1995 ISUZU TROOPER Workshop Manual

Fig. 70-42
9. Needle bearing
10. Bearing collar (Fig. 70-43)
11. Ball
12. Plate
Fig. 70-43
13. Ball bearing (AIT)
li0\1 • Use a bench press and the ball bearing
I.S!il remover to remove the ball bearing (Fig. 70-
44).
Bearing remover: J-22912-01
(AfT)
J-22912·01
Fig. 70-44
TRANSFER CASE 70-19
14. Input shaft (AIT)
15. Bearing snap ring
16.
Front output gear assembly
• Use a pair of snap ring pliers to expand the
bearing snap ring.
• Use a plastic hammer to tap the front output
gear assembly free (Fig. 70-45).
Fig. 70-45
17. Bearing snap ring
18.
Ball bearing
19. Bearing
collar
20. Sub-gear snap ring (MIT)
21. Spacer (MIT)
22. Belleville spring (MIT)
23. Sub-gear (MIT)
24. Front output gear
25. Needle bearing
li0\1 • Use a bench press and the bearing remover to
I.S!il remove the parts above (Fig. 70-46).
Bearing remover: J-22912-01
Fig.
70-46
26. Clutch sleeve and hub
• Use a bench press to remove the clutch sleeve
and hub (Fig.
70-47).

70-20 TRANSFER CASE
Fig. 70-47
27. Ball bearing
• Use the bearing remover to remove the ball
bearing (Fig. 70-48).
Bearing remover: J-22912-01
Fig. 70-48
28. Front output shaft
29. Bearing snap ring
30. Counter gear
assembly
• Remove the counter gear assembly from the
transfer case.
31. Snap ring
• Use a pair of snap ring pliers to remove the
snap ring.
32. Ball bearing
j®_j• Use a bench press and the bearing remover to
remove the ball bearing.
Bearing remover: J-22912-01
33. Snap ring
• Use a pair of snap ring pliers to remove the
snap ring.
34. Ball bearing
~ • Use a bench press and the bearing remover to
remove the
ball bearing (fig. 70-49). Bearing
remover: J-22912-01
Fig. 70-49
35. Spacer
36.
Bellevilfe spring
37. Sub-gear
38. Counter gear
39. Transfer case
(with oil seal)
• Cover the shaft splines with adhesive tape CD.
This will prevent damage to the oil seal lip ®
(MIT) (Fig. 70-49a).
• Remove the transfer case together with
intermediate plate with gear assembly from the ~
transmission case (MIT).
• Remove the transfer case from the inter­
mediate plate
with gear assembly (MIT).
IM/TI
Fig. 70-49a
IL•I INSPECTION AND REPAIR
Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
Wash
all parts thoroughly in clean solvent. Be sure all
old
lubricant, metallic particles, dirt, or foreign material
are removed from the surfaces
of every part. Apply
compressed
air to each oil feed port and channel in
each case
half to remove any obstructions or cleaning
solvent residue.
•

GEARS
• Inspect all gear teeth for signs of excessive wear
'--" or damage and check all gear splines for burrs,
nicks,
wear or damage. Remove minor nicks or
scratches on an oil stone. Replace any part
exhibiting excessive wear or damage.
GEAR INSIDE DIAMETER (Fig. 7D-50}
• Use an inside dial indicator to measure the gear
inside diameter.
• If the measured value exceeds the specified limit,
the gear
must be replaced.
Gear inside diameter
mm (in)
Standard
48.000 -48.013 (1.8898 -1.8903)
Limit 48.1 0 (1.894)
Fig.
70-50
CLUTCH HUB SPLINE PLAY (Fig. 7D-51)
• Set a dial indicator to the clutch hub to the
measured.
• Move the clutch hub as far as possible to both the
right and the left.
Note the dial indicator reading.
• If the measured value exceeds the specified limit,
the clutch hub
must be replaced.
Clutch hub spline play
mm (in)
Standard
0 -0.1 (0 -0.004)
Limit 0.2 (0.008)
TRANSFER CASE 7D-21
I I
Fig. 70-51
BEARINGS
• Inspect the condition of all needles, and ball
bearings. Wash bearings thoroughly in a cleaning
solvent.
Apply compressed air to bearings.
W NOTE:
Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage
the
rollers.
Lubricate bearings with a light oil and check them
for roughness by slowly turning the race by hand.
BALL BEARING PLAY (Fig. 7D-52}
• Use a dial indicator to measure the ball bearing
play.
• If the measured value exceeds the specified limit,
the
ball bearing must be replaced.
Limit
mm (in) I 0.2 (0.008)
Fig. 70-52
SYNCHRONIZERS (MIT)
The synchronizer hubs and sliding sleeves are a
selected assembly and should be kept together
as
originally assembled.
Clean synchronizer components
with clean solvent
and air dry.

7D-22 TRANSFER CASE
Inspect the components for the following:
• Teeth for wear, scuffs, nicks, burrs or breaks.
• Keys and springs for wear, cracks or distortion,
replace
if these conditions are present.
• If scuffed, 'nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth,
replace the component.
BLOCK RING AND INSERT CLEARANCE (Fig.
7D-53)
• Use a vernier caliper to measure the clearance
between the block ring and the insert.
• If the measured value exceeds the specified limit,
the block ring and the insert
must be replaced.
Block ring and insert clearance
mm (in)
Standard
4.34-4.66 (0.171 - 0.183)
Limit 4.9 (0.193)
Fig. 7D-53
BLOCK RING AND DOG TEETH CLEARANCE
(Fig. 7D-54)
• Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
• If the measured value exceeds the specified limit,
the block ring
must be replaced. Fig.
7D-54
CLUTCH HUB AND INSERT CLEARANCE (Fig.
7D-55)
• Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
• If the measured value exceeds the specified limit,
the
clutch hub and the insert must be replaced.
Clutch hub and insert clearance
mm (in)
Standard 0.09 -
0.31 (0.0035 -0.0122)
Limit 0.4 (0.0157)
Block ring and dog teeth clearance
mm (in) Fig. 7D-55 ------~~--~------------------~ Standard 1.5 (0.059)
Limit 0.8
(0.031) DETENT SPRINGS
• Inspect the springs for distortion, cracks or wear.
Replace
if these conditions are present.
DETENT SPRING FREE LENGTH (Fig. 7D-56)
• Use a vernier caliper to measure the detent spring
free length.
• If the measured value is less than the specified
limit, the detent spring
must be replaced.
Detent spring free length
mm (in)
Standard Limit
Detent ball 25.6
(1.008) 25.0 (0.984)
Interlock pin 1.59 (0.063) 1.53
(0.060)
•