Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Service manual — part 1165
TRANSFER CASE
4D–29
Detent Springs
1. Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.
Detent Spring Free Length
1. Use a vernier caliper to measure the detent spring
free length.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Standard :
Inner 23.2 mm (0.91 in)
Outer 26.8 mm (1.06 in)
Limit :
Inner 22.6 mm (0.84 in)
Outer 26.2 mm (1.03 in)
Interlock pin
Standard : 15.9 mm (0.626 in)
Limit : 15.3 mm (0.602 in)
220RW035
Detent Spring Tension
1. Use a spring tester to measure the detent spring
tension.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent ball
Compressed height : 19.7 mm (0.776 in)
Standard :
Inner 22.6–32.4 N (5.1–7.3 lb)
Outer 91.2–101.0 N (20.5–22.7 lb)
Interlock pin
Compressed height : 11.5 mm (0.453 in)
Standard : 9.8 N (2.2 lb)
220RS013
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring.
Replace if these conditions are present.
Shift Arm Thickness
1. Use a micrometer to measure the shift arm
thickness.
2. If the measured value is less than the specified limit,
the shift arm must be replaced.
Shift arm thickness
Standard : 9.60–9.85 mm (0.378–0.388 in)
Limit : 9.0 mm (0.354 in)
230RS006
4D–30
TRANSFER CASE
Reassembly
Input Shaft Oil Seal Replacement
1. Remove the oil seal from the transfer case.
2. Apply the engine oil to the oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer J–38592 (A/T) J–37488 (M/
T) and driver handle J–8092 to install the oil seal to
the transfer case.
A/T
220RX002
EndOFCallout
M/T
220RW052
EndOFCallout
Legend
(47) Oil Seal
Legend
(48) Transmission Side Oil Seal
(49) Transfer Side Oil Seal
TRANSFER CASE
4D–31
Front Output Shaft Oil Seal Replacement
1. Remove the oil seal from the transfer case.
2. Apply engine oil to the oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer J–38594 to install the oil
seal to the transfer case.
220RW070
EndOFCallout
1. Install the transfer case (with oil seal) (42),
performing the following steps. (M/T)
• Cover the shaft splines with adhesive tape (43).
This will prevent damage to the oil seal lip (44).
A07RW022
EndOFCallout
• Apply recommended liquid gasket (LOCTITE
FMD 127) or its equivalent to the transmission,
intermediate plate and transfer case fitting
surfaces (M/T).
220RS026
Legend
(50) Front Output Shaft Oil Seal
Legend
(43) Adhesive Tape
(44) Oil Seal Lip
(45) Oil Seal Collar
(46) Bearing
4D–32
TRANSFER CASE
Install the transfer case together with intermediate
plate with gear assembly to transmission case (M/
T).
Tighten the transfer case bolts to the specified
torque a little at a time (M/T).
Torque : 37 N·m (27 lb ft)
2. Apply chassis grease (51) to the sub–gear (40) and
the counter gear (41) thrust surfaces.
226RW155
3. Install sub–gear (40) to counter gear (41).
4. Install belleville spring (39).
5. Install spacer.
6. Install ball bearing, using a bench press.
7. Select a snap ring that will allow the minimum axial
play.
Clearance : 0–0.1 mm (0–0.004 in)
226RS170
226RS021
8. Use a pair of snap ring pliers to install the snap ring
(36) to the counter gear (41).
Sub–Gear (anti–lash plate) Preload
1. Hook a length of piano wire (52) over one of the
sub–gear (53) teeth.
2. Attach the other end of the piano wire (52) to a
spring balancer.
Snap ring availability:
Thickness
Color–coding
1.50 mm (0.059 in)
White
1.55 mm (0.061 in)
Yellow
1.60 mm (0.063 in)
Blue
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