Isuzu Trooper (1998-2002 year). Manual - part 191

4D2–27

TRANSFER CASE (TOD)

Reduction Fork

Check the reduction fork and shaft for wear, distortion,

and scratches. If defects are observed, replace the
parts.

Thickness of Reduction Fork

D

If the measurement exceeds the limit, replace the
reduction fork.

Standard : 3.41-3.79 mm (0.134-0.149 in)

Allowable limit : 4.4 mm (0.173 in)

261RW026

Lock-up Fork

D

Check the lock-up fork and shaft for wear, distortion,
and scratches.  If defects are observed, replace the
parts.

Thickness Lock-up Fork

If the measurement exceeds the limit, replace the

lock-up fork.

Standard : 6.99-7.09 mm (0.275-0.279 in)

Allowable limit : 6.3 mm (0.248 in)

261RW027

Bearing

Check the profile of the needle, roller, ball, and thrust
bearings.  Wash the bearings with clean solvent
completely, and dry with air.

NOTE: If the bearing is rotated excessively, the rollers
may be damaged.  So, rotate the bearing slowly with your
hand.  Apply grease to the bearing, and check the
smoothness of the bearing while slowly rotating the race
with your hand.

D

Use a dial indicator to measure the ball bearing play.

Allowable limit : 0.23 mm (0.009 in)

226RW143

Lock-up Fork Spring

Check the lock-up fork spring for distortion, cracking,

and wear.  If defects are observed, replace the part.

Free Length of the Lock-up Fork Spring

D

If the measurement exceeds the limit, replace the
spring.

Standard : 60.96 mm (2.40 in)

Allowable limit : 55.0 mm (2.17 in)

220RW045

4D2–28 TRANSFER CASE (TOD)

Tension of Lock-up Fork Spring

D

If the measurement exceeds the limit, replace the
spring. (When compressed to 41.4 mm)

Standard : 27.1-33.8 N {2.76-3.45 kg/6.08-7.61 Ib}

Allowable limit : 24.5 N {2.5 kg/5.5 Ib}

014RW048

Tension of Detent Spring Assembly

D

If the measurement exceeds the limit, replace the
spring. N {kg} (When compressed by 3 mm from the
free length)

Standard : 139 N -203 {14.2-20.7 kg/31.3-45.6 Ib}

Allowable limit : 130 N {13.3 kg/29.3 Ib}

261RW041

Oil Pump

D

Remove foreign materials from the strainer.  If the
strainer is damaged, replace it.

D

If the area into which the shaft is inserted is
excessively worn or damaged, replace the pump.

Multi Plate Disk Clutch

D

If the burned, mirror-surfaced clutch facing, or
scraping is observed on the clutch plates, clutch
housing, armature plate, and insulator washer,
replace the part or parts.

266RW003

Coil Assembly

D

Check the resistance of the coil with a tester.  If
defects are observed, replace the assembly.
* (ordinary temperature)

Standard : 1.4

∼

2.0 

W

Allowable limit : 1.0

∼

5.0 

W

261RW031

4D2–29

TRANSFER CASE (TOD)

Cam Pulley, Cam Ball, and Cam&Coil
Housing

D

Check the cam balls and cam for excessive wear or
damage.  If defective, replace the parts.

266RW016

The Parts 4H and 4L Switch

D

Check the continuity of 4H and 4L switch.

261RW003

261RW049

Switch
Stroke

4H Switch

Signal

4L Switch

Signal

The

correspo

nding

position

B to Switch

Body

A to C

osition

of

transfer

lever

1

Open

Open

High

2

Open

Close

4L

3

Close

Close

Neutral

4D2–30 TRANSFER CASE (TOD)

Transfer Case

Disassembled View

265RW015

Legend

(1) Transfer Case
(2) Ball Bearing
(3) Ring Gear
(4) Snap Ring
(5) Input Shaft and Carrier Assembly
(6) Snap Ring

(7) Ball Bearing
(8) Snap Ring
(9) Thrust Plate

(10) Carrier Assembly

(11) Snap Ring

(12) Circular Hub
(13) Input Shaft

Reassembly

1. Remove the oil seal from the transfer case.
2. Apply engine oil to the circumference of the new oil

seal and fill the lip with grease (Besco L2 or
equivalent).