Transfer Case (Tod) - Isuzu Trooper 1999 Workshop Manual

TROOPER
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . .
Transfer Rear Oil Seal and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOD ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Cover Assembly
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case Assembly Clutch Pack and
Clutch Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
DRIVELINE/AXLE

TRANSFER CASE (TOD)

CONTENTS
4D2–1
. . . . . . . . . . . . . . . . . 4D2–2
4D2–2
4D2–3
4D2–5
4D2–5
4D2–5
4D2–5
4D2–7
4D2–7
4D2–7
4D2–8
4D2–8
4D2–9
4D2–9
4D2–9
4D2–10
. . . . . . . . . . . . . . . . 4D2–12
4D2–12
4D2–12
4D2–14
4D2–16
4D2–16
TRANSFER CASE (TOD)
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembled View . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Shafts and Shift Control Shaft
Disassembled View . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Sprocket and Mechanical Lock
Disassembled View . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pack and Clutch Cam
Disassembled View . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Data and Specifications
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
SECTION
4D2–1
4D2–16
. . . . . . . . . . . . 4D2–18
4D2–18
4D2–18
. . . . . . 4D2–20
4D2–20
4D2–21
4D2–23
4D2–23
4D2–24
4D2–26
4D2–30
4D2–30
4D2–30
. . . . . . 4D2–33
4D2–33
4D2–33
. . . . . . . . . . . . 4D2–36
4D2–36
4D2–36
. . . . . . . . . . . . . 4D2–38
4D2–38
4D2–38
. . . . . . . . . . . . . 4D2–40
4D2–42