Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual — part 1166
TRANSFER CASE
4D–33
3. Measure the sub–gear preload.
Preload : 59–98 N (13–22 lb)
226RW156
9. Install ball bearing (35), using a bench press.
10. Install snap ring (34).
11. Install the counter gear assembly (33) to the transfer
case (42).
12. Use a pair of snap ring pliers to install the snap ring
(32) to the transfer case (42).
NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.
13. Use a bench press to install the ball bearing (30) to
the front output shaft (31).
262RS012
14. Assemble the 2WD–4WD clutch hub and sleeve
assembly (28).
226RW140
15. Engage the springs in the same insert with the open
ends away from each other.
226RW141
4D–34
TRANSFER CASE
16. Install a new stopper plate (29) and the clutch hub
and sleeve assembly (28) to the front output shaft
(31).
226RW157
EndOFCallout
17. The clutch hub face (with the heavy boss) must be
facing the front output gear side.
18. Use a bench press to slowly force the clutch hub
and sleeve assembly (28) together with the stopper
plate (29) into place.
19. Align the inserts with the block ring insert grooves.
Install the block ring (27) to the clutch sleeve and
hub assembly (28).
20. Install the outside ring (26), inside ring (25) and
needle bearing (24) to the front output gear (23) and
bearing collar (18).
NOTE: Coat all parts with transmission oil before
installing them.
226RW139
21. Apply engine oil to the thrust surfaces of the sub–
gear, the belleville spring, and the spacer.
262RW014
22. Install sub–gear (anti–lash plate) (22), belleville
spring (21) and spacer (20). (M/T)
23. Install sub–gear snap ring (19). (M/T)
24. Use a bench press to install the needle bearing
collar together with the front output gear assembly,
aligning inside ring claw with block ring groove.
262RS014
Legend
(54) Front Output Gear
TRANSFER CASE
4D–35
25. Install ball bearing (17), using a bench press.
26. Select a snap ring (16) that will allow the minimum
axial play.
Clearance : 0–0.1 mm (0–0.004 in)
262RS015
226RS021
27. Use a pair of snap ring pliers to install the snap ring
(16) to the output shaft (31).
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 to (52) a
spring balancer.
3. Measure the sub–gear preload.
Preload: 59–98 N (13–22 lb)
226RW156
28. Install front output gear assembly (15) to transfer
case (42).
29. Use a pair of snap ring pliers to install the snap ring
(14) to the transfer case (42).
NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.
30. Use a bench press to install the ball bearing (12) to
the input shaft (13). (A/T)
265RS003
Snap ring availability:
Snap ring thickness
Color coding
1.55 mm (0.061 in)
White
1.60 mm (0.063 in)
Yellow
1.65 mm (0.065 in)
Blue
1.70 mm (0.067 in)
Pink
1.75 mm (0.069 in)
Green
1.80 mm (0.071 in)
Brown
1.85 mm (0.073 in)
Red
1.90 mm (0.075 in)
Orange
4D–36
TRANSFER CASE
31. Install plate (11), ball (10) and bearing collar (9).
32. Install needle bearing (8) and input gear (7).
33. The clutch hub face (with the heavy boss) must be
facing the transfer input gear side (55).
226RW158
34. Install high–low clutch hub and sleeve (6), using a
bench press.
35. Install input shaft assembly (5) to transfer case (42).
(A/T)
36. Install the snap ring (4) to the transfer case (42). (A/
T)
NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.
37. Install the front companion flange temporarily and
use the flange holder J–8614–11 and lock nut
wrench J–37219 to install the lock nut (3).
Torque: 137 N·m (101 lb ft)
226RW137
38. Use the punch to stake the lock nut (3) at one spot.
39. Use a suitable drift and hammer to install the ball
bearing (2).
226RS079
40. Install bearing snap ring (1).
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