1998 ISUZU TROOPER clutch

4C±34
DRIVE SHAFT SYSTEM
NOTE: Be careful not to damage seal.
6. Install snap ring (internal) in the groove of front axle
case.
NOTE: Be sure to install the snap ring properly.
412RW017
7. Apply differential gear oil to clutch gear, then install
clutch gear.
8. Apply differential gear oil to sleeve, then install
sleeve.
9. Clean contact surface with the front axle and actuator
mounting surface. Apply liquid gasket to the contact
surface on the front axle case, then install in the
housing.
412RW023
10. Tighten bolts to specified torque.
Torque: 116N´m (11.8 kg´m/85 lb ft)11. Clean the actuator contact surface with the housing
then Install and tighten shift position switch to
specified torque.
Torque: 39N´m (4.0 kg´m/29 lb ft)
12. Apply liquid gasket to the contact surface on the
actuator side.
412RW012
13. Align shift arm with the groove of sleeve and install the
actuator.
14. Tighten bolts to specified torque.
Torque: 13N´m (1.3 kg´m/113 lb in)
15. Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified torque.
Torque: 116N´m (11.8 kg´m/85 lb ft)
16. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity: 1.4lit (1.23 Imp qt/1.48 US qt)
Actuator Housing
Oil Capacity: 0.12lit (0.10 Imp qt/0.13 US qt)
17. Install filler plug through gasket and tighten to
specified torque.
Torque: 78N´m (58lb ft)

4D1±30
TRANSFER CASE (STANDARD TYPE)
Transfer Case Assembly
Disassembled View
226RW132
Legend
(1) Transfer Case (with oil seal)
(2) Bearing Snap Ring
(3) Front Output Gear Assembly
(4) Ball Bearing
(5) Front Output Shaft
(6) Stopper Plate (Shift On The Fly model)
(7) 2WD±4WD Clutch Hub and Sleeve Assembly
(8) Block Ring (Shift On The Fly model)
(9) Outside Ring (Shift On The Fly model)
(10) Inside Ring (Shift On The Fly model)
(11) Front Output Gear
(12) Needle Bearing
(13) Sub±Gear (anti±lash plate) (M/T)
(14) Belleville Spring (M/T)
(15) Spacer (M/T)
(16) Sub±Gear Snap Ring (M/T)
(17) Bearing Collar
(18) Ball Bearing
(19) Bearing Snap Ring
(20) Snap Ring
(21) Ball Bearing(22) Counter Gear
(23) Sub±Gear (anti±lash plate)
(24) Belleville Spring
(25) Spacer
(26) Ball Bearing
(27) Snap Ring
(28) Counter Gear Assembly
(29) Bearing Snap Ring
(30) Input Shaft Assembly
(31) Input Shaft
(32) Ball Bearing
(33) Snap Ring
(34) Plate
(35) Ball
(36) Bearing Collar
(37) Needle Bearing
(38) Transfer Input Gear
(39) High±Low Clutch Hub and Sleeve Assembly
(40) Lock Nut
(41) Ball Bearing
(42) Bearing Snap Ring

TRANSFER CASE (STANDARD TYPE)
4D1±31
Disassembly
1. Use a pair of snap ring pliers to remove the snap ring
(42).
2. Use a bearing remover 5±8840±2155±0 ( J±37217)
and puller 5±8840±2027±0 (J±37487) to remove the
ball bearing (41).
262RW069
3. Install the front companion flange temporarily.
4. Use the Companion flange holder 5±8840±0133±0
(J±8614±11) and lock nut wrench 5±8840±2156±0
(J±37219) to remove the lock nut (40).
226RW189
5. Remove the front companion flange.
6. Remove the snap ring (33) from the transfer case (1).
7. Remove the input shaft assembly (30) from the
transfer case.
265RW001
8. Use a universal puller to remove the high±low clutch
hub and sleeve (39), and transfer input gear (38).
226RS070
9. Remove needle bearing (37).

4D1±32
TRANSFER CASE (STANDARD TYPE)
10. Remove the bearing collar (36).
226RS071
11. Remove the ball (35).
12. Remove the plate (34).
13. Use a bench press and the ball bearing remover
5±8840±0015±0 (J±22912±01) to remove the ball
bearing (32) from input shaft (31).
265RW013
14. Remove the bearing snap ring (2) from the transfer
case, using a pair of snap ring pliers.15. Use a plastic hammer to tap the front output gear
assembly (3) free.
262RS009
16. Remove the bearing snap ring (19). Remove the ball
bearing (18) and bearing collar (17) together with
front output gear assembly: including following parts.
17. Use a bench press and the bearing remover
5±8840±0015±0 (J±22912±01) to remove the
following parts.
18. Remove the sub±gear snap ring (16), spacer (15),
belleville spring (14), and sub±gear (anti±lash plate)
(13).(M/T)
19. Remove the front output gear (11) and needle bearing
(12).
262RW070
20. Remove the inside ring (10). (Shift On The Fly model)
21. Remove the outside ring (9). (Shift On The Fly model)
22. Remove the block ring (8). (Shift On The Fly model)
23. Use a bench press and bearing remover
5±8840±0015±0 (J±22912±01) to remove the
2WD±4WD clutch hub and sleeve assembly (7) and
stopper plate (6). (Shift On The Fly model)

TRANSFER CASE (STANDARD TYPE)
4D1±33
NOTE: Do not reuse the stopper plate. (Shift On The Fly
model)
24. Disassemble the 2WD±4WD clutch hub and sleeve
assembly.

