Isuzu Trooper (2000 year). Service manual — part 140
4D2–2
TRANSFER CASE (TOD)
Transfer Case Assembly
Removal
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1. Disconnect the battery cable (-).
2. Remove transfer protector.
3. Remove rear propeller shaft.
4. Remove front propeller shaft.
5. Remove center console.
4D2–3
TRANSFER CASE (TOD)
6. Uncouple the shift control rod from the select lever
assembly.
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7. Place the select lever assembly near the end.
8. Remove transfer control lever.
9. Remove breather hose.
10. Remove the exhaust pipe set bolts and nuts, and shift
the pipe to the end.
11. Remove the right cross member hanger and shift the
proper shaft to the end.
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12. Unplug the 4WD switch connector from the
transmission harness.
13. Unplug the transfer connector from the top of the
transfer case.
14. Support the transfer case with a jack.
15. Remove the four bolts and three nuts from the
transfer case.
16. Remove transfer case assembly.
Installation
Pay attention to the following points.
1. Apply grease (Besco L2) or equivalent to the input
shaft spline.
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2. Mount the transfer case.
4D2–4
TRANSFER CASE (TOD)
3. Tighten the transfer case bolts (see the figure below).
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4. Tighten propeller shaft bolt.
Torque : 63 N·m (46 lb ft)
4D2–5
TRANSFER CASE (TOD)
Transfer Rear Oil Seal
Transfer Rear Oil Seal and Associated Parts
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Legend
(1) Oil Seal
(2) End Nut and Rear Companion Flange
Removal
1. Uncouple the rear propeller shaft from the transfer
case.
2. Using the flange holder J-8614-11, remove the end
nut.
3. Using the universal puller, remove the rear
companion flange and O-ring.
4. Remove the oil seal from the transfer rear case.
Installation
1. Apply oil to the circumference of the oil seal. Fill the oil
seal lip with grease (Besco L2).
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Legend
(1) Inside
(2) Outside
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