wheel ISUZU TROOPER 1995 Workshop Manual

Pilot aligner: J-24547
• Mark the flywheel, clutch cover and pressure
plate lug for alignment when installing.
4. Release bearing
• Remove the release bearing from the
transmission case (Fig. 7C-9).
5. Shift fork
• Remove the snap pin.
• Remove the shift fork pin and shift fork from the
fulcrum bridge (Fig. 7C-10).
!
Fig. 7C-9
Fig. 7C-10
6. Fulcrum bridge
• Remove the fulcrum bridge bolts.
•
Remove the fulcrum bridge from the
transmission case (Fig. 7C-11).
7. Flywheel assembly and crankshaft bearing
• Do not remove except for replacement.
~~~· Use the remover to remove the crankshaft
bearing (Fig. 7C-12).
Remover; J-5822
Sliding hammer; J-23907
Fig. 7C-11
Fig. 7C-12
[L!j INSPECTION AND REPAIR
CLUTCH 7C-7
Make necessary correction or parts replacement if
wear, damage, or any other
abnormal condition are
found through inspection.
Pressure plate assembly (Fig. 7C-13)
• Visually check the pressure plate friction
surface
for excessive wear and heat cracks.
If excessive wear or deep heat cracks are
present, the pressure
plate must be replaced.
e ·---------
Fig. 7C-13

7C-8 CLUTCH
I~U Pressure plate warpage (fig. 7C-14)
• Use a straight edge and a feeler gauge to
measure the pressure plate friction surface
flatness in
four directions.
If any of the measured values exceeds the
specified limit, the pressure plate
must be
replaced.
Pressure plate warpage
Limit
0.3 (0.012)
Fig. 7C-14
Clutch cover (fig. 7C-15)
mm (in)
• Visually check the entire clutch cover for
excessive wear, cracking, and other damage.
The clutch cover
must be replaced if any of
these conditions are present.
Fig. 7C-15
jQI Clutch set force (Fig. 7C-16)
1. Invert the pressure plate assembly.
2. Place a new driven plate over the pressure
plate.
A metal sheet
with @ thickness of 8.0 mm
(0.315 in) may be used in place of the driven
plate
..
3. Compress the pressure plate assembly until
the
distance® becomes 12 mm (0.472 in).
4. Note the pressure gauge reading.
If the measured value is less than the specified
limit, the pressure plate assembly
must be
replaced.
Clutch set force N (lb)
Standard Limit
7:208 (1621) 6669 (1499)
Fig. 7C-16
1•1 Diaphragm spring finger height (fig. 7C-17)
1. Place a new driven plate or a 8.0 mm (0.315 in)
spacer beneath the pressure plate.
2. Fully compress the pressure plate and
diaphragm spring.
There are
two ways to do this.
a. Use a bench press to press down on the
asst~mbly from the top.
b. Tighten the fixing bolts.
IDNOTE:
Yf Pre-Load on diaphragm spring finger must be 49-
98N
(11-~~2 lb) in direction of release, when clutch
cover
assembly is bolted to the flywheel.
3. Measure the spring height from base to spring
tip@.
If the measured value exceeds the specified
limit, the pressure plate assembly
must be
replaced.
Spring finger height
mm (in)
Standard
49.9 -51.9 (1.965 -
2.043))
•

Shift fork (Fig. 7C-23)
• Visually check the surfaces of the shift fork
making contact
with the release bearing for
excessive wear and damage.
• Remove any minor stepping or ah,rasion from
shift fork with an oil stone.
Replace any exhibiting
· ex«?~ssive wear or
damage.
Fig.
7C-23
1••1 INSTALLATION
To install, follow the removal steps in the reverse
order, noting the
following points:
7. Flywheel assembly and crankshaft bearing
§I• Clean and lubricate with grease.
1®..1• Use the installer to install the crankshaft
bearing (Fig. 7C-24).
Installer: J-26516-A
Driver handle: J-8092
Fig.
7C-24
CLUTCH 7C-11
• Bolts: flywheel fixing (Fig. 7C-25)
• Install new bolts in the order illustrated and
tighten them to the specified torque.
1~1 Torque N·m (lb·ft) I 54 (40)
6.
NOTE:
• Do not reuse the bolt.
•
Do not apply oil or thread lock to the bolt.
Fig. 7C-25
Fulcrum bridge (Fig. 7C-26)
• Install the fulcrum bridge to the transmission
case.
• Tighten three fulcrum bridge bolts to the
specified torque.
I~I __ T_o_rq~u_e __ N_·_m~(_lb_·ft_l~ _____ 3_8_(_28_) ____ _
5. Shift fork (Fig. 7C-27)
• Apply molybednum disulfide contained type
grease
to the pin hole inner circumferences
and thrust surfaces.
