ISUZU AXIOM 2002 Service Repair Manual

4D2±18
TRANSFER CASE (TOD)
Reassembly
1. Install the clutch pack assembly which the multi clutch
plate is orderly installed to the output shaft.
NOTE:

Install the clutch pack assembly while adjusting the
phase of both the clutch housing and drive sprocket.

During installation, the plate of the clutch pack
assembly may slide out of this fixed position (the
correct position is shown in the illustration). If this
occurs, remove all of the clutch plates of the clutch
pack assembly and reinstall them to their correct
position.
266RY00009
2. Install the insulator washer and armature plate to the
clutch pack assembly.
266RY00008
3. Using snap ring pliers, install the snap ring to the
output shaft.
266RY00007
4. Install the wave spring to the output shaft.
266RY00006

4D2±19 TRANSFER CASE (TOD)
5. Install the cam pulley.
6. Place a ball on each groove of the cam pulley.
266RY00005
7. Install the cam and coil housing to the output shaft.
8. Install the thrust bearing.
9. Install the lockup fork spring.
261RY00020

4D2±20
TRANSFER CASE (TOD)
Chain, Sprocket and Mechanical Lock (Transfer Case Assembly)
262RY00021
Legend
(1) Transfer Case Assembly
(2) Cam and Shaft Rail Assembly
(3) Front Output Shaft
(4) Chain
(5) Lower Drive Sprocket
(6) Front Tone Wheel
(7) Drive Sprocket
(8) Spacer
(9) Shift Fork and Rail Assembly
(10) Lockup Rail(11) Spring Pin
(12) Shift Fork Assembly
(13) Lockup Fork
(14) Lockup Fork Spring
(15) Reduction Hub
(16) Rear Output Shaft
(17) Oil Pump Assembly (with Strainer)
(18) Thrust Washer
(19) Lockup Hub
(20) Lockup Collar Assembly
(21) Magnet

4D2±21 TRANSFER CASE (TOD)
Disassembly
1. Remove the spacer.
2. Remove the front tone wheel, lower drive sprocket,
drive sprocket and chain together from the front and
rear output shaft.
266RY00010
3. Remove the lockup collar assembly and lockup fork
together.
266RY00011
4. Remove the lockup hub.
5. Remove the thrust washer.6. Remove the magnet from the strainer set position
together with the oil pump assembly.
266RY00012
7. Remove the output shaft.
8. Remove the cam and shaft rail assembly.
262RY00015
9. Remove the shift fork and rail assembly, and
reduction hub.
10. Remove the spring pin from the shift fork and rail
assembly.
11. Remove the shift fork assembly from the lockup rail.
12. Remove the front output shaft from the transfer case.

4D2±22
TRANSFER CASE (TOD)
Reassembly
1. Apply ATF to the inside of the ball bearing.
2. Install the front output shaft to the transfer case.
262RY00019
3. Install the shift fork assembly to the lockup rail and fix
the assembly with the snap ring.
4. Install the shaft fork and rail assembly and reduction
hub to the transfer case.
262RY00015
5. Install the output shaft to the transfer case.
6. Install the oil pump assembly to the output shaft and
attach the magnet to the strainer set position.7. Install the thrust washer.
8. Install the lockup hub.
9. Install the cam and shaft rail assembly.
266RY00012
10. Install the lockup collar assembly and lockup fork
together.
266RY00011

4D2±23 TRANSFER CASE (TOD)
11. Apply ATF to the chain and engage it to both
sprockets.
12. Mount the chain and sprocket assembly to both
output shafts.
NOTE: When installing chain, the copper colored ring of
the chain (indicated by the arrow) to be installed in
direction of rear.
13. Install the front torn wheel to the front output shaft.
14. Install the spacer to the drive sprocket assembly.
266RY00018

4D2±24
TRANSFER CASE (TOD)
Transfer Case Assembly
265RY00001
Legend
(1) Transfer Case (with Oil Seal)
(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) Circular Hub
(10) Carrier Assembly
(11) Snap Ring
(12) Thrust Plate
(13) Sun Gear
(14) Input Shaft Assembly (with Bearing and
Bushing)
Disassembly
1. Using snap ring pliers, open the snap ring from the
gap on the carrier assembly.
While opening the snap ring, remove the input shaft
assembly, carrier assembly and thrust plate together
from the transfer case.
265RY00002

4D2±25 TRANSFER CASE (TOD)
2. Remove the snap ring from the transfer case.
265RY00003
3. Using snap ring pliers, remove the snap ring.
265RW009
4. Using the bearing remover J±22912±01, remove the
ball bearing from the input shaft.
265R200001
5. Remove the circular hub.
6. Remove the snap ring from the carrier assembly.
265RW006
7. Remove the thrust plate from the carrier assembly.

4D2±26
TRANSFER CASE (TOD)
8. Remove the snap ring before the ring gear.
261RW025
9. Using the ring gear remover J±42806 and a bench
press, remove the ring gear from the transfer case.
261R200005
NOTE: Removing ring gear needs a high-load press.
This means the transfer case may be damaged.
To remove and replace the ring gear, it is recommended
that the transfer case assembly should be replaced.10. Remove the ball bearing of the front output shaft from
the transfer case.
261RY00021
Reassembly
Oil Seal Replacement
1. Remove the oil seal of the front output shaft and input
shaft from the transfer case.
2. Apply the circumference of the new oil seal and fill the
lip with grease (BESCO L2 or its equivalent).
3. Using the oil seal installer J±42807, install the front
output shaft oil seal to the transfer case.
266RY00013

4D2±27 TRANSFER CASE (TOD)
4. Using the oil seal installer J±42808, install the input
shaft oil seal to the transfer case.
261RY00031
5. Using the ring gear installer J±42809 and a bench
press, install the ring gear to the transfer case.
NOTE: Pay attention to the following points.

Identify the correct direction of gear.

Do not damage the gear.

Do not press-fit the ring gear slantingly.

Press-fit the ring gear to the innermost.

Remove burrs generated by press-fitting.

If the transfer case has serrations, match them with
those of the gear and press-fit the gear.
261R200007
6. Install the snap ring.
7. Install the thrust plate to the carrier assembly.
Attach the snap ring to the carrier assembly.
8. Install the carrier assembly to the input shaft.
9. With care the direction of circular hub, mount it to the
input shaft.
265RW008
10. Press the ball bearing to the input shaft so that the
snap ring will be attached to the input shaft.
265RY00004
11. Install the snap ring to the input shaft.
12. Install the ball bearing of the front output shaft to the
transfer case.