Inspection And Repair - Isuzu 2000 Trooper Workshop Manual

30. Disassemble the 2WD–4WD clutch hub and sleeve
assembly.
D Springs (1)
D Inserts (2)
D Clutch Hub (3)
D Sleeve (4)
31. Remove stopper plate.
NOTE: Do not reuse the stopper plate.
32. Remove ball bearing, use the ball bearing remover
J–22912–01 to remove the ball bearing.
33. Remove front output shaft.
34. Remove bearing snap ring.
35. Remove the counter gear assembly from the transfer
case.
36. Remove snap ring, use a pair of snap ring pliers to
remove the snap ring.
TRANSFER CASE (STANDARD TYPE)
37. Remove ball bearing, use a bench press and the
bearing remover J–22912–01 to remove the ball
bearing.
38. Remove snap ring, use a pair of snap ring pliers to
remove the snap ring.
39. Remove ball bearing, use a bench press and the
bearing remover J–22912–01 to remove the ball
bearing.
226RW133
40. Remove spacer.
41. Remove belleville spring.
42. Remove sub–gear (anti–lash plate).
43. Remove counter gear.

Inspection and Repair

1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. Wash all parts thoroughly in clean solvent. Be sure all
old lubricant, metallic particles, dirt, or foreign
material are removed from the surfaces of every part.
Apply compressed air to each oil feed port and
channel in each case half to remove any obstructions
or cleaning solvent residue.
Gears
1. Inspect all the gear teeth for signs of excessive wear
or damage and check all the gear splines for burrs,
nicks, wear or damage. Remove the minor nicks or
scratches on an oil stone. Replace any part exhibiting
excessive wear or damage.
262RS011
Gear Inside Diameter
1. Use an inside dial indicator to measure the gear inside
diameter.
4D1–21
226RS073