Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 663

TRANSFER CASE (STANDARD TYPE)

4D1–27

Reassembly

1. Install transfer case (with oil seal).

Input shaft oil seal (1) 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–38592 to install the oil

seal to the transfer case.

220RW032

Front output shaft oil seal (2) 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.

220RW033

2. Install counter gear.
3. Install sub–gear and apply chassis grease (3) to the

sub–gear and the counter gear thrust surfaces.

226RW134

4D1–28 TRANSFER CASE (STANDARD TYPE)

4. Install belleville spring.
5. Install spacer.
6. Install ball bearing.
7. Select a snap ring that will allow the minimum axial

play.

Clearance : 0–0.1 mm (0–0.004 in)

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

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

the counter gear.

226RS170

226RS021

Sub–Gear (anti–lash plate) Preload

1. Hook a length of piano wire (4) over one of the

sub–gear (5) teeth.

2. Attach the other end of the piano wire (4) to a

spring balancer.

3. Measure the sub–gear preload.

Preload : 59–98 N (13–22 lb)

226RS075

9. Install ball bearing.

10. Install snap ring.

11. Install the counter gear assembly to the transfer case.

12. Install bearing snap ring, use a pair of snap ring pliers

to install the snap ring to the transfer case.

NOTE: The snap ring must be fully inserted into the
transfer case snap ring groove.

13. Install front output shaft.
14. Install ball bearing, use a bench press to install the

ball bearing to the front output shaft.

262RS012

TRANSFER CASE (STANDARD TYPE)

4D1–29

15. Install stopper plate.
16. Assemble the clutch sleeve and hub assembly.

226RW140

17. Engage the springs in the same insert with the open

ends away from each other.

226RW141

18. Install a new stopper plate and the clutch sleeve and

hub assembly to the front output shaft.

226RW135

Legend

(6) Front Output Gear

19. The clutch hub face (with the heavy boss) must be

facing the front output gear side.

20. Use a bench press to slowly force the clutch sleeve

and hub assembly together with the stopper plate into
place.

21. Align the inserts with the block ring insert grooves.

Install the block ring to the clutch sleeve and hub
assembly.

22. Install outside ring.
23. Install the outside ring, inside ring and needle bearing

to the front output gear and bearing collar.

NOTE: Coat all parts with transmission oil before
installing them.

226RW139

24. Install needle bearing.
25. Install front output gear.
26. Install sub–gear (anti–lash plate). (M/T)

4D1–30 TRANSFER CASE (STANDARD TYPE)

27. Install belleville spring. (M/T)
28. Install spacer and apply engine oil to the thrust

surfaces of the sub–gear, the belleville spring, and the
spacer. (M/T)

262RW060

29. Install sub–gear snap ring. (M/T)
30. Install bearing collar, use a bench press to install the

needle bearing collar together with the front output
gear.

262RS014

31. Install ball bearing.

32. Install bearing snap ring and select a snap ring that

will allow the minimum axial play.

Clearance : 0–0.1 mm (0–0.004 in)

Snap ring availability:

Snap ring thickness

Color coding

1.55 mm (0.061 in)

White

1.60 mm (0.063 in)

Yellow

1.65 mm (0.065 in)

Blue

1.70 mm (0.067 in)

Pink

1.75 mm (0.069 in)

Green

1.80 mm (0.071 in)

Brown

1.85 mm (0.073 in)

Red

1.90 mm (0.075 in)

Orange

262RS015

226RS021