Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 1165

TRANSFER CASE

4D–29

Detent Springs

1. Inspect the springs for distortion, cracks or wear.

Replace if these conditions are present.

Detent Spring Free Length

1. Use a vernier caliper to measure the detent spring

free length.

2. If the measured value is less than the specified limit,

the detent spring must be replaced.

Detent spring free length

Detent ball

Standard :

Inner 23.2 mm (0.91 in)

Outer 26.8 mm (1.06 in)

Limit :

Inner 22.6 mm (0.84 in)

Outer 26.2 mm (1.03 in)

Interlock pin

Standard : 15.9 mm (0.626 in)

Limit : 15.3 mm (0.602 in)

220RW035

Detent Spring Tension

1. Use a spring tester to measure the detent spring

tension.

2. If the measured value is less than the specified limit,

the detent spring must be replaced.

Detent ball

Compressed height : 19.7 mm (0.776 in)

Standard : 

Inner 22.6–32.4 N (5.1–7.3 lb)

Outer 91.2–101.0 N (20.5–22.7 lb)

Interlock pin

Compressed height : 11.5 mm (0.453 in)

Standard : 9.8 N (2.2 lb)

220RS013

Shift Arm

1. Inspect the shift arms for wear, distortion or scoring.

Replace if these conditions are present.

Shift Arm Thickness

1. Use a micrometer to measure the shift arm

thickness.

2. If the measured value is less than the specified limit,

the shift arm must be replaced.

Shift arm thickness

Standard : 9.60–9.85 mm (0.378–0.388 in)

Limit : 9.0 mm (0.354 in)

230RS006

4D–30

TRANSFER CASE

Reassembly

Input Shaft Oil Seal Replacement

1. Remove the oil seal from the transfer case.

2. Apply the engine oil to the oil seal outer surfaces.

3. Apply recommended grease (BESCO L2) or

equivalent to the oil seal lip.

4. Use the oil seal installer J–38592 (A/T) J–37488 (M/

T) and driver handle J–8092 to install the oil seal to
the transfer case.
A/T

220RX002

EndOFCallout

M/T

220RW052

EndOFCallout

Legend

(47) Oil Seal

Legend

(48) Transmission Side Oil Seal
(49) Transfer Side Oil Seal

TRANSFER CASE

4D–31

Front Output Shaft Oil Seal Replacement

1. Remove the oil seal from the transfer case.

2. Apply engine oil to the oil seal outer surfaces.

3. Apply recommended grease (BESCO L2) or

equivalent to the oil seal lip.

4. Use the oil seal installer J–38594 to install the oil

seal to the transfer case.

220RW070

EndOFCallout

1. Install the transfer case (with oil seal) (42),

performing the following steps. (M/T)

• Cover the shaft splines with adhesive tape (43).

This will prevent damage to the oil seal lip (44).

A07RW022

EndOFCallout

• Apply recommended liquid gasket (LOCTITE

FMD 127) or its equivalent to the transmission,
intermediate  plate and transfer case fitting
surfaces (M/T).

220RS026

Legend

(50) Front Output Shaft Oil Seal

Legend

(43) Adhesive Tape
(44) Oil Seal Lip
(45) Oil Seal Collar
(46) Bearing

4D–32

TRANSFER CASE

Install the transfer case together with intermediate
plate with gear assembly to transmission case (M/
T).
Tighten the transfer case bolts to the specified

torque a little at a time (M/T).

Torque : 37 N·m (27 lb ft)

2. Apply chassis grease (51) to the sub–gear (40) and

the counter gear (41) thrust surfaces.

226RW155

3. Install sub–gear (40) to counter gear (41).

4. Install belleville spring (39).

5. Install spacer.

6. Install ball bearing, using a bench press.

7. Select a snap ring that will allow the minimum axial

play.

Clearance : 0–0.1 mm (0–0.004 in)

226RS170

226RS021

8. Use a pair of snap ring pliers to install the snap ring

(36) to the counter gear (41).

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 (52) to a

spring balancer.

Snap ring availability:

Thickness

Color–coding

1.50 mm (0.059 in)

White

1.55 mm (0.061 in)

Yellow

1.60 mm (0.063 in)

Blue