Transfer Case

Note: Isuzu manuals address both the Automatic and Manual transmission transfer case procedure in the same repair section. Where there is a distinction between Automatic and Manual transmissions concerning transfer case it is noted in the article or image.








DISASSEMBLY


1. Bearing snap ring





2. Mainshaft end ball bearing
Use a pair of snap ring pliers to remove the snap ring
Use a bearing remover to remove the ball bearing

Remover: J-37217 Lock nut wrench: J-37217
Puller: J-37487





3. Mainshaft end lock nut and washer
Engage the high-low synchronizer with the low gear.
Engage the 4X4 Transfer sleeve with the front output gear
Use the lock nut wrench to remove the lock

Lock nut wrench: J-37219
Companion flange holder: J-37221


4. High-low clutch hub and sleeve
5. High-low block ring (M/T only)





6. Transfer input gear

Note: Use the universal puller to remove the high- low synchronizer assembly, the high-low block ring, and the transfer input gear.


7. Needle bearing






8. Bearing collar

Note: Using screw driver to remove the bearing collar.

9. Ball
10. Plate






11. Bearing snap ring

Note: Use a pair of snap ring pliers to expand the bearing snap ring. Use a plastic hammer to tap the front output gear assembly free


12. Front output gear assembly
13. Bearing snap ring





14. Ball bearing

Note: Use a bench press and the ball hearing remover to remove the ball hearing.

Bearing remover: J-22912-O1


15. Bearing collar
16. Sub-gear snap ring (M/T only)
17. Spacer (M/T only)
18. Belleville spring (M/T only)
19. Sub-gear (M/T only)
20. Front output gear
21. Needle bearing
22. Clutch hub and sleeve





23. Ball bearing

Note: Use a bench press and the bearing remover to remove the ball bearing.

Bearing remover: J-22912-O1

24. Front output shaft
25. Bearing snap ring
26. Counter gear assembly
27. Snap ring
28. Ball bearing
29. Snap ring





30. Ball bearing

Note: Use a pair of snap ring pliers to remove the snap rings. Use a bench press and the bearing remover to remove the ball bearings.


31. Spacer (M/T only)
32. Belleville spring (M/T only)
33. Sub-gear (M/T only)
34. Counter gear
35. Transfer case


REASSEMBLY

35. Transfer case





Note: Cover the shaft splines with adhesive tape 1. This will prevent damage to the oil seal lip 2.




Apply recommend liquid gasket or its equivalent to the transfer case fitting surfaces.

Tighten the transfer case bolts to the specified torque a little at a time.

Torque: 37 (28) N.m (lb.ft.)

34. Counter gear
33. Sub-gear (M/T only)




Note: Apply chassis grease to the sub-gear and the counter gear thrust surfaces


32. Belleville spring (M/T only)
31. Spacer (M/T only)
30. Ball bearing
29 Snap ring
28. Ball bearing








27. Snap ring

Note: Select a snap ring that will allow the minimum axial play. Use a pair of snap ring pliers to install the snap ring to the counter gear.

26. Counter gear assembly
25. Bearing snap ring
24. Front output shaft
23. Ball bearing
22. Clutch hub and sleeve
21. Needle bearing
20. Front output gear





19. Sub-gear (M/T only)

Note: Apply engine oil to the thrust surfaces of the subgear, the Belleville spring, and the spacer

18. Belleville spring (M/T only)
17. Spacer (M/T only)
16. Sub-gear snap ring (M/T only)





15. Bearing collar

Note: Use a bench press to install the needle hearing and collar together with the front output gear.



14. Ball bearing












13. Bearing snap ring

Note: Select a snap ring that will allow the minimum axial play. Use a pair of snap ring pliers to install the snap ring to the output shaft.

12. Front output gear assembly
11. Bearing snap ring
10. Plate
9. Ball
8. Bearing collar
7. Needle bearing
6. Transfer input gear
5. High-low block ring (M/T only)








4. High-low clutch hub and sleeve

Note: Turn the shallow clutch hub face # 1 toward the side of the sleeve with small groove # 2 on the outer circumference

Note: In case of M/T model, the clutch hub groove A must be aligned with the key groove of sleeve


Sub Gear Preload





Note: Hook a length of piano wire over one of the sub-gear teeth. Attach the other end of the piano wire to a spring balancer. Measure the sub-gear preload

Preload: 49 118 (11 - 27) N.m (lb)

3. Mainshaft end lock nut





Note: Use the lock nut wrench to tighten the mainshaft end lock nut to the specified torque
Torque: 129 (94) N.m (lb.ft.)

Stake the lock nut.
Lock nut wrench: J-37219




2. Mainshaft end ball bearing

Note: Use the ball bearing installer to install the ball bearing
Installer: J-37223

1. Bearing snap ring