Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 659

TRANSFER CASE (STANDARD TYPE)

4D1–11

6. Join the rod grooves of 2WD–4WD actuator

assembly (12) and shift rod (11).

220RW030

Legend

(11) Shift Rod: 2WD–4WD (Position: 4WD)

(12) 2WD–4WD Actuator Assembly (Mode: 2WD)
(13) Rear Case Assembly

7. Push the 2WD–4WD actuator assembly (12) with

2WD–4WD shift rod (11) till the shift rod (11) reaches
the 2WD position.

220RW031

Legend

(14) Position: 2WD
(15) Mode: 2WD

8. Tighten the 2WD–4WD actuator bolts to the specified

torque.

Torque: 19 N·m (14 lb ft)

9. Connect the actuator breather hose to actuator.

10. Install control box assembly.

Torque: 19 N·m (14 lb ft)

11. Install rear companion flange.

12. Install front companion flange, use the companion

flange holder J–8614–11 to tighten the flange nuts to
the transfer case.

262RW009

13. Tighten the new transfer flange nuts to the specified

torque.

Torque
Rear companion flange: 167 N·m (123 lb ft)
Front companion flange: 137 N·m (101 lb ft)

4D1–12 TRANSFER CASE (STANDARD TYPE)

14. Use the punch J–39209 to stake the rear companion

flange nut at two spots.

266RS001

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15. Stake the front companion flange nut at one spot.

NOTE: Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.

16. Install the O–ring (8) to the speedometer driven gear

bushing (7).

17. Install the driven gear to the speedometer driven gear

bushing (7).

18. Install the speedometer driven gear assembly to the

transfer rear cover.

19. Install the plate (6) to the transfer rear case and

tighten to the specified torque.

Torque: 15 N·m (11 lb ft)

20. Install the speedometer sensor and tighten to the

specified torque.

Torque: 27 N·m (20 lb ft)

225RW005

TRANSFER CASE (STANDARD TYPE)

4D1–13

Disassembly

226RW131

Legend

(1) Rear Output Shaft Assembly
(2) Rear Output Shaft
(3) Bearing Snap Ring
(4) Ball Bearing

(5) Bearing Snap Ring
(6) Ball
(7) Speedometer Drive Gear
(8) Ball Bearing
(9) Transfer Rear Case (with oil seal)

1. Remove bearing snap ring, use a pair of snap ring

pliers to remove the snap ring.

226RS060

4D1–14 TRANSFER CASE (STANDARD TYPE)

2. Remove the rear output shaft assembly from the

transfer rear case.

3. Remove ball bearing, use a bench press and the

bearing remover J–22912–01 to remove the ball
bearing.

226RS061

4. Remove speedometer drive gear.
5. Remove ball.
6. Remove bearing snap ring, use a pair of snap ring

pliers to remove the snap ring.

7. Remove ball bearing.
8. Remove rear output shaft, use a bench press and the

bearing remover J–22912–01 to remove the ball
bearing.

226RS062

9. Remove transfer rear case (with oil seal).

Inspection and Repair

Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.

Reassembly

1. Install transfer rear case (with oil seal).

Oil seal replacement

D

Remove the oil seal from the transfer rear case.

D

Apply engine oil to the oil seal outer surfaces.

D

Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.

D

Use the oil seal installer to install J–39208 to the
rear oil seal to the transfer rear case.

220RS019

2. Install rear output shaft.
3. Install ball bearing, use the ball bearing installer

J–37223 and the adapter J–37486–A to install the ball
bearing.

262RW021

4. Install bearing snap ring.
5. Install ball.