ISUZU TROOPER 1995 Workshop Manual

Fig. 7D-56
DETENT SPRING TENSION (Fig. 70-57)
• Use a spring tester to measure the detent spring
tension.
• If the measured value is less than the specified
limit, the detent spring must be replaced.
Detent spring tension
Compressed Standard N (lb)
height mm(in)
Detent
ball 20.5 (0.807) 65-75
(14.6 -16.8)
Interlock pin 11.5 (0.453) 9.8 (2.2)
Fig. 7D-57
SHIFT ARM
•
Inspect the shift arms for wear, distortion or
scoring. Replace
if these conditions are present.
SHIFT ARM THICKNESS (Fig. 70-58)
• Use a micrometer to measure the shift arm
thickness.
• If the measured value is less than the specified
limit, the shift arm must be replaced.
TRANSFER CASE 70-23
Shift arm thickness mm (in)
Standard
9.60 - 9.85 (0.378 -0.388)
Limit 9.0 (0.354)
Fig. 7D-58
l•!•l REASSEMBL V
39. Transfer case (with oil seal)
Oil
seal replacement
Input shaft oil seal:
• Remove the oil seal from the transfer case.
j3 • Apply engine oil to the oil seal outer surfaces.
r.:;::'l • Apply recommended grease (BESCO L2) or
D equivalent to the oil seal lip.
li:\1 • Use the oil seal installer to install the oil seal to
~ the transfer case (Fig. 7D-59 & Fig. 7D-60).

70-24 TRANSFER CASE
Transfer side
(M/TI
--...___ (A/TI
T/M side
Front
Input shaft oil seal
Fig. 70-59
Fig. 70-60
lc::: I \f~ /(\A\~
t \l(
~~~
-------'"'-~'~
Transmission side
T/F side
Oil seal installer: J-37488 } MIT
Driver handle: J-8092
Oil
seal installer: J-38592 (AIT)
Front
output shaft oil seal:
• Remove the oil seal from the transfer case.
j §]•
~·
Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
Use the oil seal
installer to install the oil seal to
the transfer case (Fig.
70-61 ).
Oil sHal installer: J-38594
• Cover the shaft splines with adhesive tape CD.
This will prevent damage to the oil seal lip ®
(MIT) (Fig. 70-62).
Fig. 70-61
•

IMITI
Fig. 70-62
~~~· Apply recommended liquid gasket (LOCTITE
FMO 127) or its equivalent to the transmission,
intermediate
plate and transfer case fitting
surfaces (M/T) (Fig. 70-63).
• Install the transfer case together with
intermediate plate with gear asssembly to
transmission case (M/T).
~~~· Tighten the transfer case bolts to the specified
torque a
little at a time (M/T).
Torque
N·m (lb·ft)
38. Counter gear
37. Sub-gear
Fig. 70-63
37 (27)
§!• Apply chassis grease to the sub-gear and the
counter gear thrust surfaces (Fig. 70-64).
TRANSFER CASE 70-25
36. Belleville spring
35. Spacer
34.
Ball bearing
33.
Snap ring
Fig. 70-64
Apply chassis
grease
rfil • Select a snap ring that will allow the minimum
l!l:.l axial play (Fig. 70-65 & 70-66).
Clearance mm (in) I 0 -0.1 (0 -0.004)
Snap ring availability (Fig. 70-66) mm (in)
Thickness
Color-Coding
1.50 (0.059) White
1.55 (0.061)
Yellow
1.60 (0.063) Blue
•
Use a pair of snap ring pliers to install the snap
ring to the counter gear.
Fig. 70-65

70-26 TRANSFER CASE
Fig. 70-66
Sub Gear Preload (Fig. 70-67)
~·
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
32. Ball bearing
31.
Snap ring
N (lb)
Fig. 70-67
30. Counter gear assembly
59-98 (13-22)
• Install the counter gear assembly to the
transfer case.
29. Bearing snap ring
• Use a pair of snap ring pliers to install the snap
ring
to the transfer case.
W NOTE:
~ The snap ring must be fully inserted into the
transfer case snap ring groove.
28. Front output shaft
27. Ball bearing
• Use a bench press to install the ball bearing to
the front output shaft (Fig. 70-68).
Fig. 70-68
26. Clutch hub and sleeve
• Use a bench press to install the clutch hub to
the front output shaft (Fig. 70-69).
25. Needle bearing
24.
Front output gear
23. Sub-gear
(MIT)
22. Belleville spring (MIT)
21. Spacer (M/T)
C1 • Apply engine oil to the thrust surfaces of the
t.::::::J sub-gear, the belleville spring, and the spacer
(Fig.
70-70).
