transmission ISUZU TROOPER 1995 Workshop Manual

TRANSFER CASE 70-3
ON-VEHICLE SERVICE
TRANSFER CASE (A/T)
5
<;J---5 6
7
' 8
9
~
10
Removal steps Installation steps
1. Exhaust and transfer protectors 6. Selector lever
assembly To
install, follow the removal
steps in the reverse order.
2. Rear propeller shaft 7.
Transfer control lever
3. Front propeller shaft 8.
Wiring harness connector
4. Exhaust pipe 9. Transmission-transfer bolt
5. Engine control module
(ECM)
cover and front console 10.
Transfer case assembly
Fig. 7D-2
l••l REMOVAL
Preparation:
• Disconnect battery negative (-) cable.
•
Drain transfer case fluid.
1. Exhaust and transfer protectors
2. Rear propeller shaft
3. Front propeller shaft
• Remove the rear and front propeller shaft from
the transfer case side.
4. Exhaust pipe
• Remove the pre-catalytic converter.
• Remove the center exhaust pipe.
• Disconnect oxygen sensor connector from the
transmission harness.
5. ECM cover and front console
• Remove the transfer control lever knob.
• Disconnect the harness connectors.
6. Selector lever assembly
• Disconnect the shift lock cable from the
selector lever assembly side (Fig. 7D-3).
• Disconnect the harness connectors.
• Disconnect the shift control rod from the
selector lever assembly side (Fig. 7D-4).

70-4 TRANSFER CASE
Fig. 70-3
Fig. 70-4
7. Transfer control lever
8. Wiring harness connector
• Disconnect the 4WD switch and speed sensor
harness connector from the transmission
harness.
9. Transmission-transfer bolt
• Support the transfer case with a transmission
jack.
• Remove four transmission-transfer bolts and
three nuts.
10. Transfer case assembly
• Remove the transfer case assembly from the
vehicle.
1••1 INSTALLATION
To install, follow the removal steps in the reverse ~
order, noting the following points:
1. Transfer case assembly
r;:;J • Apply a thin coat of molybdenum disulfide
D grease to the input shaft spline (Fig. 70-5).
Fig. 70-5
• Transmission-transfer bolt (Fig. 70-6)
1~1 Torque N·m (lb·ft)
2. Exhaust pipe bolt
1~1 Torque
Center pipe front side
Pre-catalytic converter bolt
3. Propeller shaft bolt
1~1 Torque N·m (lb·ft)
46 (34)
N·m (lb·ft)
43 (32)
43 (32)
63 (46)
•

70-20 TRANSFER CASE
Fig. 70-47
27. Ball bearing
• Use the bearing remover to remove the ball
bearing (Fig. 70-48).
Bearing remover: J-22912-01
Fig. 70-48
28. Front output shaft
29. Bearing snap ring
30. Counter gear
assembly
• Remove the counter gear assembly from the
transfer case.
31. Snap ring
• Use a pair of snap ring pliers to remove the
snap ring.
32. Ball bearing
j®_j• Use a bench press and the bearing remover to
remove the ball bearing.
Bearing remover: J-22912-01
33. Snap ring
• Use a pair of snap ring pliers to remove the
snap ring.
34. Ball bearing
~ • Use a bench press and the bearing remover to
remove the
ball bearing (fig. 70-49). Bearing
remover: J-22912-01
Fig. 70-49
35. Spacer
36.
Bellevilfe spring
37. Sub-gear
38. Counter gear
39. Transfer case
(with oil seal)
• Cover the shaft splines with adhesive tape CD.
This will prevent damage to the oil seal lip ®
(MIT) (Fig. 70-49a).
• Remove the transfer case together with
intermediate plate with gear assembly from the ~
transmission case (MIT).
• Remove the transfer case from the inter­
mediate plate
with gear assembly (MIT).
IM/TI
Fig. 70-49a
IL•I INSPECTION AND REPAIR
Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
Wash
all parts thoroughly in clean solvent. Be sure all
old
lubricant, metallic particles, dirt, or foreign material
are removed from the surfaces
of every part. Apply
compressed
air to each oil feed port and channel in
each case
half to remove any obstructions or cleaning
solvent residue.
•

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

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

-·*; ~---
8-2 CHASSIS ELECTRICAL
GENERAL INFORMATION
The chassis electrical system is of 12-volt specifications with a negative ground polarity.
Wire sizes are appropriate
to respective circuits, and classified by color. (The classification of harnesses by
color is shown on the circuit diagram for ease of harness identification.)
The
wire size is determined by load capacity and the length of wire required.
The
vehicle harnesses are: body harness, chassis harness, engine room harness, instrument harness,
transmission harness, engine
ECGI harness, dome light harness, door harness, rear body harness, tailgate
harness,
SRS harness and battery cables.
The harnesses are protected either
by tape or corrugated tube, depending on harness location.
The circuit
for each system consists of the power source, wire, fuse, relay, switch, load parts and ground, all of
which are shown on the circuit diagram.
In this manual, each electrical device is classified by system. For major parts shown on the circuit based on
the circuit diagram
for each system, a summary, diagnosis oftroubles, inspection and removal and installation
procedures are detailed.
NOTES FOR WORKING ON ELECTRICAL ITEMS
Disconnecting the Battery Cable (Fig. 8-1)
Ground cable
Fig. 8-1
1. All switches should be in the "OFF" position.
2. Disconnect the battery ground cable.
3. Disconnect the battery positive cable.
W CAUTION:
It is important that the battery ground cable be
disconnected first.
Disconnecting the battery positive cable first can
result in a short circuit.
Connecting the Battery Cable
Follow the disconnecting procedure in the reverse
order.
\V CAUTION:
Clean the battery terminal and apply a light coat
of grease to prevent terminal corrosion.
Connector Handling
Disconnecting The Connectors (Fig. 8-2)
Fig. 8-2
Some connectors have a tang lock to hold the connec­
tors together during vehicle operation.
Some tang locks are released by pulling them towards
you
G).
Other tang locks are released by pressing them for­
ward®.
Determine which type oftang lock is on the connector
being handled.
Firmly grasp both sides (male and female)
of the
connector. Release the tang lock and carefully pull the
two halves
of the connector apart.
Never pull on the wires
to separate the connectors.
This
will result in wire breakage (Fig. 8-3).
.,
..

