1995 ISUZU TROOPER Workshop Manual

20. Sub-gear snap ring (MIT)
19. Bearing collar
• Use a bench press to install the needle bearing
collar together with the front output gear (Fig.
70-71).
Fig. 70-71
18. Ball bearing
17. Bearing snap ring
rfil • Select a snap ring that will allow the minimum
~ axial play (Fig. 70-72 & Fig. 70-73).
Clearance mm (in) 0 -0.1 (0 -0.004)
Snap ring availability mm (in)
Snap ring thickness Color coding
1.55 (0.061)
White
1.60 (0.063)
Yellow
1.65 (0.065) Blue
1. 70 (0.067)
Pink
1.75 (0.069)
Green
1.80 (0.071)
Brown
1.85 (0.073)
Red
1.90 (0.075) Orange
•
Use a pair of snap ring pliers to install the snap
ring
to the output shaft.
TRANSFER CASE 70-27
Fig. 70-72
Fig. 70-73
Sub gear preload MIT (Fig. 70-74)
~·
Hook a length of piano wire over one ofthe sub­
gear teeth.
• Attach the other end of the piano wire to a
spring
balancer.
•
Measure the sub-gear preload.
Preload
N (lb) I 59 -98 (13 -22)
Fig. 70-74

70-28 TRANSFER CASE
16. Front output gear assembly
15. Bearing snap ring
• Use a pair of snap ring pliers to install the snap
ring to the transfer case.
U7NOTE:
VI The snap ring must be fully inserted into the
transfer case snap ring groove.
14. Input shaft (A/T)
13.
Ball bearing (A/T)
• Use a bench press to install the ball bearing to
the
input shaft (Fig. 70-75).
(A/TI
12. Plate
11. Ball
10.
Bearing collar
9. Needle bearing
Fig. 70-75
8. Transfer input gear
7. High-low block ring (MIT)
6. High-low sleeve & hub (A/T) or High-low
synchronizer assembly (MIT)
r=l • The clutch hub face (with the heavy boss) must
1=.1 be facing the transfer input gear side (Fig. 70-
76).
• The clutch hub groove® must be aligned with
the key groove
of sleeve (M/T) (Fig. 70-77).
Transfer input
gear side
Fig. 70-76 Fig.
70-77
5. Input shaft assembly (AIT)
4. Snap ring (A/T)
• Install the snap ring to the input shaft.
• Install the input shaft assembly to the transfer
case.
• lnstal1l the snap ring to the transfer case.
U7 NOTE:
VI The snap ring must be fully inserted into the
transfer case snap ring groove.
3. Lock nut
• Install the front companion flange temporarily.
1®..1• Use the flange holder and lock nut wrench to
install the lock nut (Fig. 70-78)
Companion
flange holder: J-37221
Lock nut wrench: J-37219
1~1 Torque N·m (lb·ft) 137 (101)
2.
• Use the punch to stake the lock nut at one
spots
..
Fig. 70-78
Ball bearing
• Use a suitable drift and hammer to install the
ball bHaring (Fig. 70-79).
•

TRANSFER CASE 70-29
1. Bearing snap ring
Fig. 70-79
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Type Constant mesh type gears shifting between the 2 and 4
wheel drive mode.
Synchronized type gear
(M/T only) between "low" and
"high".
Control method Direct control with the gear shift lever on the floor.
Gear ratio
High; 1.000
Low; 2.283
Oil capacity lit. (U.S. quart) 1.45 (1.53)
Type of lubricant Engine oil
Refer to chart in Section
0

70-30 TRANSFER CASE
TORQUE SPECIFICATIONS
TRANSFER CASE (A/T)
~
-1 J2_ -"
'
~'~
~
r;;;;·
I 43 (32) I
N·m (lb·ft)
~"
1-
~----------------------------------------------------------~ Fig. 70-80
•

