Transfer Case
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. Block ring (M/T)
2. Bearing snap ring
Note: Use a pair of snap ring pliers to remove the snap ring
3. Rear output shaft assembly
Note: Remove the rear output shaft assembly from the transfer rear case.
4. Ball bearing
Note: Use a bench press and the bearing remover to remove the bail bearing
Bearing remover: J-22912-O1
5. Speedometer drive gear
6. Ball
7. Collar
8. Bearing snap ring
Note: Use a pair of snap ring pliers to remove the snap ring.
9. Ball bearing
10. Rear output shaft
Note: Use a bench press and the bearing remover to remove the ball bearing
Bearing remover: J-22912-01
11. Transfer rear case (with oil seal)
REASSEMBLY
11. Transfer rear case (with oil seal) Oil seal replacement
- Remove the oil seal from the transfer rear case.
- Apply engine oil to the oil seal outer surfaces.
- Fill in recommended grease (BESCO L2) or equivalent in the oil seal lip.
- Use the oil seal installer to install the rear oil seal to the transfer rear case
Oil seal installer: J-39208
10. Rear output shaft
9. Ball bearing
Note: Use the ball bearing installer and the adapter to install the ball bearing
Ball bearing installer: J-37223
Adapter: J-374B6
8. Bearing snap ring
7. Collar
6. Ball
5. Speedometer drive gear
4. Ball bearing
Note: Use the ball bearing installer to install the ball bearing
Ball bearing installer: J-37223
3. Rear output shaft assembly
Note: Install the rear output shaft assembly to the transfer rear case.
2. Bearing snap ring
Note: The snap ring must be fully inserted into the transfer rear case snap ring groove.
1. Block ring (M/T)
DETENT, SHIFT ARM and INTERLOCK PIN
DISASSEMBLY
1. Detent ball, spring and plug
2. Spring pin and bridge
Note:Use a spring pin remover to remove the spring pin from the bridge
3. Spring pin
4. Spring
5. 2WD-4WD shift rod
Note: Engage the 2WD-4WD sleeve with front output gear. Remove the spring pin from the block. Remove the shift rod
6. Shift arm
7. Shift block
8. 4WD indicator switch
9. Interlock pin
10. Spring
Note: Use a magnetic tool to remove the interlock pin from the transfer case
11. Select rod assembly
12. Spring pin
13. High-low shift rod
Note: Use a spring pin remover to remove the shift arm spring pins from the shift arm and shift block. Remove the high-low shift rod
14. Shift arm
15. Shift block
16. Transfer case
REASSEMBLY
16. Transfer case
15. Shift block
14. Shift arm
13. High-low shift rod
12. Spring pin
- Engage the High-Low sleeve with 4H side.
- Install the spring pin to the shift block and shift arm
11. Select rod assembly
10. Spring
9. Interlock pin
Note: Engage the High-Low sleeve with 4H side and install the interlock pin # 1 in proper direction. Install the shift rod: 2WD-4WD with interlock pin pushed in
8. 4WD indicator switch
Torque: 39 (29) N.m (lbft)
7. Shift block
6. Shift arm
5. 2WD-4WD shift rod
4. Spring
3. Spring pin
Note: Engage the 2WD-4WD sleeve with the 4WD side and install the spring pin
2. Spring pin and bridge
1. Detent ball, spring and plug
- Tighten the plug to the specified torque.
Torque: 25 (18) N.m (lbft)
TRANSFER CASE ASSEMBLY
DISASSEMBLY
1. Bearing snap ring
- Use a pair of snap ring pliers to remove the snap ring.
2. Ball bearing
- Use a bearing remover to remove the bail bearing
Bearing remover: J-37217 Puller: J-8433
3. Lock nut
- Install the front companion flange temporarily.
- Use the flange holder and lock nut wrench to remove the lock nut.
Companion flange holder: J-37221 Lock nut wrench: J-37219
- Remove the front companion flange.
4. Snap ring (A/T)
5. Input shaft assembly (A/T)
- Remove the input shaft assembly from the transfer case
6. High-low sleeve and hub (A/T) or High-low synchronizer assembly (M/T)
7. High-low block ring (M/T)
8. Transfer input gear
- Use the universal puller to remove the high-low sleeve and hub (A/T) or High-low synchronizer assembly (M/T), High-low block ring (M/T), and transfer input gear
9. Needle hearing
10. Bearing collar
11. Ball
12. Plate
13. Ball bearing (A/T)
Note: Use a bench press and the ball bearing remover to remove the ball bearing
Bearing remover: J-22912-O1
14. Input shaft (A/T)
15. Bearing snap ring
16. Front output gear assembly
Note: Use a pair of snap ring pliers to expand the bearing snap ring.
Note: Use a plastic hammer to tap the front output gear assembly free
17. Bearing snap ring
18. Ball bearing
19. Bearing collar
20. Sub-gear snap ring (M/T)
21. Spacer (M/T)
22. Belleville spring (M/T)
23. Sub-gear (M/T)
24. Front output gear
25. Needle bearing
Note: Use a bench press and the bearing remover to remove the parts above (steps 18 - 25)
26. Clutch sleeve and hub
Note: Use a bench press to remove the clutch sleeve and hub
27. Ball bearing
Note: Use the bearing remover to remove the ball bearing
Bearing remover: J-22912-01
28. Front output shaft
29. Bearing snap ring
30. Counter gear assembly
Note: Remove the counter gear assembly from the transfer case.
