1998 ISUZU TROOPER 4WD

TRANSFER CASE (STANDARD TYPE)
4D1±13
10. Offset the actuator assembly.
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11. Remove the actuator assembly.
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Legend
(7) Position: 4WD
(8) Mode: 2WD
12. Remove the transfer rear cover assembly from the
transfer case assembly.
Installation
1. Apply the recommended liquid gasket (LOCTITE
17430) or its equivalent to the transfer rear cover
fitting faces.
220RS017
2. Install the transfer rear cover assembly to the transfer
case assembly.
3. Perform the following steps before fitting the transfer
rear case:
1. Shift the high±low shift rod to the 4H side.
2. The cut±away portion of the select rod head (9)
should align with that of the rear case hole's
stopper (10).
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4. Tighten the transfer rear case bolts to the specified
torque.
Torque: 37 N´m (3.8kg´m/27 lb ft)
5. Shift the 2WD±4WD shift rod (11) to the 4WD side.

4D1±14
TRANSFER CASE (STANDARD TYPE)
6. Join the rod grooves of 2WD±4WD actuator
assembly (12) and shift rod (11).
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Legend
(11) Shift Rod: 2WD±4WD (Position: 4WD)
(12) 2WD±4WD Actuator Assembly (Mode: 2WD)
(13) Rear Cover Assembly
7. Push the 2WD±4WD actuator assembly (12) with
2WD±4WD shift rod (11) till the shift rod (11) reaches
the 2WD position.
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Legend
(14) Position: 2WD
(15) Mode: 2WD
8. Tighten the 2WD±4WD actuator bolts to the specified
torque.
Torque: 19 N´m (1.9kg´m/14 lb ft)
9. Install the actuator heat protector.
10. Connect the actuator breather hose to the actuator.11. Install the control box assembly.
Torque: 19 N´m (1.9kg´m/14 lb ft)
12. Connect the breather hoses to the control box.
13. Install the rear companion flange and front
companion flange, using the companion flange holder
5±8840±0133±0 (J±8614±11) to tighten the flange
nuts to the transfer case.
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14. Tighten the new transfer flange nuts to the specified
torque.
Torque
Rear companion flange: 167 N´m (17.0kg´m/123
lb ft)
Front companion flange: 137 N´m (14.0kg´m/101
lb ft)
15. Use the punch 5±8840±2293±0 (J±39209) to stake
the rear companion flange nut at two spots.
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TRANSFER CASE (STANDARD TYPE)
4D1±19
Transfer Rear Cover Assembly (Except 4WD Switch Model)
Transfer Rear Cover Assembly and Associated Parts
220RW116
Legend
(1) Speedometer Sensor, Speedometer Driven
Gear and Plate
(2) Front Companion Flange(3) Rear Companion Flange
(4) Control Box Assembly
(5) Transfer Rear Cover Assembly
(6) Transfer Case Assembly

4D1±20
TRANSFER CASE (STANDARD TYPE)
Removal
1. Remove the speedometer sensor.
2. Remove the plate.
3. Remove the speedometer driven gear bushing and
driven gear.
NOTE: Apply a reference mark to the driven gear bushing
before removal.
4. Remove the front companion flange and the rear
companion flange, using the flange companion holder
5±8840±0133±0 (J±8614±11) to remove the end
nuts.
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NOTE: U s e a u n i v e r s a l p u l l e r t o remove the rear
companion flange.
5. Disconnect the transfer breather hose from the
control box.
6. Remove the control box assembly.
7. Remove the transfer rear cover assembly from the
transfer case assembly.
Installation
1. Apply the recommended liquid gasket (LOCTITE
17430) or its equivalent to the transfer rear cover
fitting faces.
220RS017
2. Install the transfer rear cover assembly to the transfer
case assembly.
3. Perform the following steps before fitting the transfer
rear case:
1. Shift the high±low shift rod to the 4H side.
2. Turn the select rod counterclockwise so that the
select block projection may enter into the
2WD±4WD shift block.
3. The cut±away portion of the select rod head (9)
should align with that of the rear case hole's
stopper (10).
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4. Tighten the transfer rear case bolts to the specified
torque.
Torque: 37 N´m (3.8kg´m/27 lb ft)

