Isuzu Trooper (1998-2002 year). Manual - part 188

4D2–15

TRANSFER CASE (TOD)

4. Apply a thin coat of grease to the seal ring of each

front and rear speed sensor, and mount the sensors
carefully.

5. Tighten the bolts to the specified torque.

Torque : 5 N·m (0.5 kg·m/43 lb in)

NOTE: Pay  attention not to mount the front (or rear)
sensor to the rear (or front) sensor position.

6. Install the ball bearing (1) for the front output shaft as

flat as shown in the figure.

261RW008

7. Mount the coil assembly and tighten the nuts to the

specified torque.

Torque : 10 N·m (1.0 kg·m/87 lb in)

8. Connect the terminal in the central connector.

NOTE: Be careful not to damage other terminals.

9. Install speed gear and tone wheel.

10. Mount the ball bearing (2) as flat as shown in the

figure.

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11. Using snap ring pliers, install the snap ring to the

transfer cover assembly.

NOTE: Securely install the snap ring to the groove of the
transfer cover assembly.

4D2–16 TRANSFER CASE (TOD)

Transfer Case Assembly Clutch Pack and Clutch Cam

Disassembled View

266RW006

Legend

(1) Clutch Pack Assembly
(2) Insulator Washer
(3) Armature Plate
(4) Snap Ring

(5) Wave Spring
(6) Cam Pulley
(7) Cam Ball
(8) Cam and Coil Housing
(9) Thrust Bearing

Disassembly

1. Remove the thrust bearing.
2. Remove the cam and coil housing.

NOTE: When the cam and coil housing is removed, the
cam balls may be detached together with the housing.  Be
careful not to lose the ball.

3. Remove the cam ball.

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4D2–17

TRANSFER CASE (TOD)

4. Remove the cam pulley.
5. Remove the wave spring.
6. Using snap ring pliers, remove the snap ring.

NOTE: Be careful not to damage the snap ring.

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7. Remove the armature plate.
8. Remove the insulator washer.
9. Remove the clutch pack assembly as a package.

266RW017

4D2–18 TRANSFER CASE (TOD)

Sprocket and Mechanical Lock

Disassembled View

266RW008

Legend

(1) Strainer
(2) Hose
(3) Oil Pump Assembly
(4) Thrust Washer
(5) Mechanical Lock Hub
(6) Lock-up Sleeve

(7) Lock-up Fork
(8) Chain
(9) Lower Driven Sprocket

(10) Front Tone Wheel

(11) Drive Sprocket

(12) Sprocket Spacer

Disassembly

1. Remove the sprocket spacer.
2. Remove the front tone wheel.