Fig. 70-69
(M/TI
Apply engine oil
Fig. 70-70
•

20. Sub-gear snap ring (MIT)
19. Bearing collar
• Use a bench press to install the needle bearing
collar together with the front output gear (Fig.
70-71).
Fig. 70-71
18. Ball bearing
17. Bearing snap ring
rfil • Select a snap ring that will allow the minimum
~ axial play (Fig. 70-72 & Fig. 70-73).
Clearance mm (in) 0 -0.1 (0 -0.004)
Snap ring availability mm (in)
Snap ring thickness Color coding
1.55 (0.061)
White
1.60 (0.063)
Yellow
1.65 (0.065) Blue
1. 70 (0.067)
Pink
1.75 (0.069)
Green
1.80 (0.071)
Brown
1.85 (0.073)
Red
1.90 (0.075) Orange
•
Use a pair of snap ring pliers to install the snap
ring
to the output shaft.
TRANSFER CASE 70-27
Fig. 70-72
Fig. 70-73
Sub gear preload MIT (Fig. 70-74)
~·
Hook a length of piano wire over one ofthe sub­
gear teeth.
• Attach the other end of the piano wire to a
spring
balancer.
•
Measure the sub-gear preload.
Preload
N (lb) I 59 -98 (13 -22)
Fig. 70-74

70-28 TRANSFER CASE
16. Front output gear assembly
15. Bearing snap ring
• Use a pair of snap ring pliers to install the snap
ring to the transfer case.
U7NOTE:
VI The snap ring must be fully inserted into the
transfer case snap ring groove.
14. Input shaft (A/T)
13.
Ball bearing (A/T)
• Use a bench press to install the ball bearing to
the
input shaft (Fig. 70-75).
(A/TI
12. Plate
11. Ball
10.
Bearing collar
9. Needle bearing
Fig. 70-75
8. Transfer input gear
7. High-low block ring (MIT)
6. High-low sleeve & hub (A/T) or High-low
synchronizer assembly (MIT)
r=l • The clutch hub face (with the heavy boss) must
1=.1 be facing the transfer input gear side (Fig. 70-
76).
• The clutch hub groove® must be aligned with
the key groove
of sleeve (M/T) (Fig. 70-77).
Transfer input
gear side
Fig. 70-76 Fig.
70-77
5. Input shaft assembly (AIT)
4. Snap ring (A/T)
• Install the snap ring to the input shaft.
• Install the input shaft assembly to the transfer
case.
• lnstal1l the snap ring to the transfer case.
U7 NOTE:
VI The snap ring must be fully inserted into the
transfer case snap ring groove.
3. Lock nut
• Install the front companion flange temporarily.
1®..1• Use the flange holder and lock nut wrench to
install the lock nut (Fig. 70-78)
Companion
flange holder: J-37221
Lock nut wrench: J-37219
1~1 Torque N·m (lb·ft) 137 (101)
2.
• Use the punch to stake the lock nut at one
spots
..
Fig. 70-78
Ball bearing
• Use a suitable drift and hammer to install the
ball bHaring (Fig. 70-79).
•

TRANSFER CASE 70-29
1. Bearing snap ring
Fig. 70-79
MAIN DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Type Constant mesh type gears shifting between the 2 and 4
wheel drive mode.
Synchronized type gear
(M/T only) between "low" and
"high".
Control method Direct control with the gear shift lever on the floor.
Gear ratio
High; 1.000
Low; 2.283
Oil capacity lit. (U.S. quart) 1.45 (1.53)
Type of lubricant Engine oil
Refer to chart in Section
0

70-30 TRANSFER CASE
TORQUE SPECIFICATIONS
TRANSFER CASE (A/T)
~
-1 J2_ -"
'
~'~
~
r;;;;·
I 43 (32) I
N·m (lb·ft)
~"
1-
~----------------------------------------------------------~ Fig. 70-80
•

TRANSFER CASE 70~31
TORQUE SPECIFICATIONS N·m (lb·ft)
Fig. 70-81

70-32 TRANSFER CASE
SPECIAL TOOLS
ILLUSTRATION TOOL NO.
TOOL NAME ILLUSTRATION TOOL NO.
TOOL NAME
!l!l
J-22912-01
Bearing remover/installer
~
J-37221
--~ Transfer flange holder
~
J-38592
Transfer case
oil seal
installer
(A/T) ~
J-37217 Mainshaft end bearing
remover
y
J-37219
Mainshaft nut wrench
~
J-8433
Puller 1
~
J-37223
Rear
output shaft end ..... bearing installer ===-
J-8092
-Driver handle
~
J-37488
Transfer case
oil seal
installer
(MIT)
~
J-39209
Punch, end nut
~
J-38594
Front
output shaft oil
seal installer
~
J-39208
Rear oil seal installer
~
J-37486
Bearing
installer adapter
•