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 8-23
REFERENCE TABLE OF FUSE, FUSIBLE LINK AND CIRCUIT BREAKER
FUSE
'--"' (Relay and fuse box)
Fuse No. Capacity
Indication on· label Parts (Load)
F-1 --
-
F-2 10A 02 SENSOR HEATER Oxygen sensor
F-3 15A HORN HAZARD Horn, Horn relay, Horn SW, Hazard warning SW,
Flasher
unit, Anti-theft horn, Anti-theft controller
F-4 15A
H/LAMP-LH Headlight (LH), High beam indicator light, Dimmer·
passing SW, Cornering light SW, Fog light SW, Fog
light relay, Cornering light, Cornering light relay
F-5 15A
H/LAMP-RH Headlight (RH), Dimmer·passing SW
F-6 ---
F-7 --
-
F-8 15A (FRT FOG) Fog light, Fog light relay
F-9 20A ABS Hydraulic unit, Rear wheel anti-lock brake controller,
Electronic brake control module
F-10 15A FUEL PUMP
Fuel pump
F-11 ---
F-12 15A TAIL Tail
relay, Lighting SW, FRT side maker light, Parking
light, Taillight, Trailer harness connector, Illumination
controller, Illumination light, Glove
box SW, License
plate light, A/T shift indicator control unit
(Fuse Box)
Fuse No. Capacity
Indication on label Parts (Load)
C-1 10A STARTER RELAY Starter relay, Clutch start SW (M/T), Mode SW (A/T),
Anti-theft controller, DERM (SRS)
C-2 15A (SEAT
HEATER) Seat heater SW (LH & RH), Seat heater (LH & RH)
C-3 15A TURN BACK Transmission control module, Turn signal SW, Front
turn signal light, Rear turn signal light, Turn signal
indicator light, Flasher unit, Cornering light relay,
Backup light, Backup light SW (M/T), Mode SW (A/T),
A/T shift indicator control unit, Lighting SW, A/T shift
lock control unit, A/T shift indicator, Cruise control
unit, Cancel SW

8-24 CHASSIS ELECTRICAL
(Fuse Box)
Fuse No.
Capacity Indication on label Parts (Load)
C-4 10A
ELEC.IGN. Cruise control unit, Rear defogger SW, Rear defogger
relay, Rear
defo9ger SW indicator light, Clutch SW
(M{T), Transmission SW-1, 2 (M!T), Transmission
SW-3, 4 (M{T), Cancel
SW (Combination SW), Cruise
control main
SW, Cruise control main relay, Cruise
control indicator light, Cruise control
SW, Door mirror,
Door mirror defogger SW, AfT shift lock control unit,
Power window relay, Electronic brake control module,
Transmission control module, G sensor, Upshift-2
relay, Upshift indicator (Meter)
C-5 15A FRTWIPER &WASHER
Windshield wipt~r and washer SW, Windshield wiper
motor, Windshit~ld washer motor, Windshield wiper
intermittent relay
C-6 10A RR WIPER & WASHER
Rear wiper & washer SW, Rear washer motor, Rear
wiper motor, Rear wiper intermittent relay
C-7 10A (H/LAMP WIPER) Headlight wiper SW, Headlight wiper motor, Headlight
washer motor, Headlight
wiper timer
C-8 15A ENGINE Generator, ECM main relay, V.S.V; EGA, V.S.V: canister,
V.S.V: intake air
(DOHC)
C-9 15A IGN. COIL Ignition control module, Engine control module
C-10 10A METER GAUGE Vehicle speed stmsor, Remind Buzzer, Meter and
gauge
(Voltmeter, Engine coolant temperature gauge,
Tachometer, Speedometer,
Oil pressure gauge, Fuel
gauge),
Indicator and warning light (Anti-lock brake
system, Rear wheel anti-lock, Seat belt, check engine,
Low fuel, 4WD,
Oil pressure, Upshift, Brake system,
Charge,
AfT oil temp, Cruise control indicator light,
Check trans indicator light,
Power drive indicator
light,
Winter drive indicator light), 4WD SW, Parking
brake SW, Seat belt SW, Brake differential SW
Electronic brake control module, Engine control
module, Rear wheel anti-lock brake controller
C-11 10A (AUDIO[ACCJ) MIRROR Audio, Door mirror, Door mirror control SW, Door
mirror folding SW, Digital clock, Speaker
C-12 20A CIGARETTE Cigarette lighter
C-13 10A
ANTI THEFT Anti-theft controller
C-14 15A
STOP AfT CONT Stoplight SW (w/o cruise control), Brake SW (w/cruise
control), Rear wheel anti-lock brake controller,
Stoplight, Transmission control module, Electronic
brake control module, Trailer harness connector,
Cruise control unit,
AfT shift lock control unit, Lockup
off relay
C-15
20A (AUDIO[B]) Horn,
Horn relay, Horn SW, Hazard warning light SW,
Flasher unit, Anti-theft horn, Hazard warning light,
Audio
•