Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 149

4D2–10 TRANSFER CASE (TOD)

Disassembly

1. Remove the drain plug from the transfer case and

drain the oil.

2. Remove the speedometer sensor and driven gear.
3. Remove the front and rear speed sensor of the

harness assembly from the transfer cover assembly.

NOTE: Use care to prevent damage to speed sensor
when removing speed sensor.

4. Disconnect the clutch solenoid coil, 4H and 4L switch

harness connector.

D

Remove the harness bracket from the transfer
cover.

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5. Remove the connector bracket from the transfer

case.

D

Remove the harness assembly and shift motor
harness connector from the connector bracket.

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6. Remove the 4H and 4L switch from the transfer case.
7. Remove the shift motor assembly from the transfer

cover.

8. Using the flange holder J–8614–11, remove the end

nut.
Remove the washers, oil seals, front and rear
companion flange.

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9. Remove the transfer cover retaining bolts and the

transfer cover assembly from the transfer case
assembly.

NOTE: When removing the transfer cover assembly, use
care to prevent damage to oil seal.

10. Remove the breather hose from the transfer case.

Reassembly

1. Apply recommended liquid gasket (LOCTITE 598 or

its equivalent) uniformly to the transfer case and
cover fitting surface.

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4D2–11

TRANSFER CASE (TOD)

2. Install the plate, bracket, connector bracket and

ground cable of the harness assembly, and tighten
the transfer cover retaining bolts (16 pieces) to
specified torque.

Torque: 31 N·m (23 lb ft)

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3. Install the front and rear companion flange.
4. Install the oil seal and washer, and using the flange

holder J–8614–11, install the new end nut to the
specified torque.

Torque: 167 N·m (123 lb ft)

5. Securely stake the end nut at one spot.

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

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4D2–12 TRANSFER CASE (TOD)

6. Apply recommended liquid gasket (LOCTITE 598 or

its equivalent) to the transfer cover and shift motor
assembly fitting surface.

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7. Install the shift motor assembly to the transfer cover

assembly.

Torque: 10 N·m (87 lb in)

8. Install the 4H and 4L switch.

Torque: 24 N·m (17 lb ft)

9. Install the harness assembly and shift motor harness

connector to the connector bracket.

10. Install the front and rear speed sensors to the transfer

cover.

Torque: 5 N·m (43 lb in)

11. Connect the harness assembly connector to the

clutch solenoid coil harness connector and 4H and 4L
switch.

D

Fix the harness with harness bracket.

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12. Install the driven gear and speedometer sensor to the

transfer case.

Torque: 25 N·m (19 lb ft)

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13. Remove the filler plug and fill the transfer case with

ATF DEXRON



–II or III.

14. Wind the sealing tape around the filler plug thread and

tighten the plug to the specified torque.

Torque: 25 N·m (19 lb ft)

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15. Install the breather hose to the transfer case.

4D2–13

TRANSFER CASE (TOD)

Transfer Cover Assembly

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Legend

(1) Coil Assembly
(2) Snap Ring
(3) Ball Bearing

(4) Speed Gear and Tone Wheel
(5) Ball Bearing
(6) Transfer Cover (With Oil Seal)
(7) Oil Drain Plug and Oil Filler Plug

Disassembly

1. Using a precision screwdriver or a suitable tool, push

down the lock to unlatch the terminal for the coil
assembly, and pull the terminal out.

NOTE: Use care to prevent damage to harness terminal
and connector.

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