Springs (1) (Shift On The Fly model)

Inserts (2) (Shift On The Fly model)

Clutch Hub (3)

Sleeve (4)
226RW133
25. Use a bench press and the ball bearing remover
5±8840±0015±0 (J±22912±01) to remove the ball
bearing (4) from front output shaft (5).
262RW071
26. Remove bearing snap ring (29) from transfer case.
27. Remove the counter gear assembly (28) from the
transfer case (1).
28. Use a pair of snap ring pliers to remove the snap ring
(20).29. Use a bench press and the bearing remover
5±8840±0015±0 (J±22912±01) to remove the ball
bearing (21).
30. Use a pair of snap ring pliers to remove the snap ring
(27).
31. Use a bench press and the bearing remover
5±8840±0015±0 (J±22912±01) to remove the ball
bearing (26).
226RW191
32. Remove the spacer (25).
33. Remove the belleville spring (24).
34. Remove the sub±gear (anti±lash plate) (23) from the
counter gear (22).
Inspection and Repair
1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. 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
1. Inspect all the gear teeth for signs of excessive wear
or damage and check all the gear splines for burrs,
nicks, wear or damage. Remove the minor nicks or
scratches on an oil stone. Replace any part exhibiting
excessive wear or damage.
Front Output Gear Inside Diameter
1. Use an inside dial indicator to measure the gear inside
diameter.

4D1±34
TRANSFER CASE (STANDARD TYPE)
2. If the measured value exceeds the specified limit, the
gear must be replaced.
Gear inside diameter
Standard : 48.000±48.013 mm (1.8898±1.8903 in)
Limit : 48.10 mm (1.894 in)
226RS040
Clutch Hub Spline Play
1. Set a dial indicator to the clutch hub to measured.
2. Move the clutch hub as far as possible to both the right
and the left.
Note the dial indicator reading.
3. If the measured value exceeds the specified limit, the
clutch hub must be replaced.
Clutch hub spline play
Standard : 0±0.1 mm (0±0.004 in)
Limit : 0.2 mm (0.008 in)
226RS042
Bearings
1. Inspect the condition of all the needles and ball
bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.
Ball Bearing Play
1. Use a dial indicator to measure the ball bearing play.
2. If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)
226RS043
Synchronizers
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.
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
1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
2. If the measured value exceeds the specified limit, the
block ring and the insert must be replaced.
Block ring and insert clearance
Standard : 2.46±2.74 mm (0.097±0.108 in)

TRANSFER CASE (STANDARD TYPE)
4D1±35
Limit : 3.0 mm (0.118 in)
226RS037
2WD±4WD 3±Cone Synchronizer (Shift On
The Fly model)
1. Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
2. If the measured value exceeds the specified limit, the
2WD±4WD synchronizer assembly must be
replaced.
Block ring and insert clearance
Standard : 1.5 mm (0.059 in)
Limit : 0.8 mm (0.031 in)
226RW142
Clutch Hub and Insert Clearance
1. Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
2. If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard : 0.01±0.19 mm (0.0004±0.0075 in)
Limit : 0.3 mm (0.012 in)
226RS038
Detent Springs
1. Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.
Detent Spring Free Length
1. Use a vernier caliper to measure the detent spring
free length.

TRANSFER CASE (STANDARD TYPE)
4D1±39
14. Assemble the 2WD±4WD clutch hub and sleeve
assembly (7).
226RW140
15. Engage the springs in the same insert with the open
ends away from each other. (Shift On The Fly model)
226RW141
16. Place the snap ring (2), a new stopper plate (6) (Shift
On The Fly model) and the clutch sleeve and hub
assembly (7) on the front output shaft (5).
226RW135
Legend
(6) Front Output Gear
17. The clutch hub face (with the heavy boss) must be
facing the front output gear side.
18. Use a bench press to slowly force the clutch hub and
sleeve assembly (7) together with the stopper plate
(6) (Shift On The Fly model) into place.
19. Align the inserts with the block ring insert grooves.
Install the block ring (8) (Shift On The Fly model) to
the clutch sleeve and hub assembly (7).
20. Install the outside ring (9) (Shift On The Fly model),
inside ring (10) (Shift On The Fly model) and needle
bearing (12) to the front output gear (11) and bearing
collar (17).
NOTE: C o a t a l l p a r t s w i t h t r a n s mission oil before
installing them.
226RW139