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Home >> Isuzu Truck >> 1987 >> Pickup L4-2238cc DSL (C223) >> Repair and Diagnosis >> Transmission and Drivetrain >> Transfer Case >> Service and Repair >> Overhaul >> Disassembly

Disassembly

DISASSEMBLY




MAJOR COMPONENTS

Important operations




6. Belleville spring
Remove the bearing retainer and the retainer gasket and belleville spring.




9. Transmission case
Remove the transfer case, the center support and the transmission case, then remove the transmission case and gasket.




10. Transfer case
Remove the transfer countershaft lock plate and the distance plate.

Main shaft gear assembly, cluster gear assembly and top gear shaft assembly.:




MINOR COMPONENT

Disassembly steps
1. Plate ; detent spring
2. Spring ; detent ball
3. Bail; detent, gear shift
4. Shaft ; arm, gear shift, reverse-5th *
5. Fork ; reverse-5th, shift
6. Shaft; gear shift low-2nd *
7. Shaft; gear shift, top-3rd *
8. Fork; top-3rd, shift
9. Fork; low-2nd, shift
10. Pin and plug inter lock
11. Nut; thrust input hub *
12. Thrust input hub
13. Thrust input gear
14. Collar; needle bearing
15. Collar thrust input gear
16. Ring ; snap
17. Ring ; snap adapter case
18. Bearing ; roller main shaft center
19. Bolt; oil guide
20. Oil guide
21. Adapter case
22. Ring ; snap, ball bearing
23. Ring ; snap, thrust ring
24. Retaining ring
25. Thrust ring ; 5th gear
26. Washer; thrust, 5th
27. Nut; self lock, counter
28. Washer ; plain, counter 5th gear
29. Bearing ; ball, counter end *
30. Gear; counter, 5th *
31. Gear assembly; 5th with synchronizer cone
32. Bearing ; needle, 5th
33. Ring ; block, 5th
34. Nut; main shaft *
35. Washer; lock, main shaft
36. Synchronizer assembly; reverse-5th
37. Gear; reverse, main shaft
38. Bearing; needle, low
39. Nut; self lock, counter
40. Washer; thrust, reverse idle, rear
41. Gear ; reverse idle, with bushing
42. Washer; thrust, reverse idle, front
43. Plate ; intermediate
44. Ring ; snap, bearing to top shaft
45. Shaft; top gear, with synchronizer cone
46. Bearing ; ball, top gear shaft *
47. Bearing ; needle, main shaft
48. Ring; block, top-3rd
49. Ring ; snap, main shaft
50. Synchronizer assembly; top-3rd
51. Ring ; block, top-3rd
52. Gear assembly; 3rd with synchronizer cone
53. Bearing ; needle, 2nd, 3rd
54. Gear assembly; low-2nd *
55. Washer; thrust, low
56. Bearing ; radial ball, main shaft *
57. Collar; needle bearing, low
58. Washer; thrust, low
59. Gear assembly; low, with synchronizer cone
60. Bearing ; needle, low
61. Collar; needle bearing, low
62. Ring ; block, low-2nd
63. Synchronizer assembly ; low-2nd
64. Ring ; block, low-2nd
65. Gear assembly ; 2nd with synchronizer cone
66. Bearing ; needle, 2nd, 3rd
67. Gear; counter reverse *
68. Bearing ; angular ball, cluster *
69. Gear; cluster
70. Ring ; snap, cluster gear
71. Bearing ; ball, counter front
72. Ring ; snap, antilash plate
73. Ring ; snap, main shaft
74. Shaft ; reverse idle

* Important Operations

Important operations

4. Shaft arm gear shift reverse - 5th

6. Shaft ; gear shift low - 2nd

7. Shaft gear shift top - 3rd




When removing the spring, hold a round bar against the end of the shift rod to prevent damage.




Carefully remove the reverse shifter rod forward to avoid losing the detent interlock pins.

NOTE: Remove the shifter rods carefully. Detent interlock pins are located between the shifter rods in the center support.




11. Nut; thrust input hub

Wrench : J-33441

29. Bearing ball, counter end




30. Gear ; counter, 5th

Remover : J-22888

34. Nut ; main shaft




1. Engage top/3rd synchronizer with the third gear and Low/2nd side synchronizer with the Low gear, then attach Tool J-29768 to the main shaft and the countergear.




2. This operation is necessary to prevent turning of the shaft when removing main shaft rear and countershaft reverse gear lock nut

Wrench : J-33441




46. Bearing ; ball, top gear shaft
Use a bench press

Remover : J-22912-01




54. Gear assembly ; low-2nd
Remove the parts (47 through 58) from the main shaft together using special tool.

Remover : J-22912-01




56. Bearing : radial ball, main shaft
Use a bench press.

Remover : J-22912-01

67. Gear ; counter reverse




68. Bearing ; angular ball, cluster
Use a bench press for removal

Remover : J-22912-01

Transfer Case:




MINOR COMPONENTS

Important operations




3. Transfer counter shaft assembly
Lightly tap the transfer countershaft assembly out through the shaft fitting hole in the case.

4. O-ring
From the transfer countershaft, remove the O-ring, thrust washer, countergear, needle roller bearings, and thrust washer.




13. Output shaft assembly
Expand the rear output shaft front bearing snap ring and remove the output shaft assembly forward.

14. Nut

Nut hex 41 mm (1-5/8 in.)




15. Ball bearing
Use a bench press.

Remover : J-22912-01




19. Ball bearing
Use a bench press.

Remover : J-22912-01

Transfer Side Case:




MINOR COMPONENTS

Important operations

4, 6. Shift rods




Remove the spring pin from the shift arm.




Drive the shift rod toward the output side.




9. Idler gear shaft
Force out the shaft by turning in the 8 mm (P.1.25 mm) bolt in the threaded hole at end of the idler shaft, then remove the thrust washers, idler gear and needle roller bearing.




13. Front output shaft cover
Remove the front output shaft cover, then remove the distance




15. Front output shaft
Set J-8614-01 or equivalent, to the flanged portion of the front output shaft and loosen and remove the shaft nut spring washer and plain washer.

17. Front output shaft front bearing




18. Front Output shaft rear bearing

Remover and installer : J-29040
Grip : J-8092

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