain proper phasing.
The spider holes should be in line as originally marked
prior to disassembly.
5. Position boot onto tube and yoke shaft in its
assembled position.
6. Attach boot clamps and secure using pliers.
7. Be sure clamp is properly seated and secure.
CAUTION: Only use a similar type or same as the
original type clamp. Using any other clamp may
create an imbalanced shaft or lead to grease leakage.
4C–86
DRIVE SHAFT SYSTEM
Main Data and Specifications
General Specifications
2WD Model
4WD Model
Engine
Y22SE
6VD1
6VD1
Transmission
M/T
A/T
M/T
A/T
M/T
A/T
Type (See illustration)
1
2
1
2
2
3
Length
between two spiders
center)
1314.4mm
(51.75in)
1334.7mm
(52.55in)
1298.4mm
(51.12in)
1323.0mm
(52.09in)
1191.2mm
(46.9in)
1021.2mm
(40.21in)
Universal joint type
Cardan type
Torque Specifications
401R100001
4D2–1
TRANSFER CASE (TOD)
AXIOM
DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution
4D2–1
. . . . . . . . . . . . . . . . . . . . . .
General Description
4D2–2
. . . . . . . . . . . . . . . . . . . . .
Removal and Installation of Tfansfer Case
Assembly
4D2–3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal
4D2–4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
4D2–4
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal
4D2–6
. . . . . . . . . . . . . . . . . . .
Removal
4D2–6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
4D2–6
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD Control Unit
4D2–8
. . . . . . . . . . . . . . . . . . . . . . . .
Removal
4D2–8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation
4D2–8
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair
4D2–9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly and Reassembly of Major
Components
4D2–9
. . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
4D2–10
. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–10
. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Cover Assembly
4D2–13
. . . . . . . . . . . . . . . .
Disassembly
4D2–13
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
4D2–14
. . . . . . . . . . . . . . . . . .
Reassembly
4D2–15
. . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pack and Clutch Cam
(Transfer Case Assembly)
4D2–16
. . . . . . . . . . . . . . .
Disassembly
4D2–16
. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–18
. . . . . . . . . . . . . . . . . . . . . . . . . .
Chain, Sprocket and Mechanical Lock
(Transfer Case Assembly)
4D2–20
. . . . . . . . . . . . . . .
Disassembly
4D2–21
. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–22
. . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly
4D2–24
. . . . . . . . . . . . . . . . .
Disassembly
4D2–24
. . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly
4D2–26
. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair
(Transfer Case Assembly)
4D2–28
. . . . . . . . . . . . . .
Main Data and Specification
4D2–32
. . . . . . . . . . . . . .
General Specification
4D2–32
. . . . . . . . . . . . . . . . . .
Torque Specifications
4D2–33
. . . . . . . . . . . . . . . . . .
Torque Specifications (Cont’d)
4D2–34
. . . . . . . . . . .
Torque Specifications (Cont’d)
4D2–35
. . . . . . . . . . .
Special Tools
4D2–36
. . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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