• Attach the shift fork to the fulcrum bridge and
insert the pin
from below of the fulcrum bridge.
• Install the washer and snap pin.
Fig.
7C-26

Fig. 7C-36
(6) Clutch pedal engagement height inspection
(Fig.
7C-37)
block the wheels.
® Start the engine, fully step on the clutch
pedal,
and move the shift lever to 1st
position.
@ With the engine idling, release the
clutch pedal slowly and measure its
stroke -just prior
to its clutching
position.
Clutch pedal engagement height (H3) mm (in)
MIN. 30 (1.18)
If the
measured value exceeds the specified
limit, check the following points. Repair if
necessary.
• Hydraulic circuit for fluid leakage or air in
circuit.
• Clutch disc warped.
• Diaphragm spring weakened or tip of
fingers worn.
• Driven plate sticking on sprines.
• Release bearing worn or damaged.
• Master cylinder and slave cylinder worn.
Floor panel
Fig. 7C-37
CLUTCH 7C-15
2. Torque N·m (lb·ft)
Master cylinder to dash panel 16 (12)
Clutch pedal to dash panel 21 (15)
Master cylinder push rod to yoke 17 (12)
Clutch pipe to master cylinder 20 (14)
Clutch pipe
to damper cylinder 12
(104 lb·in)
Clutch
pipe to flex, hose 20 (14)
Slave cylinder to case 43 (32)
Slave
cylinder bleeder screw 8 (691b·in)
Clutch
pipe to slave cylinder 20 (14)
Damper cylinder bleeder union nut 49 (36)
Damper cylinder bleeder pipe 15 (11)
Damper cylinder
bleeder screw 8 (69 lb·in)
3. Bleeding
(1) Check
the level of clutch fluid in the reservoir
and
replenish if necessary (Fig. 7C-38).
Fig. 7C-38
Bleeding the damper cylinder (Fig. 7C-39)
Damper cylinder
Fig. 7C-39

TRANSFER CASE 7D-1
SECTION 70
TRANSFER CASE
w CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were removed. If a
fastener needs
to be replaced, use the correct part number fastener for that application. If the correct part
number is not available, a fastener
of equal size and strength (or stronger) may be used. Fasteners that are
not reused, and those requiring thread locking compound, will
be called out. The correct torque values must
be used when installing fasteners that require torque.
If the above conditions are not followed, parts or
system damage could result.
CONTENTS
General Description ................... 7D-1
Construction . . . . . . . . . . . . . . . . . . . . . . . . . 7D-2
On-Vehicle Service .................... 7D-3
Transfer
Case (A/T) .................. 7D-3
Transfer Rear
Oil Seal ................ 7D-5
Unit Repair ........................... 7D-8
Transfer
Case Assembly (AfT) ........ 7D-8
Transfer Rear
Case Assembly . .

. . . . . 7D-11
Detent, Shift Arm, And
Interlock Pin (Transfer
Case Assembly) . .

. . . . . . . . . . . . . . . . . . 7D-14 Transfer
Case
Assembly . .
. . . . . . . . . .
7D-17
Main Data And Specifications . . . . . . . .
70-29
General
Specifications . .
. . . . . . . . . . . .
70-29
Torque
Specifications ............... 7D-30
Special Tools
........................ 7D-32
GENERAL DESCRIPTION
The transfer case is used to provide a means of
providing power flow to the front axle. The transfer
case also provides a means of disconnecting the front
axle, providing better fuel economy and quieter
operation when the vehicle is driven
on improved
roads where four wheel drive is not required.
In
addition, the transfer case provides an additional gear
reduction when placed in low range, which
is useful
when difficult off-road conditions are encountered. A
floor mounted shift lever is used to select the
operating range. When four wheel drive has been
selected, the four wheel drive indicator light is
designed to come
on when the front axle has been
engaged.

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

CHASSIS ELECTRICAL 8-1
·SECTION 8
CHASSIS ELECTRICAL
'\f CAUTION: .
When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct
part number fastener is not
available, a fastener of equal size and strength (or stronger) may be used.
Fasteners that are not reused, and those requiring thread
locking compound, will be called out. The correct
torque
values must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.
CONTENTS
General Information .................................... 8-2
Notes for Working on Electrical
Items .................................................... 8-2
Symbols and Abbreviations ................. 8-8
Symbols ............................................ 8-8
Abbreviations ................................... 8-9
Parts for Electrical Circuit ..................... 8-10
Wiring ............................................... 8-10
Fuse .................................................. 8-11
Fusible Link ....................................... 8-12
Circuit Breaker ................................... 8-12
Relay ................................................. 8-12
Relay Specifications and
Configurations ................................ 8-13
Diode ................................................. 8-14
Connector ......................................... 8-15
Reading the Circuit Diagram ................ 8-17
Main Data and Specifications .................... 8-19
Bulb Specifications ................................ 8-19
Fuse,
Fusible Link and
Circuit Breaker Location ..................... 8-21
Fuse
Block Circuit .................................. 8-22
Reference Table of Fuse, Fusible
Link and Circuit Breaker ..................... 8-23
Relay Location ....................................... 8-27
Diode Location .......................................
