1995 ISUZU TROOPER Workshop Manual

TRANSFER CASE 70-3
ON-VEHICLE SERVICE
TRANSFER CASE (A/T)
5
<;J---5 6
7
' 8
9
~
10
Removal steps Installation steps
1. Exhaust and transfer protectors 6. Selector lever
assembly To
install, follow the removal
steps in the reverse order.
2. Rear propeller shaft 7.
Transfer control lever
3. Front propeller shaft 8.
Wiring harness connector
4. Exhaust pipe 9. Transmission-transfer bolt
5. Engine control module
(ECM)
cover and front console 10.
Transfer case assembly
Fig. 7D-2
l••l REMOVAL
Preparation:
• Disconnect battery negative (-) cable.
•
Drain transfer case fluid.
1. Exhaust and transfer protectors
2. Rear propeller shaft
3. Front propeller shaft
• Remove the rear and front propeller shaft from
the transfer case side.
4. Exhaust pipe
• Remove the pre-catalytic converter.
• Remove the center exhaust pipe.
• Disconnect oxygen sensor connector from the
transmission harness.
5. ECM cover and front console
• Remove the transfer control lever knob.
• Disconnect the harness connectors.
6. Selector lever assembly
• Disconnect the shift lock cable from the
selector lever assembly side (Fig. 7D-3).
• Disconnect the harness connectors.
• Disconnect the shift control rod from the
selector lever assembly side (Fig. 7D-4).

70-4 TRANSFER CASE
Fig. 70-3
Fig. 70-4
7. Transfer control lever
8. Wiring harness connector
• Disconnect the 4WD switch and speed sensor
harness connector from the transmission
harness.
9. Transmission-transfer bolt
• Support the transfer case with a transmission
jack.
• Remove four transmission-transfer bolts and
three nuts.
10. Transfer case assembly
• Remove the transfer case assembly from the
vehicle.
1••1 INSTALLATION
To install, follow the removal steps in the reverse ~
order, noting the following points:
1. Transfer case assembly
r;:;J • Apply a thin coat of molybdenum disulfide
D grease to the input shaft spline (Fig. 70-5).
Fig. 70-5
• Transmission-transfer bolt (Fig. 70-6)
1~1 Torque N·m (lb·ft)
2. Exhaust pipe bolt
1~1 Torque
Center pipe front side
Pre-catalytic converter bolt
3. Propeller shaft bolt
1~1 Torque N·m (lb·ft)
46 (34)
N·m (lb·ft)
43 (32)
43 (32)
63 (46)
•

46/34
30
T/F Case
T/M case

+/F Case
T/M Case
TRANSFER REAR OIL SEAL
Removal steps
1. Rear propeller shaft
2. End nut and rear companion
flange
3.
Oil seal
Fig. 70-6
Fig. 70-7
1
TRANSFER CASE 70-5
1~1 Torque: N·m /lb·ft
Length: mm
50
15 28
15 20
T/M Cas! I
T/F Case
50
28 15
T/M Ca~e I
T/F case
2
0 ,""o
Installation steps
To install, follow the removal
steps in the reverse order.

70-6 TRANSFER CASE
EJ REMOVAL
1. Rear propeller shaft
• Disconnect the rear propeller shaft from the
transfer case side.
2. End nut and rear companion flange.
li5\l • Use the companion flange holder to remove
~ the end nut (Fig. 70-8).
Companion flange holder: J-37221
• Use the universal puller to remove the rear
companion flange and 0-ring.
Fig. 70-8
3. Oil seal
•
Remove the oil seal from the transfer case.
1••1 INSTALLATION
To install, follow the removal steps in the reverse
order, noting the
following points:
3. Oil seal
l hl • Apply recommended grease (BESCO L2) or
D equivalent to the oil seal lip.
li5\l • Use the oil seal installer to install the rear seal to
~ the transfer rear case (Fig. 70-9).
Rear oil seal installer: J-39208
Fig. 70-9
2. Rear companion flange and end nut
• Install the rear companion flange and 0-ring.
l<9l..l• Use the flange holder to install the end nut.
Companion flange holder:
J-37221
1~1 Torque N·m (lb·ft) I 167 (123)
~·
Use the punch to stake the end nut at two spots
(Fig.
70-10 & Fig. 70-11).
Punch: J-39209
m Note: Be sure to confirm that there is no crack at
VI the staked portion of the end nut after staking.
Fig. 70-10
•

TRANSFER CASE 70-7
mm(in)
MAX. 1.5 (0.06)
MAX. 1.5 (0.06)
MIN. 4 (0.16)
MIN. 4 (0.16)
Fig. 70-11
1. Rear propeller shaft
• Connect the rear propeller shaft to the transfer
case.
l~l Torque N·m (lb·ft) 63 (46)

70-8 TRANSFER CASE
UNIT REPAIR
TRANSFER CASE ASSEMBLY (A/T)
1
A/T
3
5
Disassembly steps Reassembly
steps
1. Speedometer sensor and
speedometer driven gear 4. Control box assembly To reassemble,
follow the disassembly steps in the
reverse order.
5.
Transfer case assembly
2. Front companion flange 6. Transfer rear case assembly
3. Rear companion flange
Fig. 70-12
j .. ! .. j DISASSEMBLY
1. Speedometer sensor and speedometer driven
gear
• Remove the speedometer sensor.
• Remove the plate.
•
Remove the speedometer driven gear bushing
and driven gear.
W NOTE: Apply a reference mark to the driven gear
bushing before
removal.
2. Front companion flange
3. Rear companion flange
li5\l • Use the flange holder to remove the end nut
~ (Fig. 7D-13).
Flange companion holder: J-37221
• Remove the front and rear companion flange.
\flNOTE:
'if Use the universal puller to remove the rear
companion
flange.
•