Isuzu Trooper (2000 year). Service manual - part 132

TRANSFER CASE (STANDARD TYPE)

4D1–5

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8. Connect the rear propeller shaft to the transfer case

and tighten to the specified torque.

Torque: 63 N·m 46 (lb ft)

Transfer Case Assembly

Removal

NOTE: Before removing transmission & transfer
assembly from vehicle, change the transfer mode to 2WD
by pushing button switch on dash panel.

1. Disconnect the battery ground cable.
2. Drain the transfer case fluid.
3. Remove transfer protector.
4. Remove rear propeller shaft.
5. Remove the rear and front propeller shaft from the

transfer case side.

6. Disconnect the four oxygen sensor connectors from

the transmission harness.

7. Remove the right and left catalytic converter

assemblies and exhaust pipe.

8. Remove the transfer control lever knob.
9. Remove the selector lever assembly. Refer to

Selector Lever in the Section 7A.

10. Remove transfer control lever.

11. Disconnect the 4WD switch and speed sensor

harness connector and 2WD–4WD actuator harness
connector from the transmission harness.

12. Remove transmission–transfer bolt and support the

transfer case with a transmission jack.

13. Remove four transmission–transfer bolts and the

three nuts.

14. Remove the transfer case assembly from the vehicle.

Installation

To install, follow the removal steps in the reverse order,
noting the following points:

1. Install transfer case assembly and apply a thin coat of

molybdenum disulfide grease to the input shaft
spline.

4D1–6

TRANSFER CASE (STANDARD TYPE)

2. Tighten the transmission–transfer bolt to the

specified torque.

Torque: 46 N·m (34 lb ft)

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3. Tighten the exhaust pipe to exhaust manifold bolt to

the specified torque.

Torque: 67 N·m (49 lb ft)

4. Tighten the exhaust pipe flange bolt to the specified

torque.

Torque: 43 N·m (32 lb ft)

5. Tighten the propeller shaft bolt to the specified torque.

Torque: 63 N·m (46 lb ft)

6. Tighten the transfer protector bolt to the specified

torque.

Torque: 37 N·m (27 lb ft)

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TRANSFER CASE (STANDARD TYPE)

4D1–7

Transfer Rear Case Assembly

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 front companion flange.
5. Remove rear companion flange, use the flange

companion holder J–8614–11 to remove the end nut.

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6. Remove the front and rear companion flange.

NOTE: Use the universal puller to remove the rear
companion flange.

7. Remove control box assembly.
8. Disconnect the actuator breather hose from the

2WD–4WD actuator assembly.

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9. Remove the 2WD–4WD actuator assembly bolts.

10. Pull the 2WD–4WD actuator assembly with

2WD–4WD shift rod.

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Legend

(1) Shift Rod: 2WD–4WD (Position: 2WD)
(2) 2WD–4WD Actuator Assembly
(3) Pull
(4) Rear Case Assembly
(5) Position: 4WD
(6) Mode: 2WD

4D1–8

TRANSFER CASE (STANDARD TYPE)

11. Off set the actuator assembly.

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12. Remove the actuator assembly.

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Legend

(7) Position: 4WD
(8) Mode: 2WD

13. Remove transfer case assembly.
14. Remove transfer rear case assembly.

Installation

1. Install transfer rear case assembly.

2. Install transfer case assembly and apply the

recommended liquid gasket (LOCTITE 17430) or its
equivalent to the transfer rear case fitting faces.

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3. Perform the following steps before fitting the transfer

rear case:
1. Shift the high–low shift to the 4H side.

2. Turn the select rod counterclockwise so that the

select block projection A 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 (27 lb ft)

5. Shift the 2WD–4WD shift rod (11) to the 4WD side.