Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Service manual - part 665

TRANSFER CASE (STANDARD TYPE)

4D1–35

E07RW010

4D1–36 TRANSFER CASE (STANDARD TYPE)

Special Tools

ILLUSTRATION

PART NO.

PART NAME

J–22912–01

Bearing

remover/installer

J–38592

Transfer case oil seal

installer

J–37219

Mainshaft nut wrench

J–37223

Rear output shaft and

bearing installer

J–39209

Punch, end nut

J–38594

Front output shaft oil

seal installer

ILLUSTRATION

PART NO.

PART NAME

J–39208

Rear oil seal installer

J–37486–A

Bearing installer adapter

J–8614–11

Flange holder

J–37217

Mainshaft end bearing

remover

J–37487

Puller

J–8092

Driver handle

TRANSFER CASE (TOD)

4D2–1

TROOPER

DRIVELINE/AXLE

TRANSFER CASE (TOD)

CONTENTS

Service Precaution

4D2–1

. . . . . . . . . . . . . . . . . . . . . . 

Transfer Case Assembly

4D2–2

. . . . . . . . . . . . . . . . . 

Removal

4D2–2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

4D2–3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Rear Oil Seal

4D2–5

. . . . . . . . . . . . . . . . . . . 

Transfer Rear Oil Seal and Associated
 Parts

4D2–5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Removal

4D2–5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

4D2–5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

TOD ECU

4D2–7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Removal

4D2–7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Installation

4D2–7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Unit Repair

4D2–8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection

4D2–8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Case

4D2–9

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Disassembled View

4D2–9

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–9

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–10

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Cover Assembly

4D2–12

. . . . . . . . . . . . . . . . 

Disassembled View

4D2–12

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–12

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–14

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Case Assembly Clutch Pack and
 Clutch Cam

4D2–16

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 

Disassembled View

4D2–16

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–16

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Sprocket and Mechanical Lock

4D2–18

. . . . . . . . . . . . 

Disassembled View

4D2–18

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–18

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Output Shafts and Shift Control Shaft

4D2–20

. . . . . . 

Disassembled View

4D2–20

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–21

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Transfer Case

4D2–23

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Disassembled View

4D2–23

. . . . . . . . . . . . . . . . . . . . 

Disassembly

4D2–23

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Inspection and Repair

4D2–26

. . . . . . . . . . . . . . . . . . 

Transfer Case

4D2–30

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Disassembled View

4D2–30

. . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–30

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Output Shafts and Shift Control Shaft

4D2–34

. . . . . . 

Disassembled View

4D2–34

. . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–35

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Sprocket and Mechanical Lock

4D2–37

. . . . . . . . . . . . 

Disassembled View

4D2–37

. . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–37

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Clutch Pack and Clutch Cam

4D2–39

. . . . . . . . . . . . . 

Disassembled View

4D2–39

. . . . . . . . . . . . . . . . . . . . 

Reassembly

4D2–39

. . . . . . . . . . . . . . . . . . . . . . . . . . 

Main Data and Specifications

4D2–41

. . . . . . . . . . . . . 

Special Tools

4D2–43

. . . . . . . . . . . . . . . . . . . . . . . . . . . 

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.

SECTION

4D2–2 TRANSFER CASE (TOD)

Transfer Case Assembly

Removal

F07RW083

Legend

(1) Transfer Protector
(2) Rear Propeller Shaft
(3) Front Propeller Shaft
(4) Front Console
(5) Selector Lever Assembly
(6) Transfer Control Lever

(7) Breather Hose
(8) Exhaust Pipe
(9) Seat Belt Tension Rod

(10) Speed Sensor Harness Connector

(11) Transfer Harness Connector

(12) Transfer Case Bolt
(13) Transfer Case

1. Disconnect the ground cable (-).
2. Remove the transfer protector.
3. Remove the rear propeller shaft from the transfer

case.

4. Remove the front propeller shaft from the transfer

case.

5. Remove the shift control rod from the selector lever

assembly.