8-28
Grounding Point .................................... 8-29
Reference Table ................................ 8-29
Location ............................................ 8-31
Cable Harness Routing .......................... 8-34
System Repair .............................................. 8-38
Start and Charging ................................ 8-38
Engine Control Module
(ECM) ................................................... 8-47
Headlight and Fog Light ........................ 8-58
Front Side Marker Light, Parking Light,
Taillight, License Plate Light and
Illumination Light .............................. 8-76
Stoplight and Rear Defogger .............. 8-92
Turn Signal Light, Hazard
Warning
Light, Cornering Light,
Backup
Light and Horn ..................... 8-106
Dome Light, Luggage room Light,
Courtesy Light, Map Light,
Seat Belt Switch and
Warning Buzzer ................................. 8-128
Power Door Lock ................................. 8-142
Power
Window .................................... 8-156
Cruise
Control ...................................... 8-172
Anti-Lock Brake
System (ABS) ........... 8-178
Rear
Wheel Anti-Lock Brake
System (RWAL) ................................. 8-185
Transmission
Control Module
(TCM) ................................................. 8-192
A/T Shift Lock ...................................... 8-200
Windshield
Wiper/Washer and
Rear
Wiper/Washer .......................... 8-205
Headlight wiper /washer ..................... 8-232
Audio, Auto Antenna,
Cigarette
Lighter and digital clock ... 8-246
Power Door Mirror ............................... 8-254
Anti-theft System ................................ 8-270
Meter and Warning/Indicator Light ... 8-288
A/T Shift Indicator ............................... 8-336
Heater and
Air Conditioning ............... 8-340
Sun
Roof ............................................... 8-346
Power Seat ........................................... 8-360
Seat
Heater .......................................... 8-37 4
Supplemental Restraint
System (SRS) -AIR BAG ................... 8-382

CHASSIS ELECTRICAL 8-9
ABBREVIATIONS
Abbreviation
Meaning of Abbreviation Abbreviation Meaning of Abbreviation
A Ampere
(S) LH Left
hand
ABS Anti-lock brake system LWB Long wheel base
ASM Assembly M!f Manual transmission
AC Alternating current OD Over drive
A/C
Air conditioner OPT Option
ACC Accessories QOS Quick on start
A/T Automatic
transmission
RH Right hand
C/8 Circuit
breaker
RR Rear
CSD Cold start device RWAL Rear
wheel anti-lock brake system
DIS Direct ignition system SRS Supplemental restraint system
EBCM Electronic brake control module
ST Start
ECGI Electronic control gasoline injection STD Standard
ECM Engine control module sw Switch
ECU Electronic control unit SWB Short wheel
base
EFE Early fuel evaporation TCM Transmission
control module
4A/T 4-speed
automatic transmission
3A/T 3-speed
automatic transmission
4X4 Four-wheel drive
v Volt
FL Fusible link vsv Vacuum switching valve
FRT Front w Watt {S)
H/L Headlight WOT Wide open throttle
IC Integrated circuit WI With
IG Ignition W/0 Without
kW
kilowatt

CHASSIS ELECTRICAL 8-21
FUSE, FUSIBLE LINK AND CIRCUIT BREAKER LOCATION
ooooo 112~12~1~1~1
00 E
EEr 00 ~
Relay & fuse box
SJOOO 7-6
I lw ;;::;~ Fuse box ~ ~
1l1~~ ~lff~UIH~Inll
w~ F-a FL-4 ~
00 FL·S~ r---, F-11 'l2~J1~ 1~1&11~11~1,\l~31hl1~1
0
0
FL-6 'F-i2
I' ~
\a~ a~;
0000
0000
I ~
l/
~
j
~/~/ e:;?' v II I / / .I / /
('-/ .
