Isuzu Trooper (2000 year). Manual - part 140

4D2–2

TRANSFER CASE (TOD)

Transfer Case Assembly

Removal

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1. Disconnect the battery cable (-).
2. Remove transfer protector.
3. Remove rear propeller shaft.
4. Remove front propeller shaft.
5. Remove center console.

4D2–3

TRANSFER CASE (TOD)

6. Uncouple the shift control rod from the select lever

assembly.

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7. Place the select lever assembly near the end.
8. Remove transfer control lever.
9. Remove breather hose.

10. Remove the exhaust pipe set bolts and nuts, and shift

the pipe to the end.

11. Remove the right cross member hanger and shift the

proper shaft to the end.

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12. Unplug the 4WD switch connector from the

transmission harness.

13. Unplug the transfer connector from the top of the

transfer case.

14. Support the transfer case with a jack.
15. Remove the four bolts and three nuts from the

transfer case.

16. Remove transfer case assembly.

Installation

Pay attention to the following points.

1. Apply grease (Besco L2) or equivalent to the input

shaft spline.

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2. Mount the transfer case.

4D2–4

TRANSFER CASE (TOD)

3. Tighten the transfer case bolts (see the figure below).

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4. Tighten propeller shaft bolt.

Torque : 63 N·m (46 lb ft)

4D2–5

TRANSFER CASE (TOD)

Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts

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Legend

(1) Oil Seal
(2) End Nut and Rear Companion Flange

Removal

1. Uncouple the rear propeller shaft from the transfer

case.

2. Using the flange holder J-8614-11, remove the end

nut.

3. Using the universal puller, remove the rear

companion flange and O-ring.

4. Remove the oil seal from the transfer rear case.

Installation

1. Apply oil to the circumference of the oil seal.  Fill the oil

seal lip with grease (Besco L2).

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Legend

(1) Inside
(2) Outside