Isuzu Trooper (2000 year). Manual - part 141

4D2–6

TRANSFER CASE (TOD)

2. Using the oil seal installer J-42804, attach the oil seal.

NOTE: When attaching the oil seal, pay attention to the
direction.

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3. Mount the rear companion flange, O-ring , washer,

and nuts to the transfer in this order.

4. Using the flange holder J-8614-11, set the end nut.

Torque : 167 N·m (123 lb ft)

5. Using the punch J-39209, stake the end nut at two

places.

NOTE: Check the staked end nut is free from cracks.

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6. Connect the rear propeller shaft to the transfer case

and tighten to the specified torque.

Torque : 63 N·m 46 (lb ft)

4D2–7

TRANSFER CASE (TOD)

TOD ECU

Removal

1. Disconnect the battery cable (-).
2. Move the passenger seat forward and remove the

second seat foot rest (1).

3. Unplug the connector from the ECU (2).
4. Remove the set bolts and detach the ECU (2) from

the bracket.

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Installation

1. Perform the removal step in reverse order.

4D2–8

TRANSFER CASE (TOD)

Unit Repair

Inspection

Before disassembling and after assembling, check the
following items on the transfer connector terminals.

No.

NAME

CONTENTS

1

Ref . (Ref . )

Rear speed sensor refer-
ence output

2

Ref . (Frt . )

Front speed sensor refer-
ence output

3

SW GND

SW GND

4

4H SW (+)

4H SW plus terminal

5

Rer . (+)

Rear speed sensor plus

6

Frt . (+)

Front speed sensor plus

7

POWER GND

Power GND

8

SOL (+)

Electromagnetic solenoid

9

COM (–) (Ref .)

Rear speed sensor GND

10

COM (–) (Frt .)

Front speed sensor GND

11

NC

12

4L SW (+)

4L SW plus terminal

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4H and 4L switches

Check whether the 4H switch (terminals 4 and 7) and 4L
switch (terminals 12 and 3 ) work as specified in the table
below.  If yes, the continuity is established on these
switches. If not, check the switches, shift rails, transfer
case, and rear cover, and replace the failed parts.

Position

High

Neutral

4L

4H SW

OFF

ON

OFF

4L SW

OFF

ON

ON

Power GND

Check that there is a continuity between the power GND
pin (terminal 7) and transfer case.  If not, replace the
grounding wire.

Resistance of electromagnetic coil

Check the resistance between electromagnetic clutch
solenoid (terminal 8) and power GND (terminal 7).  If not,
replace the electromagnetic coil.

Standard : 1.4 

∼

 2.0

W

Allowable : 1.0 

∼

 5.0

W

4D2–9

TRANSFER CASE (TOD)

Transfer Case

Disassembled View

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Legend

(1) Front Companion Flange
(2) 4H and 4L Switch, Grounding Cable, and

Center Connector

(3) Offset Lever

(4) Spring Pin
(5) Transfer Case Assembly
(6) Transfer Cover Assembly
(7) Rear Companion Flange

Disassembly

1. Remove the drain plug from the transfer case and

drain the oil.

2. Disconnect the 4H and 4L switch and grounding

cable.

3. Remove the clip fixing the harness.
4. Remove front companion flange and using the flange

holder J-8614-11, remove the flange nut.

5. Remove rear companion flange and using the flange

holder J-8614-11, remove the flange nut.

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