Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 666

TRANSFER CASE (TOD)

4D2–3

6. Disconnect the wiring harness, transfer control lever

knob, and shift lock cable and then remove the front
console.

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7. Remove the selector lever assembly and put it aside.
8. Remove the transfer control lever.
9. Disconnect the breather hose.

10. Remove the left exhaust pipe fixing bolts and nuts,

and put the exhaust pipe aside.

11. Remove the left seat belt tension rod and put the rear

proper shaft aside.

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12. Disconnect the transfer harness connector from the

top of the transfer case.

13. Disconnect the speed sensor harness connector.
14. Remove the fuel pipe clip fixing bolt on the transfer

case.

15. Support the transfer case with a jack.
16. Remove the seven bolts from the transfer case.
17. Remove the transfer case assembly.

Installation

To install, follow the removed steps in the reverse order,
noting the following points.

1. Apply a thin coat of grease (Besco L2) or equivalent to

the input shaft spline.

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2. Mount the transfer case.

4D2–4 TRANSFER CASE (TOD)

3. Tighten the transfer case bolts (see the figure below).

Torque : 46 N·m (34 lb ft)

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4. Tighten propeller shaft bolt.

Torque : 63 N·m (46 lb ft)

TRANSFER CASE (TOD)

4D2–5

Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts

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Legend

(1) Oil Seal
(2) End Nut and Rear Companion Flange

Removal

1. Remove the rear propeller shaft from the transfer

case.

2. Using the flange holder J-8614-11, remove the end

nut.

3. Using the universal puller, remove the rear

companion flange and O-ring.

4. Remove the oil seal from the transfer rear case.

Installation

1. Apply engine oil to the circumference of the oil seal.

Fill the oil seal lip with grease (Besco L2).

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Legend

(1) Inside
(2) Outside

4D2–6 TRANSFER CASE (TOD)

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

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

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Rear Output Shaft Oil Seal

Distance between the transfer case and oil seal.

NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it.
Distance : 9.85–10.35 mm (0.39–0.41 in)

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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, install a new end

nut.

Torque : 167 N·m (123 lb ft)

5. Stake the end nut at one place so that there is no gap

between a flat portion on the shaft and the nut staked
portion.

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

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6. Install the rear propeller shaft to the transfer case and

tighten to the specified torque.

Torque : 63 N·m 46 (lb ft)