Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 1161

TRANSFER CASE

4D–13

11. Off set the actuator assembly.

220RW028

12. Remove the actuator assembly (6).

220RW066

EndOFCallout

13. Remove transfer rear cover assembly (7) from

transfer case assembly.

Installation

1. Apply the recommended liquid gasket (LOCTITE

17430) or its equivalent to the transfer rear cover
fitting faces.

220RS017

2. Install transfer rear cover assembly (7) to transfer

case assembly (8).

3. Perform the following steps before fitting the transfer

rear case.

1. Shift the high–low shift rod to the 4H side.

2. The cut–away portion of the select rod head

(15) should align with that of the rear case hole's
stopper (16).

230RW009

Legend

(13) Position: 4WD
(14) Mode: 2WD

4D–14

TRANSFER CASE

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 (17) to the 4WD side.

6. Join the rod grooves of 2WD–4WD actuator

assembly (6) and shift rod (17).

220RW067

EndOFCallout

7. Push the 2WD–4WD actuator assembly (6) with

2WD–4WD shift rod (17) till the shift rod (17)
reaches the 2WD position.

220RW068

EndOFCallout

8. Tighten the 2WD–4WD actuator bolts to the

specified torque.

Torque: 19 N·m (14 lb ft)

9. Connect the actuator breather hose to actuator.

10. Install actuator heat protector (5).

11. Install control box assembly (4).

Torque: 19 N·m (14 lb ft)

12. Connect breather hoses to control box (4).

13. Install rear companion flange (3) and front

companion flange (2), using the companion flange
holder J–8614–11 to tighten the flange nuts to the
transfer case.

262RW009

14. Tighten the new transfer flange nuts to the specified

torque.

Torque

Rear companion flange: 167 N·m (123 lb ft)

Front companion flange: 137 N·m (101 lb ft)

Legend

(6) 2WD–4WD Actuator Assembly (Mode: 2WD)
(7) Rear Cover Assembly

(17) Shift Rod: 2WD–4WD (Position: 4WD)

Legend

(18) Position: 2WD
(19) Mode: 2WD

TRANSFER CASE

4D–15

15. Use the punch J–39209 to stake the rear

companion flange nut (3) at two spots.

266RS001

266RW002

16. Stake the front companion flange nut (2) at one

spot.

NOTE:  Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.

17. Install the O–ring (23) to the speedometer driven

gear bushing (22).

18. Install the driven gear to the speedometer driven

gear bushing (22).

19. Install the speedometer driven gear assembly to the

transfer rear cover.

20. Install the plate (21) to the transfer rear case and

tighten to the specified torque.

Torque: 15 N·m (11 lb ft)

21. Install the speedometer sensor and tighten to the

specified torque.

Torque: 27 N·m (20 lb ft)

225RW004

EndOFCallout

Legend

(20) Bolt
(21) Plate
(22) Bushing
(23) O–ring

4D–16

TRANSFER CASE

Transfer Rear Cover Assembly

226RW154

EndOFCallout

Disassembly

1. Remove bearing snap ring, use a pair of snap ring

pliers to remove the snap ring (3).

226RS060

Legend

(1) Rear Output Shaft Assembly
(2) Rear Output Shaft
(3) Bearing Snap Ring
(4) Ball Bearing

(5) Bearing Snap Ring
(6) Ball
(7) Speedometer Drive Gear
(8) Ball Bearing
(9) Transfer Rear Cover (with oil seal)