Isuzu Trooper (2000 year). Manual — part 132
TRANSFER CASE (STANDARD TYPE)
4D1–5
266RW002
8. Connect the rear propeller shaft to the transfer case
and tighten to the specified torque.
Torque: 63 N·m 46 (lb ft)
Transfer Case Assembly
Removal
NOTE: Before removing transmission & transfer
assembly from vehicle, change the transfer mode to 2WD
by pushing button switch on dash panel.
1. Disconnect the battery ground cable.
2. Drain the transfer case fluid.
3. Remove transfer protector.
4. Remove rear propeller shaft.
5. Remove the rear and front propeller shaft from the
transfer case side.
6. Disconnect the four oxygen sensor connectors from
the transmission harness.
7. Remove the right and left catalytic converter
assemblies and exhaust pipe.
8. Remove the transfer control lever knob.
9. Remove the selector lever assembly. Refer to
Selector Lever in the Section 7A.
10. Remove transfer control lever.
11. Disconnect the 4WD switch and speed sensor
harness connector and 2WD–4WD actuator harness
connector from the transmission harness.
12. Remove transmission–transfer bolt and support the
transfer case with a transmission jack.
13. Remove four transmission–transfer bolts and the
three nuts.
14. Remove the transfer case assembly from the vehicle.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. Install transfer case assembly and apply a thin coat of
molybdenum disulfide grease to the input shaft
spline.
4D1–6
TRANSFER CASE (STANDARD TYPE)
2. Tighten the transmission–transfer bolt to the
specified torque.
Torque: 46 N·m (34 lb ft)
260RW001
3. Tighten the exhaust pipe to exhaust manifold bolt to
the specified torque.
Torque: 67 N·m (49 lb ft)
4. Tighten the exhaust pipe flange bolt to the specified
torque.
Torque: 43 N·m (32 lb ft)
5. Tighten the propeller shaft bolt to the specified torque.
Torque: 63 N·m (46 lb ft)
6. Tighten the transfer protector bolt to the specified
torque.
Torque: 37 N·m (27 lb ft)
256RW026
TRANSFER CASE (STANDARD TYPE)
4D1–7
Transfer Rear Case Assembly
Removal
1. Remove the speedometer sensor.
2. Remove the plate.
3. Remove the speedometer driven gear bushing and
driven gear.
NOTE: Apply a reference mark to the driven gear bushing
before removal.
4. Remove front companion flange.
5. Remove rear companion flange, use the flange
companion holder J–8614–11 to remove the end nut.
262RW009
6. Remove the front and rear companion flange.
NOTE: Use the universal puller to remove the rear
companion flange.
7. Remove control box assembly.
8. Disconnect the actuator breather hose from the
2WD–4WD actuator assembly.
220RW085
9. Remove the 2WD–4WD actuator assembly bolts.
10. Pull the 2WD–4WD actuator assembly with
2WD–4WD shift rod.
220RW027
Legend
(1) Shift Rod: 2WD–4WD (Position: 2WD)
(2) 2WD–4WD Actuator Assembly
(3) Pull
(4) Rear Case Assembly
(5) Position: 4WD
(6) Mode: 2WD
4D1–8
TRANSFER CASE (STANDARD TYPE)
11. Off set the actuator assembly.
220RW028
12. Remove the actuator assembly.
220RW029
Legend
(7) Position: 4WD
(8) Mode: 2WD
13. Remove transfer case assembly.
14. Remove transfer rear case assembly.
Installation
1. Install transfer rear case assembly.
2. Install transfer case assembly and apply the
recommended liquid gasket (LOCTITE 17430) or its
equivalent to the transfer rear case fitting faces.
220RS017
3. Perform the following steps before fitting the transfer
rear case:
1. Shift the high–low shift to the 4H side.
2. Turn the select rod counterclockwise so that the
select block projection A may enter into the
2WD–4WD shift block.
3. The cut–away portion of the select rod head (9)
should align with that of the rear case hole’s
stopper (10).
230RW004
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 (11) to the 4WD side.
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