Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual — part 1164
TRANSFER CASE
4D–25
9. Remove needle bearing (8).
10. Remove bearing collar (9).
226RS071
11. Remove ball (10).
12. Remove plate (11).
13. Use a bench press and the ball bearing remover J–
22912–01 to remove the ball bearing (12) from the
input shaft (13). (A/T)
265RS002
14. Use a pair of snap ring pliers to remove the bearing
snap ring (14).
15. Use a plastic hammer to tap the front output gear
assembly (15) free.
262RS009
16. Remove bearing snap ring (16).
17. Use a bench press and the bearing remover J–
22912–01 to remove the following parts.
18. Remove ball bearing (17), and bearing collar (18).
Remove sub–gear snap ring (19), spacer (20),
belleville spring (21), and sub–gear (anti–lash plate)
(22). (M/T)
Remove front output gear (23) and needle bearing
(24).
262RS010
19. Remove inside ring (25).
20. Remove outside ring (26).
21. Remove block ring (27).
4D–26
TRANSFER CASE
22. Use a bench press and bearing remover J–22912–
01 to remove 2WD–4WD clutch hub and sleeve
assembly (28) and stopper plate (29).
NOTE: Do not reuse the stopper plate.
23. Disassemble the 2WD–4WD clutch hub and sleeve
assembly (28).
• Springs (1)
• Inserts (2)
• Clutch Hub (3)
• Sleeve (4)
226RW133
24. Use a bench press and the ball bearing remover J–
22912–01 to remove the ball bearing (30) from front
output shaft (31).
262RS011
25. Remove bearing snap ring (32).
26. Remove the counter gear assembly (33) from the
transfer case (42).
27. Use a pair of snap ring pliers to remove the snap
ring (34).
28. Use a bench press and the bearing remover J–
22912–01 to remove the ball bearing (35).
29. Use a pair of snap ring pliers to remove the snap
ring (36).
30. Use a bench press and the bearing remover J–
22912–01 to remove the ball bearing (37).
226RS073
31. Remove spacer (38).
32. Remove belleville spring (39).
33. Remove sub–gear (anti–lash plate) (40).
34. Remove counter gear (41).
35. Remove transfer case (with oil seal) (42),
performing the following steps (M/T)
• Cover the shaft splines with adhesive tape (43).
A07RW022
EndOFCallout
Legend
(43) Adhesive Tape
(44) Oil Seal Lip
(45) Oil Seal Collar
(46) Bearing
TRANSFER CASE
4D–27
• Remove the transfer case together with
intermediate plate with gear assembly from the
transmission case (M/T).
• Remove the transfer case from the intermediate
plate with gear assembly (M/T).
Inspection and Repair
1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. Wash all parts thoroughly in clean solvent. Be sure
all old lubricant, metallic particles, dirt, or foreign
material are removed from the surfaces of every
part. Apply compressed air to each oil feed port and
channel in each case half to remove any
obstructions or cleaning solvent residue.
Gears
1. Inspect all the gear teeth for signs of excessive
wear or damage and check all the gear splines for
burrs, nicks, wear or damage. Remove the minor
nicks or scratches on an oil stone. Replace any part
exhibiting excessive wear or damage.
Front Output Gear Inside Diameter
1. Use an inside dial indicator to measure the gear
inside diameter.
2. If the measured value exceeds the specified limit,
the gear must be replaced.
Gear inside diameter
Standard : 48.000–48.013 mm (1.8898–1.8903 in)
Limit : 48.10 mm (1.894 in)
226RS040
Clutch Hub Spline Play
1. Set a dial indicator to the clutch hub to be
measured.
2. Move the clutch hub as far as possible to both the
right and the left.
Note the dial indicator reading.
3. If the measured value exceeds the specified limit,
the clutch hub must be replaced.
Clutch hub spline play
Standard : 0–0.1 mm (0–0.004 in)
Limit : 0.2 mm (0.008 in)
226RS042
Bearings
1. Inspect the condition of all the needles and ball
bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check
them for roughness by slowly turning the race by
hand.
Ball Bearing Play
1. Use a dial indicator to measure the ball bearing play.
2. If the measured value exceeds the specified limit,
the ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)
226RS043
4D–28
TRANSFER CASE
Synchronizers
The synchronizer hubs and sliding sleeves are a
selected assembly and should be kept together as
originally assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:
• Teeth for wear, scuffs, nicks, burrs or breaks.
• Keys and springs for wear, cracks or distortion,
replace if these conditions are present.
• If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace
the component.
Block Ring and Insert Clearance
1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
2. If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.
Block ring and insert clearance
Standard : 2.46–2.74 mm (0.097–0.108 in)
Limit : 3.0 mm (0.118 in)
226RS037
2WD–4WD Synchronizer (3–Cone)
1. Use a thickness gauge to measure the clearance
between the block ring and the dog teeth.
2. If the measured value exceeds the specified limit,
the 2WD–4WD synchronizer assembly must be
replaced.
Block ring and insert clearance
Standard : 1.5 mm (0.059 in)
Limit : 0.8 mm (0.031 in)
226RW142
Clutch Hub and Insert Clearance
1. Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
2. If the measured value exceeds the specified limit,
the clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard : 0.01–0.19 mm (0.0004–0.0075 in)
Limit : 0.3 mm (0.012 in)
226RS038
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