Isuzu N-Series. Manual - part 860

MANUAL TRANSMISSION 7B-101

Transfer (MYY Rigid Type)

Disassembly

Caution:
Make sure to shift the gear to 4H before disassembling
the front & rear transfer case.

1. Securely raise the caulking parts of the lock nut of

the coupling driver.

2. Fix the rear coupling driver using the flange holder

5-8840-2043-0, and remove the lock nut.

3. Fix the front coupling driver using the flange holder

5-8840-0133-0, and remove the lock nut.

• The rear coupling driver is shown in the figure

below.

4. Remove the 2WD/4WD change warning lamp

switch.

5. Remove the breather.

6. Remove the speed sensor driven gear.

7. Remove the low / high change lever.

8. Remove the control cable bracket.
9. Remove the detent ball and detent spring.

• Two  parts

N7A0445E

N7A0446E

Legend

1. Insertion key
2. Vehicle speed sensor
3. Plate
4. Bush
5. O-ring
6. Driven gear

Legend

1. Spring pin
2. Select external lever
3. Select internal lever

1

5

4

2

3

6

1

5

4

2

3

6

1

5

4

2

3

6

N7A0290E

N7A0448E

7B-102 MANUAL TRANSMISSION

10. Remove the transfer rear case.

• Remove the 18 bolts.

11. Remove the low / high change shift arm and the

shift lock.

• Drive out the spring pin, and then remove the

shift arm and the shift rod.

12. Remove the 2WD / 4WD change shift arm and shift

rod.

• Loosen the shift arm fixing bolt, and remove the

shift arm and the shift rod.

13. Remove the speedometer driven gear and the

thrust washer.

N7A0449E

N7A0450E

N7A0451E

N7A0452E

MANUAL TRANSMISSION 7B-103

14. Remove the idle gear shaft from the transfer case.

15. Remove the rear output gear shaft from the trans-

fer case.

16. Remove the input gear shaft from the transfer

case.

17. Remove the front output gear shaft from the trans-

fer case.

N7A0453E

N7A0454E

N7A0455E

N7A0456E

7B-104 MANUAL TRANSMISSION

18. Remove the front & rear bearing from the idle shaft.

• Remove the front bearing using a general-pur-

pose bearing remover.

• Remove the rear bearing using the insert

303173 and the collet 44801 from among the
parts of the bearing remover 5-8840-2587-0.

19. Disassemble the front output gear shaft.

• Before removing the ball bearing, put a mark

which indicates the installation direction.

• Remove the front & rear bearing using a gener-

al-purpose bearing remover.

• After removing the ball bearing, remove the col-

lar, thrust washer, front output drive gear and
needle bearing.

20. Disassemble the input gear shaft.

• Remove the front & rear bearing using a gener-

al-purpose bearing remover.

• After removing the front bearing, remove the

thrust washer, transfer high gear, needle bear-
ing and sleeve.

• After removing the rear bearing, remove the

thrust washer, transfer low gear and needle
bearing.

21. Remove the front & rear bearing from the rear out-

put gear shaft.

• Remove using the bearing remover 5-8840-

2587-0.

• Remove using the insert 303173 and the collet

44801 from among the parts of the bearing re-
mover.

N7A0457E

N7A0458E

N7A0459E

N7A0460E