ISUZU TROOPER 1998 Service Repair Manual

MUA MODEL 7B1 – 51
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives
you important points as well as the order of operation. Be sure that you understand everything in this
Section before you begin.
Important Operations – Removal
Battery Cable
Disconnect the negative (–) cable from the battery
terminal.
Engine Hood
Apply setting marks to the engine hood and the engine
hood hinges before removing the engine hood.
Gear Shift Lever and Transfer Change Lever
1. Place the gear shift lever in the neutral position.
2. Place the transfer change lever in the “H” position.
3. Remove the gear shift lever knob and transfer
change lever konb.
4. Remove the center console assembly and front
console assembly.
5. Remove the grommet and dust cover.
6. Remove the gear shift lever cover bolt.
7. Remove the gear shift lever.
8. Remove the transfer change lever retainer bolts.
9. Remove the transfer change lever and O-ring.
Note:
Cover the shift lever and change lever holes to prevent
the entry of foreign material into the transmission.
Lifting the Vehicle
1. Jack up the vehicle.
2. Place chassis stands at the front and the rear of the
vehicle.
Transfer Case Protector (Except 00 Year or Subsequent
ones)
Remove the transfer case protector from the transmission
mounting member and the side member.
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MUA MODEL 7B1 – 53
Front Propeller Shaft
Remove the splined yoke flange bolt at the transfer case
side.
Do not allow the splined yoke to fall away from the front
propeller shaft.
If the splined yoke should fall away from the front
propeller shaft, align the setting marks
3on the splined
yoke 1and the propeller shaft 2to reassemble the two
parts.
The setting marks 3are punched circles approximately 3
mm (0.12 in) in diameter.
TDC Sensor (4JA1TC Model)
Disconnect the TDC sensor from the transmission
housing.
Harness Connector
Disconnect the 4WD switch connectors, back up light
switch connector and the speedometer sensor connector.
220R200001
Slave Cylinder
Remove the slave cylinder from the transmission case.
220LV019
Engine LIfting Hanger
1. Attach the engine lifting hanger to the front portion of
the engine.
2. Attach the lifting wire to both ends of the engine
lifting hange.

MUA MODEL 7B1 – 57
Starter Motor
1. Install the starter motor to the engine rear plate.
Starter Motor Bolt Torque kg·m (lb·ft/N·m)
8.0 ± 1.6 (58 ± 12/78 ± 16)
Engine Rear Mounting and Mounting Member
1. Install the engine rear mounting to the transmission.
Rear Mounting Bolt Torque kg·m (lb·ft/N·m)
4.2 ± 0.5 (30 ± 3.6/41 ± 4.9)
2. Install the mounting member 1to the mounting
rubber 2.
Mounting Rubber Nut Torque kg·m (lb·ft/N·m)
5.1 ± 0.6 (37 ± 4.3/50 ± 6)
3. Install the mounting member to the sidemembers.
Mounting Member Bolt Torque kg·m (lb·ft/N·m)
5.1 ± 0.6 (37 ± 4.3/50 ± 6)
Slave Cylinder
Install the slave cylinder to the transmission case.
Slave Cylinder Bolt Torque kg·m (lb·ft/N·m)
4.1 ± 1.0 (30 ± 7.2/40 ± 10)
Harness Connector
Disconnect the 4WD switch connectors back up light
switch connector and speedometer sensor connector.
220LV019
TDC Sensor (4JA1TC Model)
Connect the TDC sensor from the transmission housing.
220R200001

MUA MODEL 7B1 – 59
Exhaust Pipe
1. Connect the front exhaust pipe and 2nd-3rd exhaust
pipe.
2. Install the exhaust pipe bracket to the transmission
case.
220LV018
Transfer Case Protector (Except 00 Year or Subsequent
ones)
1. Install the transfer case protector 1to the mounting
member 2and the sidemebers 3.
2. Tighten the transfer case protector bolts to the
specified torque.
Transfer Case Protector Bolt Torque kg·m (lb·ft/N·m)
3.7 ± 1.0 (26.8 ± 7.2/36.3 ± 9.8)
Gear Shift Lever and Transfer Change Lever
1. Replenish the transmission case and the transfer
case with the specified engine oil.
Transmission and Transfer Case Oil lit (US/UK qt.)
Transmission Case 2.95 (3.12/2.6)
Transfer Case 1.45 (1.53/1.28)
2. Install the gear shift lever to the gear control box.
Shift Lever Cover Bolt Torque kg·m (lb·ft/N·m)
2.0 ± 0.2 (14.5 ± 1.5/19.6 ± 1.96)
3. Install the dust cover.
4. Insert the transfer change lever to the transfer case.
Change Lever Retainer Bolt Torque kg·m (lb·ft/N·m)
2.0 ± 0.2 (14.5 ± 1.5/19.6 ± 1.96)
5. Install the grommet.
6. Install the front console assembly and center console
assembly.
7. Install the gear shift lever and the transfer change
lever knobs.
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