Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual — part 1158
TRANSFER CASE
4D–1
RODEO
DRIVELINE/AXLE
CONTENTS
TRANSFER CASE
Service Precaution. . . . . . . . . . . . . . . . . . . . .
4D–1
General Description . . . . . . . . . . . . . . . . . .
4D–2
Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . .
4D–4
Transfer Rear Oil Seal and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4D–4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
4D–4
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
4D–4
Transfer Case Assembly (A/T) . . . . . . . . . . .
4D–6
Transfer Case Assembly (A/T) and
Associated Parts . . . . . . . . . . . . . . . . . . . . .
4D–6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
4D–6
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
4D–8
Transfer Rear Case Assembly (A/T) . . . . . . .
4D–11
Transfer Rear Case Assembly (A/T) and
Associated Parts . . . . . . . . . . . . . . . . . . . . .
4D–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
4D–11
Installation . . . . . . . . . . . . . . . . . . . . . . . . .
4D–13
Transfer Rear Cover Assembly . . . . . . . . .
4D–16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . .
4D–16
Inspection and Repair. . . . . . . . . . . . . . . . .
4D–17
Reassembly . . . . . . . . . . . . . . . . . . . . . . . .
4D–17
Detent, Shift Arm, and Interlock Pin
(Transfer Case Assembly) . . . . . . . . . . . . .
4D–19
Disassembled View . . . . . . . . . . . . . . . . . .
4D–19
Disassembly . . . . . . . . . . . . . . . . . . . . . . . .
4D–20
Inspection and Repair. . . . . . . . . . . . . . . . .
4D–21
Reassembly . . . . . . . . . . . . . . . . . . . . . . . .
4D–21
Transfer Case Assembly . . . . . . . . . . . . . . . .
4D–23
Disassembled View . . . . . . . . . . . . . . . . . .
4D–23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . .
4D–24
Inspection and Repair. . . . . . . . . . . . . . . . .
4D–27
Reassembly . . . . . . . . . . . . . . . . . . . . . . . .
4D–30
Main Data and Specifications . . . . . . . . . . . .
4D–37
Special Tools . . . . . . . . . . . . . . . . . . . . . . .
4D–40
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE
SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS
SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
4D–2
TRANSFER CASE
General Description
Transfer Case (for M/T)
A07RW002
TRANSFER CASE
4D–3
Transfer Case (for A/T)
A07RW001
The transfer case is used to provide a means of
providing power flow to the front axle. The transfer case
also provides a means of disconnecting the front axle,
providing better fuel economy and quieter operation
when the vehicle is driven on improved roads where
four wheel drive is not required. In addition, the transfer
case provides an additional gear reduction when
placed in low range, which is useful when difficult off–
road conditions are encountered.
A floor mounted shift lever is used to select the high–
low range. When four wheel drive switch has been
turned on, the four wheel drive indicator light is
designed to come on and the front axle has been
engaged.
4D–4
TRANSFER CASE
Transfer Rear Oil Seal
Transfer Rear Oil Seal and Associated Parts
220RS015
EndOFCallout
Removal
1. Disconnect the rear propeller shaft (1) from the
transfer case side.
2. Remove end nut and rear companion flange (2),
using the companion flange holder J–8614–11.
266RW001
3. Use the universal puller to remove the rear
companion flange and O–ring.
4. Remove the oil seal from the transfer case.
Installation
1. Install oil seal and apply engine oil to the oil seal
outer surfaces.
2. Apply the recommended grease (BESCO L2) or
equivalent to the oil seal lip.
3. Use the oil seal installer J–39208 to install the rear
seal (3) to the transfer rear case.
220RS016
Legend
(1) Rear Propeller Shaft
(2) End Nut and Rear Companion Flange
(3) Oil Seal
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