TRANSFER CASE 70~31
TORQUE SPECIFICATIONS N·m (lb·ft)
Fig. 70-81

70-32 TRANSFER CASE
SPECIAL TOOLS
ILLUSTRATION TOOL NO.
TOOL NAME ILLUSTRATION TOOL NO.
TOOL NAME
!l!l
J-22912-01
Bearing remover/installer
~
J-37221
--~ Transfer flange holder
~
J-38592
Transfer case
oil seal
installer
(A/T) ~
J-37217 Mainshaft end bearing
remover
y
J-37219
Mainshaft nut wrench
~
J-8433
Puller 1
~
J-37223
Rear
output shaft end ..... bearing installer ===-
J-8092
-Driver handle
~
J-37488
Transfer case
oil seal
installer
(MIT)
~
J-39209
Punch, end nut
~
J-38594
Front
output shaft oil
seal installer
~
J-39208
Rear oil seal installer
~
J-37486
Bearing
installer adapter
•

CHASSIS ELECTRICAL 8-1
·SECTION 8
CHASSIS ELECTRICAL
'\f CAUTION: .
When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct
part number fastener is not
available, a fastener of equal size and strength (or stronger) may be used.
Fasteners that are not reused, and those requiring thread
locking compound, will be called out. The correct
torque
values must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.
CONTENTS
General Information .................................... 8-2
Notes for Working on Electrical
Items .................................................... 8-2
Symbols and Abbreviations ................. 8-8
Symbols ............................................ 8-8
Abbreviations ................................... 8-9
Parts for Electrical Circuit ..................... 8-10
Wiring ............................................... 8-10
Fuse .................................................. 8-11
Fusible Link ....................................... 8-12
Circuit Breaker ................................... 8-12
Relay ................................................. 8-12
Relay Specifications and
Configurations ................................ 8-13
Diode ................................................. 8-14
Connector ......................................... 8-15
Reading the Circuit Diagram ................ 8-17
Main Data and Specifications .................... 8-19
Bulb Specifications ................................ 8-19
Fuse,
Fusible Link and
Circuit Breaker Location ..................... 8-21
Fuse
Block Circuit .................................. 8-22
Reference Table of Fuse, Fusible
Link and Circuit Breaker ..................... 8-23
Relay Location ....................................... 8-27
Diode Location .......................................
8-28
Grounding Point .................................... 8-29
Reference Table ................................ 8-29
Location ............................................ 8-31
Cable Harness Routing .......................... 8-34
System Repair .............................................. 8-38
Start and Charging ................................ 8-38
Engine Control Module
(ECM) ................................................... 8-47
Headlight and Fog Light ........................ 8-58
Front Side Marker Light, Parking Light,
Taillight, License Plate Light and
Illumination Light .............................. 8-76
Stoplight and Rear Defogger .............. 8-92
Turn Signal Light, Hazard
Warning
Light, Cornering Light,
Backup
Light and Horn ..................... 8-106
Dome Light, Luggage room Light,
Courtesy Light, Map Light,
Seat Belt Switch and
Warning Buzzer ................................. 8-128
Power Door Lock ................................. 8-142
Power
Window .................................... 8-156
Cruise
Control ...................................... 8-172
Anti-Lock Brake
System (ABS) ........... 8-178
Rear
Wheel Anti-Lock Brake
System (RWAL) ................................. 8-185
Transmission
Control Module
(TCM) ................................................. 8-192
A/T Shift Lock ...................................... 8-200
Windshield
Wiper/Washer and
Rear
Wiper/Washer .......................... 8-205
Headlight wiper /washer ..................... 8-232
Audio, Auto Antenna,
Cigarette
Lighter and digital clock ... 8-246
Power Door Mirror ............................... 8-254
Anti-theft System ................................ 8-270
Meter and Warning/Indicator Light ... 8-288
A/T Shift Indicator ............................... 8-336
Heater and
Air Conditioning ............... 8-340
Sun
Roof ............................................... 8-346
Power Seat ........................................... 8-360
Seat
Heater .......................................... 8-37 4
Supplemental Restraint
System (SRS) -AIR BAG ................... 8-382