Isuzu Trooper (2000 year). Manual - part 131

TRANSFER CASE (STANDARD TYPE)

4D1–1

TROOPER

DRIVELINE/AXLE

TRANSFER CASE (STANDARD TYPE)

CONTENTS

Service Precaution

4D1–1

. . . . . . . . . . . . . . . . . . . . . . 

General Description

4D1–2

. . . . . . . . . . . . . . . . . . . . . 

Transfer Rear Oil Seal

4D1–4

. . . . . . . . . . . . . . . . . . . 

Removal

4D1–4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

4D1–4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Case Assembly

4D1–5

. . . . . . . . . . . . . . . . . 

Removal

4D1–5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

4D1–5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Rear Case Assembly

4D1–7

. . . . . . . . . . . . 

Removal

4D1–7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

4D1–8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Disassembly

4D1–11

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

4D1–12

. . . . . . . . . . . . . . . . . . 

Reassembly

4D1–12

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Detent, Shift Arm, and Interlock Pin
 (Transfer Case Assembly)

4D1–14

. . . . . . . . . . . . . . . 

Disassembled View

4D1–14

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D1–14

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

4D1–16

. . . . . . . . . . . . . . . . . . 

Reassembly

4D1–16

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Case Assembly

4D1–18

. . . . . . . . . . . . . . . . . 

Disassembled View

4D1–18

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D1–19

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

4D1–21

. . . . . . . . . . . . . . . . . . 

Reassembly

4D1–25

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Main Data and Specifications

4D1–31

. . . . . . . . . . . . . 

Special Tools

4D1–34

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

4D1–2

TRANSFER CASE (STANDARD TYPE)

General Description

M/T model

A07RW019

TRANSFER CASE (STANDARD TYPE)

4D1–3

A/T model

A07RW001

The transfer case is used to provide a means of providing
power flow to the front axle. The transfer case also
provides a means of disconnecting the front axle,
providing better fuel economy and quieter operation when
the vehicle is driven on improved roads where four wheel
drive is not required. In addition, the transfer case
provides an additional gear reduction when placed in low
range, which is useful when difficult off–road conditions
are encountered.
A floor mounted shift lever is used to select the operating
range. When four wheel drive has been selected, the four
wheel drive indicator light is designed to come on when
the front axle has been engaged.

4D1–4

TRANSFER CASE (STANDARD TYPE)

Transfer Rear Oil Seal

Removal

1. Disconnect the rear propeller shaft from the transfer

case side.

2. Remove end nut and rear companion flange, use the

companion flange holder J–8614–11 to remove the
end nut.

266RW001

3. Use the universal puller to remove the rear

companion flange and O–ring.

4. Remove the oil seal from the transfer case.

Installation

To install, follow the removal steps in the reverse order,
noting the following points:

1. Install oil seal and apply engine oil to the oil seal outer

surfaces.

2. Apply the recommended grease (BESCO L2) or

equivalent to the oil seal lip.

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

seal to the transfer rear case.

220RS016

4. Rear companion flange and end nut.
5. Install the rear companion flange and O–ring.
6. Use the companion flange holder J–37221 to install a

new end nut and tighten to the specified torque.

Torque: 167 N·m (123 lb ft)

7. Use the punch J–39209 to stake the end nut at two

spots.

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

266RS001