31. Snap ring
Note: Use a pair of snap ring pliers to remove the snap ring.
32. Ball bearing
Note: Use a bench press and the bearing remover to remove the ball bearing.
Bearing remover: J-22912-O1
33. Snap ring
Note: Use a pair of snap ring pliers to remove the snap ring.
34. Ball bearing
Note: Use a bench press and the bearing remover to remove the ball bearing
35. Spacer
36. Belleville spring
37. Sub-gear
38. Counter gear
39. Transfer case (with oil seal)
Note: Cover the shaft splines with adhesive tape 01. This will prevent damage to the oil seal lip 02 (M/T)
REASSEMBLY
39. Transfer case (with oil seal)
- Oil seal replacement
- Input shaft oil seal:
- Remove the oil seal from the transfer case.
- Apply engine oil to the oil seal outer surfaces.
- Apply recommended grease (BESCO L2) or equivalent to the oil seal lip.
- Use the oil seal installer to install the oil seal to the transfer case
Front output shaft oil seal:
- Remove the oil seal from the transfer case.
- Apply engine oil to the oil seal outer surfaces.
- Apply recommended grease (BESCO L2) or equivalent to the oil seal lip.
- Use the oil seal installer to install the oil seal to the transfer case
- Cover the shaft splines with adhesive tape 01. This will prevent damage to the oil seal lip 02 (M/T)
- Apply recommended liquid gasket (LOCTITE 17430) or its equivalent to the transfer case fitting surfaces (M/T). Tighten the transfer case bolts to the specified torque a little at a time (M/T).
Torque: 37 (27) N.m (lbft)
38. Counter gear
37. Sub-gear
Note: Apply chassis grease to the sub-gear and the counter gear thrust surfaces
36. Belleville spring
35. Spacer
34. Ball bearing
33. Snap ring
Select a snap ring that will allow the minimum axial play
Clearance 0 - 0.1(0 - 0.004) mm (in)
- Use a pair of snap ring pliers to install the snap ring to the counter gear.
Sub Gear Preload
- Hook a length of piano wire over one of the sub- gear teeth.
- Attach the other end of the piano wire to a spring balancer.
- Measure the sub-gear preload.
Preload 59-98 (13-22) N (lb)
32. Ball bearing
31. Snap ring
30. Counter gear assembly
- Install the counter gear assembly to the transfer case.
29. Bearing snap ring
- Use a pair of snap ring pliers to install the snap ring to the transfer case.
- The snap ring must be fully inserted into the transfer case snap ring groove.
28. Front output shaft
27. Ball bearing
- Use a bench press to install the ball bearing to the front output shaft .
26. Clutch hub and sleeve
- Use a bench press to install the clutch hub to the front output shaft
25. Needle bearing
24. Front output gear
23. Sub-gear (M/T)
22. Belleville spring (M/T)
21. Spacer (M/T)
- Apply engine oil to the thrust surfaces of the sub-gear, the Belleville spring, and the spacer
20. Sub-gear snap ring (M/T)
19. Bearing collar
- Use a bench press to install the needle bearing collar together with the front output gear
18. Ball bearing
17. Bearing snap ring
- Select a snap ring that will allow the minimum axial play
Clearance 0 0.1(0 - 0.004) mm (in)
- Use a pair of snap ring pliers to install the snap ring to the output shaft.
Sub gear preload (M/T)
- Hook a length of piano wire over one of the sub- gear teeth.
- Attach the other end of the piano wire to a spring balancer.
- Measure the sub-gear preload.
Preload 59 - 98 (13 - 22) N (lb)
16. Front output gear assembly
15. Bearing snap ring
- Use a pair of snap ring pliers to install the snap ring to the transfer case.
Note: The snap ring must be fully inserted into the transfer case snap ring groove.
14. Input shaft (A/T)
13. Ball bearing (A/T)
- Use a bench press to install the ball bearing to the input shaft
12. Plate
11. Ball
10. Bearing collar
9. Needle bearing
8. Transfer input gear
7. High-low block ring (M/T)
6. High-low sleeve & hub (A/T). High-low synchronizer assembly (M/T)
- The clutch hub face (with the heavy boss) must be facing the transfer input gear side
- The clutch hub groove must be aligned with the key groove of sleeve (M/T)
5. Input shaft assembly (A/T)
4. Snap ring (A/T)
- Install the snap ring to the input shaft.
- Install the input shaft assembly to the transfer case.
- Install the snap ring to the transfer case.
- The snap ring must be fully inserted into the transfer case snap ring groove.
3. Lock nut
- Install the front companion flange temporarily.
- Use the flange holder and lock nut wrench to install the lock nut
Companion flange holder: J-37221
Lock nut wrench: J-37219
Torque: 137 (101) N.m (lbft)
- Use the punch to stake the lock nut at one spots.
2. Ball bearing
- Use a suitable drift and hammer to install the ball bearing
1. Bearing snap ring