Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Service manual — part 1161
TRANSFER CASE
4D–13
11. Off set the actuator assembly.
220RW028
12. Remove the actuator assembly (6).
220RW066
EndOFCallout
13. Remove transfer rear cover assembly (7) from
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 transfer rear cover assembly (7) to transfer
case assembly (8).
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
(15) should align with that of the rear case hole's
stopper (16).
230RW009
Legend
(13) Position: 4WD
(14) Mode: 2WD
4D–14
TRANSFER CASE
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 (17) to the 4WD side.
6. Join the rod grooves of 2WD–4WD actuator
assembly (6) and shift rod (17).
220RW067
EndOFCallout
7. Push the 2WD–4WD actuator assembly (6) with
2WD–4WD shift rod (17) till the shift rod (17)
reaches the 2WD position.
220RW068
EndOFCallout
8. Tighten the 2WD–4WD actuator bolts to the
specified torque.
Torque: 19 N·m (14 lb ft)
9. Connect the actuator breather hose to actuator.
10. Install actuator heat protector (5).
11. Install control box assembly (4).
Torque: 19 N·m (14 lb ft)
12. Connect breather hoses to control box (4).
13. Install rear companion flange (3) and front
companion flange (2), using the companion flange
holder J–8614–11 to tighten the flange nuts to the
transfer case.
262RW009
14. Tighten the new transfer flange nuts to the specified
torque.
Torque
Rear companion flange: 167 N·m (123 lb ft)
Front companion flange: 137 N·m (101 lb ft)
Legend
(6) 2WD–4WD Actuator Assembly (Mode: 2WD)
(7) Rear Cover Assembly
(17) Shift Rod: 2WD–4WD (Position: 4WD)
Legend
(18) Position: 2WD
(19) Mode: 2WD
TRANSFER CASE
4D–15
15. Use the punch J–39209 to stake the rear
companion flange nut (3) at two spots.
266RS001
266RW002
16. Stake the front companion flange nut (2) at one
spot.
NOTE: Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.
17. Install the O–ring (23) to the speedometer driven
gear bushing (22).
18. Install the driven gear to the speedometer driven
gear bushing (22).
19. Install the speedometer driven gear assembly to the
transfer rear cover.
20. Install the plate (21) to the transfer rear case and
tighten to the specified torque.
Torque: 15 N·m (11 lb ft)
21. Install the speedometer sensor and tighten to the
specified torque.
Torque: 27 N·m (20 lb ft)
225RW004
EndOFCallout
Legend
(20) Bolt
(21) Plate
(22) Bushing
(23) O–ring
4D–16
TRANSFER CASE
Transfer Rear Cover Assembly
226RW154
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Disassembly
1. Remove bearing snap ring, use a pair of snap ring
pliers to remove the snap ring (3).
226RS060
Legend
(1) Rear Output Shaft Assembly
(2) Rear Output Shaft
(3) Bearing Snap Ring
(4) Ball Bearing
(5) Bearing Snap Ring
(6) Ball
(7) Speedometer Drive Gear
(8) Ball Bearing
(9) Transfer Rear Cover (with oil seal)
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