Isuzu Trooper (2000 year). Service manual — part 143

4D2–14 TRANSFER CASE (TOD)

7. Using the bearing remover J-42805 and slide

hammer J-2619-01, remove the ball bearing for the
front output shaft.

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8. Remove the bolts and front and rear speed sensors.

NOTE: Pay attention not to damage the speed sensors
during the work.

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Reassembly

1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to the circumference of the new oil seal and

fill the lip with grease (Besco L2 or equivalent).

3. Using the oil seal installer J-42804, attach the oil seal

to the transfer cover assembly.

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4. Apply grease to the seal ring of each front and rear

speed sensor, and mount the sensor carefully.

5. Tighten the bolt with the specified torque.

Torque : 5 N·m (43 lb in)

NOTE: Pay attention not to mount the front (or rear)
sensor to the rear (or front) sensor position.

6. Mount the ball bearing (1) for the front output shaft flat

as shown in the figure.

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4D2–15

TRANSFER CASE (TOD)

7. Mount the coil assembly and tighten the set nuts with

the specified torque.

Torque : 10 N·m (87 lb in)

8. Plug the terminal in the central connector.

NOTE: Pay attention not to damage other terminals.

9. Install speed gear and tone wheel.

10. Mount the ball bearing (2) flat as shown in the figure.

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11. Using snap ring pliers, attach the snap ring to the

transfer cover assembly.

NOTE: Securely mount the snap ring to the groove of the
transfer cover assembly.

4D2–16 TRANSFER CASE (TOD)

Transfer Case Assembly Clutch Pack and Clutch Cam

Disassembled View

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Legend

(1) Clutch Pack Assembly
(2) Insulator Washer
(3) Armature Plate
(4) Snap Ring

(5) Wave Spring
(6) Cam Pulley
(7) Cam Ball
(8) Cam and Coil Housing
(9) Thrust Bearing

Disassembly

1. Remove thrust bearing.
2. Remove cam and coil housing.

NOTE: When the cam and coil housing is removed, the
cam balls may be detached together with the housing.
Pay attention not to lose the ball.

3. Remove cam ball.

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4D2–17

TRANSFER CASE (TOD)

4. Remove cam pulley.
5. Remove wave spring.
6. Using snap ring pliers, remove the snap ring.

NOTE: Pay attention not to damage the snap ring.

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7. Remove the armature plate.
8. Remove the insulator washer.
9. Remove the clutch pack assembly as a package.

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