Isuzu Trooper (2000 year). Manual - part 142

4D2–10 TRANSFER CASE (TOD)

6. Remove the offset lever set bolt on the right side.

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7. Remove the offset lever lock spring pin.

NOTE: When removing the spring pin, pay attention to
the recess position of the pin.

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8. Remove the offset lever.

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9. Remove the sixteen bolts and detach the transfer

cover assembly from the transfer cable assembly.

NOTE: When removing the transfer cover assembly, pay
attention not to damage the oil seal.

Reassembly

1. Apply liquid gasket (Loctite 598 or equivalent)

uniformly to the mating face that contacts the transfer
case.

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4D2–11

TRANSFER CASE (TOD)

2. Tighten the sixteen bolts with the specified torque.

Torque : 31 N·m (23 lb ft)

3. Wind the sealing tape around the drain plug thread

and tighten the plug with the specified torque.

Torque : 25 N·m (18 lb ft)

4. Install offset lever.
5. Mount the offset lever to the transfer shift and attach

the spring pin.

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6. Install rear and front companion flange.
7. Attach the O-ring and washer to the companion

flange.

NOTE: Securely push the O-ring to the dent of the
companion flange, and then attach the washer.

8. Use the flange holder J-8614-11 to tighten the flange

nuts to transfer case.

9. Tighten the flange nut with the specified torque.

Torque : 167 N·m (123 lb ft)

10. Using the punch J-39209, securely stake the flange

nut at two places

NOTE: Check the staked flange nut is free from cracks.

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11. Fix the harness with the clip.

12. Tighten the 4L and 4H switch to the specified torque.

Torque : 16 N·m (12 lb ft)

13. Fill the transfer case with ATF II or III (1.9 liters).
14. Wind the sealing tape around the filler plug thread and

tighten the plug with the specified torque.

Torque : 25 N·m (18 lb ft)

4D2–12 TRANSFER CASE (TOD)

Transfer Cover Assembly

Disassembled View

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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 Assembly
(7) Front and Rear Speed Sensors

Disassembly

1. Using snap ring pliers, remove the snap ring.

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4D2–13

TRANSFER CASE (TOD)

2. Remove ball bearing.
3. Strike the speed gear and tone wheel with a rod or

other appropriate tool from the outside of the transfer
cover assembly, and remove the ball bearing and
speed gear and tone wheel.

NOTE: Pay attention not to damage the speed gear
teeth.

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4. Remove the stopper plate on the back with a

precision screwdriver or other appropriate tool
starting from the small lock of the plate.

NOTE: Pay attention not to damage the stopper plate
during the work.

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5. Using a terminal pull-out tool or an equivalent tool,

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

NOTE: Pay attention not to damage other terminals.

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6. Remove the set bolts of the cam&coil housing from

the outside of the transfer cover assembly.  Remove
the housing from the transfer cover.

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