1998 ISUZU TROOPER Service Repair Manual

Page 753 of 3573

ISUZU TROOPER 1998  Service Repair Manual 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

Page 754 of 3573

ISUZU TROOPER 1998  Service Repair Manual 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)

Page 755 of 3573

ISUZU TROOPER 1998  Service Repair Manual 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.

Page 756 of 3573

ISUZU TROOPER 1998  Service Repair Manual 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

Page 757 of 3573

ISUZU TROOPER 1998  Service Repair Manual 4D1±36
TRANSFER CASE (STANDARD TYPE)
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Standard : 23.4 mm (0.921 in)

Page 758 of 3573

ISUZU TROOPER 1998  Service Repair Manual TRANSFER CASE (STANDARD TYPE)
4D1±37
Reassembly
1. Put the transfer case (with oil seal) as the following
illustration.
Input shaft oil seal (1) replacement
1. Remove the oil seal from the transfer c

Page 759 of 3573

ISUZU TROOPER 1998  Service Repair Manual 4D1±38
TRANSFER CASE (STANDARD TYPE)
3. Install the sub±gear (23) to the counter gear (22).
4. Install the belleville spring (24).
5. Install the spacer (25) and put the snap ring (29) on
the sub±g

Page 760 of 3573

ISUZU TROOPER 1998  Service Repair Manual 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 O