Unit Repair

Note: Isuzu manuals address both the Automatic and Manual transmission transfer case procedure in the same repair section. Where there is a distinction between Automatic and Manual transmissions concerning transfer case it is noted in the article or image.






DISASSEMBLY


1. Speedometer driven gear




2. Front companion flange

Note: Use the companion flange holder to remove the companion flange. Companion flange holder: J-37221

3. Companion flange
4. Transfer case assembly (A/T only)
5. Transfer rear case
6. Transfer case


REASSEMBLY

6. Transfer case
5. Transfer rear case






Note: Apply recommended liquid gasket or its equivalent to the transfer rear case fitting. Perform the following steps before fitting the transfer rear case:

(1) Shift the High-Low synchronizer to the 4H side.







(2) Turn the select rod counterclockwise so that the select block projection A may enter into the 2WD-4WD shift block. When the rear case is fitted under the condition (2), the direction of the cut-away portion of select rod head B aligns with that of the rear case hole's stopper C.

Tighten the rear transfer case bolts to the specified torque.

Torque: 37 (27) N.m (lb.ft.)

4. Transfer case assembly (A/T only)
3. Companion flange





2. Front companion flange

Note: Use the flange holder to tighten the flange nuts to the transfer case. Flange Holder: J-37221

Tighten the transfer flange nuts to the specified torque:

Front companion flange: 137 (101) N.m(lbft)
Rear companion flange: 177 (130) N.m (lbft)

1. Speedometer driven gear