4D1±26
TRANSFER CASE (STANDARD TYPE)
Detent, Shift Arm, and Interlock Pin
Disassembled View
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Legend
(1) Detent Ball, Spring and Plug
(2) Spring Pin and Bridge
(3) Spring Pin
(4) Spring
(5) 2WD±4WD Shift Rod
(6) Shift Arm
(7) Shift Block
(8) 4WD Indicator Switch(9) Interlock Pin
(10) Spring
(11) Select Rod Assembly
(12) Spring Pin
(13) High±Low Shift Rod
(14) Shift Arm
(15) Shift Block
(16) Transfer Case
(17) Spring (Except Shift On The Fly Model)
Disassembly
1. Remove the detent ball, spring and plug (1).

TRANSFER CASE (STANDARD TYPE)
4D1±27
2. Use a spring pin remover to remove the spring pin (2)
from the bridge (2).
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3. Remove the spring (4).
4. Engage the 2WD±4WD sleeve with the front output
gear. Remove the spring pin (3) from the block (7).
Remove the 2WD±4WD shift rod (5).
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5. Remove the shift arm (6).
6. Remove the shift block (7).
7. Remove the 4WD indicator switch (8).8. Use a magnetic tool to remove the interlock pin (9)
and spring (10) from the transfer case (16).
262RS005
9. Remove the select rod assembly (11).
10. Use a spring pin remover to remove the shift arm
spring pins (12) from the shift arm (14) and shift block
(15). Remove the high±low shift rod (13) from the
transfer case (16).
262RS006
11. Remove the shift arm (14).
12. Remove the shift block (15) from the transfer case
(16).

4D1±28
TRANSFER CASE (STANDARD TYPE)
Inspection and Repair
Refer to ªTRANSFER CASE ASSEMBLYº in this section
for inspection and repair.
Reassembly
1. Place the shift block (15) in the transfer case (16).
2. Set the shift arm (14) on the High±Low sleeve.
3. Push the High±Low shift rod (13) through the shift
arm (14) and block (14).
4. Engage the High±Low sleeve with the 4H (1) side.
5. Install the spring pins (12) to the shift block (15) and
shift arm (14).
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6. Install the select rod assembly (11), joining its lever to
the shift block groove.
7. Engage the High±Low sleeve with the 4H side and
install the the interlock pin (9) and spring (10) in the
proper direction.
8. Place the 2WD±4WD shift block (7) in the transfer
case (16).
9. Set the 2WD±4WD shift arm (6) on the 2WD±4WD
sleeve.
10. Push the 2WD±4WD shift rod (5) through the
2WD±4WD shift arm (6) and 2WD±4WD shift block
(7).
11. Install the 2WD±4WD shift rod (5) with the interlock
pin pushed in.
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Legend
(18) 2WD±4WD
(19) 4H Side
(20) Interlock pin
(21) 2WD
(22) 4WD
(23) Rod: 2±4
(24) Rod: H±L
(25) 4H
(26) 4L
(27) 4y2
(28) 4y4
12. Install the 4WD indicator switch and gasket (8).
Tighten to the specified torque.
Torque: 39 N´m (4.0kg´m/29 lb ft)
13. Install the spring (4).

TRANSFER CASE (STANDARD TYPE)
4D1±29
14. Engage the 2WD±4WD sleeve with the 4WD side and
install the spring pin (3).
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15. Install the spring pin and bridge (2).
16. Install the detent ball, spring and plug and tighten the
plug (1) to the specified torque.
Torque: 25 N´m (2.5kg´m/18 lb ft)