Isuzu Trooper (2000 year). Manual - part 147

4D2–30 TRANSFER CASE (TOD)

Transfer Case

Disassembled View

265RW002

Legend

(1) Transfer Case
(2) Ball Bearing
(3) Ring Gear
(4) Snap Ring
(5) Input Shaft and Carrier Assembly
(6) Snap Ring

(7) Ball Bearing
(8) Spring Ring
(9) Thrust Plate

(10) Carrier Assembly

(11) Snap Ring

(12) Circular Hub

Reassembly

1. Remove the oil seal from the transfer case.
2. Apply the circumference of the new oil seal and fill the

lip with grease (Besco L2 or equivalent).

4D2–31

TRANSFER CASE (TOD)

3. Using the front output shaft oil seal installer J-42807,

attach the oil seal to the transfer case.

261RW014

4. Using the input shaft (main) J-42808 oil seal installer,

attach the oil seal to the transfer case.

261RW012

5. Using the special tool J-42809, press-fit the ring gear.

Pay attention to the following points.

D

Identify the correct direction of gear.

D

Do not damage the gear.

D

Do not press-fit the ring gear slantingly.

D

Press-fit the ring gear to the innermost.

D

Remove burrs generated by press-fitting.

D

If the transfer case has serrations, match them with
those of the gear and press-fit the gear.

261RW013

261RW034

6. Install snap ring.
7. Install circular hub.
8. Attach the snap ring to the carrier.

4D2–32 TRANSFER CASE (TOD)

9. Mount the carrier assembly to the transfer case.

10. Check the direction of thrust plate and mount it to the

input shaft.

265RW008

11. Mount the ball bearing to the input shaft so that the

snap ring will be attached to the input shaft.

265RW003

12. Attach the snap ring to the input shaft.
13. Attach the snap ring to the transfer case.

14. Using the snap ring pliers, open the snap ring from the

gap on the input shaft and carrier assembly and
securely attach the part.

261RW038

15. Install ball bearing (for front output shaft)

4D2–33

TRANSFER CASE (TOD)

Output Shafts and Shift Control Shaft

Disassembled View

261RW010

Legend

(1) Transfer Case Assembly
(2) Detent Spring
(3) Front Output Shaft
(4) Reduction Hub
(5) Output Shaft
(6) Lock-up Roll Assembly
(7) Spring Pin
(8) Spring Pin
(9) Reduction Fork

(10) Cam Assembly

(11) Snap Ring

(12) Washer
(13) Cam
(14) Cam Pilot Block
(15) Shifter Shaft Assembly
(16) Shifter Lever Shaft
(17) Snap Ring
(18) Reduction Lever Assembly
(19) Snap Ring

Reassembly

1. Apply ATF to the inside of the ball bearing.