~~
-~-~;,a~ ~~ --.:_
~~~~ -
Relay & Fuse box Fuse box
Fuse
Fuse Fuse
No. Capacity Indication on label No. Capacity Indication on label No. Capacity Indication on label
F-1 --C-1 10A STARTER RELAY
C-14 15A STOP A!f CONT
F-2 10A 02 SENSOR HEATER C-2 15A (SEAT HEATER)
C-15 20A (AUDIO [8))
F-3
15A HORN HAZARD C-3 15A
TURN BACK C-16 10A CLOCK (8] ROOM
F-4
15A H/LAMP-LH C-4 10A ELEC.IGN. C-17 25A RR DEFOG
F-5
15A H/LAMP-RH C-5
15A FRTWIPER & C-18 20A (DOOR LOCK)
F-6 --WASHER C-19
25A BLOWER
F-7
- -C-6 10A RRWIPER & C-20 10A (AIR
CON)
F-8
15A (FRT.FOG) WASHER C-21 10A SRS-1
F-9 20A ABS C-7 10A (H/LAMP C-22 10A SRS-2
F-10
15A FUEL PUMP WIPER) C-23 lOA SRS-3
F-11 -
-C-8 15A ENGINE C-24 10A SRS-4
F-12
15A TAIL C-9 15A IGN. COIL CIRCUIT BREAKER
FUSIBLE
LINK
C-10 10A METER GAUGE
C/8-1 --FL-1 80A MAIN C-11 10A
(AUDIO IACC])
C/8-2 30A (P/W, P/S, S/R)
FL-2 50 A KEYSW MIRROR
FL-3 30A ECM C-12 20A CIGARETTE 02: Oxygen
FL-6 40A (ASS 4/WHEEL ONLY) C-13 10A (ANTI THEFT)
Fig. 8-44

8-22 CHASSIS ELECTRICAL
FUSE BLOCK CIRCUIT
GENERATOR -------------------~s~w~------------~~s~w~--~~~~ r- / B L 1------CHARGE SIGNAL &W _/
FL-1 80A .-----, B 11.'1 MAIN
+ Lt--
l£h
~----/ IG~----------~O~.$~B/V~-----------,
3W REL~HT1NG 1J ---'"~L 3
RELA~PUMP 4 1...---. 12 2 B/0
1.25 B/0
SW
3RJ8
5W
~~~·~ F-1 0 0 F-2 10A
I F-315A
F-8
0 0 F-7 0 0 F-81SA
F-920A
9;nlaool
I
Oz SENSOR HEATER
HORN HAZARD
H/LAMP-LH
H/LAMP-RH
(FRT. FOG)
lABS) -I ABS
I ,--------__:<;;:R·.:.:W.::..Acc·L;;:-1 ____ ----Jv F-10 1SA 2 810
I
~ECM RELAY; ECM MAIN ¢~,...,..J>--+2'-'RIW~_::2~1-o.....-<:>-f-·4.:._ __ _. ~J~CTOR
L...-_.ECM
FL-t 40A ABS 4/WHEEL ONLY
"
.... ...
SW
5W
3 8IY
F-11 0 0 F-1215A
~------' FUSE BOX
CIB-2 30A ~.,.;
C-110A :
C-215A
C-31SA
C-410A
I
J
FUEL PUMP
TAIL
P/W, PIS. SIR
STARTER RELAY
(SEAT HEATER)
TURN BACK
ELEC.IGN.
e-s
15A 1 ""'-.0---t-----+----il FRT WIPER & WASHER
"""' -
I 3W/G
C-810A '---f-+----+.:3.:BIR::::..+---¢""''-£>---i-----f-----jl RR WIPER & WASHER
ABS HYORAULIC UNIT
STARTERSW
FL-2 _JJ OFF
~ ...
..:..AKEYSW 3 W/B ay ' o.N". 3UB
~~--~--~,~------~-0 ~~IG~2Y-----------~ o-: ST 3W/B 81 -.,IG1
FUSE BOX
I
I g1~ 1 J'-:::s:R:s-:1 =I RELAY; STARTER
STARTER I r-
L~---'~-j.t 3 B/V
I I 3UB
sw
C-710A
~';::--~--~-'---~~~HI~LA~M~P~W~IP~E~R~l~~ C-81SA ""'-'>--1---...__---i ENGINE
C-111SA I J~======~l IGN. COIL (G)
C-10 10A
C-1110A
k'-1:>----t----t
~==~I
METER GAUGE
""''-£>---f----------1 (AUDIO[ACC)) MIRROR
C-12 20A
::...1310A I
C-141SA -r"\'-1)----f----t
C-15 20A L,-.
CIGARETTE
(ANTITHEFT)
STOP A/T CONT.
(AUDIO[ B))
C-1810A """"-'-.0---f----------t_j CLOCK[B) ROOM
L---+------------------------iB lt~;_ ~=~~~:~:~::~~~: C-17 2SA I
G1820A
RR DEFOG
= sw (DOOR LOCK) RELAY; HEATER &A/C .:._ __________________ .:.:3~W'-'---------------------~2to~.....-4 3UR C-19 2SA ...... BLOWER
A/C : AIR CONDITIONING ECM : ENGINE CONTIIOL MODULE 0, :OXYGEN ABS
:ANTI-LOCK
BRAKE BYBTEM
RWAL: REAR WHEEL ANTI-LOCK BRB : SUPPLEMENTAL RESTRAINT SYSTEM
C-20 10A (AIR CON)
Fig. 8-45
•