torque ISUZU AXIOM 2002 Service Repair Manual

4D2±4
TRANSFER CASE (TOD)
Removal
1. Disconnect the battery ground cable.
2. Remove the transfer protector.
3. Disconnect the rear propeller shaft assembly from the
transfer case.
4. Disconnect the front propeller shaft assembly from
the transfer case.
5. Remove the center exhaust pipe.
6. Disconnect the speedometer sensor harness
connector from the speedometer sensor, and remove
the harness clamp from the connector bracket of the
transfer case.
7. Disconnect the engine harness connector from the
transfer harness connector.
8. Support the transfer case with a transmission jack.
9. Remove the transfer bolts.
10. Remove the transfer case assembly.
Installation
1. Apply grease (Besco L2 or its equivalent) to the input
shaft spline.
260RY00011
2. Install the transfer case assembly to the transmission
assembly.
3. Install the transfer bolts to the specified torque (Refer
to
next page).
Torque: 46 N´m (34 lb ft)
4. Connect the engine harness connector to the transfer
harness connector.
5. Install the breather hose up to bottom of the transfer
case breather and clip them firmly.
6. Securely insert the breather hose into the cutout
portion of the transfer case.
260R200001

4D2±5 TRANSFER CASE (TOD)
7. Install the speedometer harness clamp to the
connector bracket of the transfer case, and then
connect the harness connector to the speedometer
sensor.
261R200008
8. Install the center exhaust pipe.
Torque: 43 N´m (32 lb ft)
9. Connect the front and rear propeller shaft assembly
to the transfer case.
Torque: 63 N´m (46 lb ft)
10. Install the transfer protector.
Torque: 37 N´m (27 lb ft)
11. Connect the battery ground cable.

4D2±7 TRANSFER CASE (TOD)
NOTE: When installing the oil seal, pay attention to the
direction.
261RW006
Legend
(1) Inside
(2) Outside
3. Install the companion flange.
4. Install the oil seal and washer, and using the flange
holder J±8614±11, install the new end nut to the
specified torque.
Torque: 167 N´m (123 lb ft)5. Securely stake the end nut at one spot.
NOTE: Be sure to confirm that there is no clack at the
staked portion of the end nut after staking.
266RY00003
266R200004
6. Connect the rear propeller shaft assembly to the
transfer case.
Torque: 63 N´m (46 lb ft)

4D2±11 TRANSFER CASE (TOD)
2. Install the plate, bracket, connector bracket and
ground cable of the harness assembly, and tighten
the transfer cover retaining bolts (16 pieces) to
specified torque.
Torque: 31 N´m (23 lb ft)
261RY00035
261RY00037
3. Install the front and rear companion flange.
4. Install the oil seal and washer, and using the flange
holder J±8614±11, install the new end nut to the
specified torque.
Torque: 167 N´m (123 lb ft)5. Securely stake the end nut at one spot.
NOTE: Be sure to confirm that there is no clack at the
staked portion of the end nut after staking.
266RY00003
266R200004

4D2±12
TRANSFER CASE (TOD)
6. Apply recommended liquid gasket (LOCTITE 598 or
its equivalent) to the transfer cover and shift motor
assembly fitting surface.
261R200003
7. Install the shift motor assembly to the transfer cover
assembly.
Torque: 10 N´m (87 lb in)
8. Install the 4H and 4L switch.
Torque: 24 N´m (17 lb ft)
9. Install the harness assembly and shift motor harness
connector to the connector bracket.
10. Install the front and rear speed sensors to the transfer
cover.
Torque: 5 N´m (43 lb in)
11. Connect the harness assembly connector to the
clutch solenoid coil harness connector and 4H and 4L
switch.

Fix the harness with harness bracket.
261RY00009
12. Install the driven gear and speedometer sensor to the
transfer case.
Torque: 25 N´m (19 lb ft)
261RY00034
13. Remove the filler plug and fill the transfer case with
ATF DEXRON)±II or III.
14. Wind the sealing tape around the filler plug thread and
tighten the plug to the specified torque.
Torque: 25 N´m (19 lb ft)
261RY00026
15. Install the breather hose to the transfer case.

4D2±15 TRANSFER CASE (TOD)
Reassembly
Transfer cover oil seal replacement
1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to 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±42804, install the oil seal
to the transfer cover assembly.
261RY00017Shift shaft oil seal replacement
4. Remove the oil seal from the transfer cover assembly.
5. Apply oil the circumference of the new oil seal.
6. Using the oil seal installer J±33951, install the oil seal
to the transfer cover assembly.
The drive in depth must be 9.4 ~ 10.4 mm (0.370 ~
0.409 in). The knurled end of the installer (indicated
by the arrow) must be flush with the oil seal
installation surface.
NOTE: Use care to prevent tilt to oil seal when installing
oil seal to the case.
261R200009
7. Install the ball bearing of the front output shaft to the
transfer cover.
8. Install the speed gear and tone wheel.
9. Install the ball bearing to the transfer cover.
10. Using snap ring pliers, install the snap ring to the
transfer cover.
NOTE: The snap ring must be fully inserted into the
transfer cover snap ring groove.
261RY00018
11. Install the coil assembly to the transfer cover and
tighten the set nuts (3 pieces) to the specified torque.
Torque: 10 N´m (87 lb in)
12. Install the connector to the harness terminal of the coil
assembly.
261RY00013

4D2±32
TRANSFER CASE (TOD)
Main Data and Specification
General Specification
TypeElectronically controlled torque split four wheel drive with two wheel
drive.
2WD: Rear two wheel drive
TOD: Electronically controlled torque split four wheel drive.
4L: Low speed mechanical lockup four wheel drive.
Rear drive: Direct drive
Front drive: Chain drive
Low range deceleration: Planetary gear drive
Control systemSwitch control
Gear ratioHigh: 1.000
Low: 2.480
Lubrication systemBuilt-in oil pump
Forced lubrication
Type of lubricantATF DEXRON)±II or III
Oil capacity1.35 liters. (1.43 US.quart)
Clutch discs number13
Planetary gear teeth numberSun gear: 58
Pinion gear: 15
Ring gear: 86

4D2±33 TRANSFER CASE (TOD)
Torque Specifications
E04R200001

4D2±34
TRANSFER CASE (TOD)
Torque Specifications (Cont'd)
E04R200002

4D2±35 TRANSFER CASE (TOD)
Torque Specifications (Cont'd)
E04R200003