Isuzu Trooper (2000 year). Manual — part 146

4D2–26 TRANSFER CASE (TOD)

265RW007

Inspection and Repair

When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all the parts with clean detergent, and
check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or residual
detergent.

Chain

D

Check whether the face that contacts the sprocket is
free from excessive wear or damage. If defects are
observed, replace the part.

D

If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that a
skipped engagement occurs between the chain and
sprocket, replace the chain.

Sprocket

D

Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.

D

If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.

Gear

Check whether the gear tooth surface is excessively

worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.

Thickness of Reduction Hub

D

Measure the thickness with a micrometer.

D

If the measurement exceeds the limit, replace the
reduction hub.

Standard : 3.05-3.30 mm (0.120-0.130 in)

Allowable limit : 2.5 mm (0.098 in)

265RW005

Lock-up Sleeve

Mount the lock-up hub, drive sprocket assembly, and

lock-up sleeve to the output shaft.

If the lock-up sleeve does not move smoothly, replace

the sleeve.

NOTE: Apply ATF to the area engaging the gear.

Thickness of Lock-up Sleeve

D

If the measurement exceeds the limit, replace the
lock-up sleeve.

Standard : 7.16-7.32 mm (0.282-0.288 in)

Allowable limit : 7.9 mm (0.311 in)

266RW014

4D2–27

TRANSFER CASE (TOD)

Reduction Fork

Check the reduction fork and shaft for wear, distortion,

and scratches. If defects are observed, replace the
parts.

Thickness of Reduction Fork

D

If the measurement exceeds the limit, replace the
reduction fork.

Standard : 3.41-3.79 mm (0.134-0.149 in)

Allowable limit : 4.4 mm (0.173 in)

261RW026

Lock-up Fork

D

Check the lock-up fork and shaft for wear, distortion,
and scratches. If defects are observed, replace the
parts.

Thickness Lock-up Fork

If the measurement exceeds the limit, replace the

lock-up fork.

Standard : 6.99-7.09 mm (0.275-0.279 in)

Allowable limit : 6.3 mm (0.248 in)

261RW027

Bearing

Check the profile of the needle, roller, ball, and thrust
bearings. Wash the bearings with clean detergent
completely, and dry with air.

NOTE: If the bearing is rotated excessively, the rollers
may be damaged. So, rotate the bearing slowly with your
hand. Apply grease to the bearing, and check the
smoothness of the bearing while slowly rotating the race
with your hand.

Allowable limit : 0.23 mm (0.009 in)

226RW143

Lock-up Fork Spring

Check the lock-up fork spring for distortion, cracking,

and wear. If defects are observed, replace the part.

Free Length of the Lock-up Fork Spring

D

If the measurement exceeds the limit, replace the
spring.

Standard : 60.96 mm (2.40 in)

Allowable limit : 55.0 mm (2.17 in)

220RW045

4D2–28 TRANSFER CASE (TOD)

Tension of Lock-up Fork Spring

D

If the measurement exceeds the limit, replace the
spring. (When compressed to 41.4 mm)

Standard : 27.1-33.8 N {2.76-3.45 kg}

Allowable limit : 24.5 N {2.5 kg}

014RW048

Tension of Detent Spring Assembly

D

If the measurement exceeds the limit, replace the
spring. N {kg} (When compressed by 3 mm from the
free length)

Standard : 139 N -203 {14.2-20.7 kg}

Allowable limit : 130 N {13.3 kg}

261RW041

Oil Pump

D

Remove foreign materials from the strainer. If the
strainer is damaged, replace it.

D

If the area into which the shaft is inserted is
excessively worn or damaged, replace the pump.

Multi Plate Disk Clutch

D

If the burned, mirror-surfaced clutch facing, or
scraping is observed on the clutch plates, clutch
housing, armature plate, and insulator washer,
replace the part or parts.

266RW003

Coil Assembly

D

Check the resistance of the coil with a tester. If
defects are observed, replace the assembly.
* (ordinary temperature)

Standard : 1.4

∼

2.0

W

Allowable limit : 1.0

∼

5.0

W

261RW031

4D2–29

TRANSFER CASE (TOD)

Cam Pulley, Cam Ball, and Cam&Coil
Housing

D

Check the cam balls and cam for excessive wear or
damage. If defective, replace the parts. 4H and 4L
switches.

266RW016

The Parts 4H and 4L Switch

D

Check the continuity of 4H and 4L switch.

261RW003

261RW049

Switch
Stroke

4H Switch

Signal

4L Switch

Signal

The

correspon

ding

position

B to Switch

Body

A to C

osition

of

transfer

lever

1

Open

Open

High

2

Open

Close

4L

3

Close

Close

Neutral