Unit Repair

NOTE: Isuzu manuals utilize an integrated Manual Transmission Manual Transmission/Transaxle and Transfer Case assembly. For Unit repair refer to Manual Transmission and also Transfer Case Assembly Transfer Case. The latter section also incorporates Automatic and Manual transfer case overhaul procedures and notes where procedure is different from Manual to Automatic models.




TRANSFER CASE ASSEMBLY (A/T)






DISASSEMBLY

1. Speedometer sensor and speedometer driven gear
- Remove the speedometer sensor.
- Remove the plate.
- Remove the speedometer driven gear bushing and driven gear.


Note: Apply a reference mark to the driven gear bushing before removal.

2. Front companion flange




3. Rear companion flange

Note: Use the flange holder to remove the end nut

Flange companion holder: J-37221

- Remove the front and rear companion flange.

Note: Use the universal puller to remove the front and rear companion flanges.

4. Control box assembly
5. Transfer case assembly
6. Transfer rear case assembly


REASSEMBLY

6. Transfer rear case assembly
5. Transfer case assembly




Note: Apply recommended liquid gasket (LOCTITE 17430) or its equivalent to the transfer rear case fitting faces.

Perform the following steps before fitting the transfer rear case.

- (1) Shift the high-Low shift 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





- (3) When the rear case is fitted under the condition (2), the direction of the cut-away portion of the select rod head OR aligns with that of the rear case hole's stopper

- Tighten the transfer rear case bolts to the specified torque.

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

4. Control box assembly
Torque: 20 (14) N.m (lb.ft)


3. Rear companion flange
2. Front companion flange
- Install the companion flange




- Use the flange holder to tighten the flange nuts to the transfer case

- Companion flange holder: J-37221

- Tighten the transfer flange nuts to the specified torque.

Torque:

Rear companion flange 167 (123) N.m (lb.ft)
Front companion flange 137 (101) N.m (lb.ft)








Note: Use the punch to stake the rear companion flange nut at two spots. Stake the front companion flange nut at one spot. Be sure to confirm that there is no crack at the staked portion of the flange nut after staking.

Punch: J-39209





1. Speedometer driven gear and speedometer sensor.
- Install the 0-ring to the speedometer driven gear bushing.
- Install the driven gear to the speedometer driven gear bushing.
- Install the speedometer driven gear assembly to the transfer rear cover
- Install the plate to the transfer rear case.

Torque: 15 (11) Nm (lbft)

- Install speedometer sensor

Torque: 27 (20) N.m (lbft)