ISUZU Amigo/Pick-ups/Rodeo/Trooper 1981-1996

Front Output Shaft Seal

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REMOVAL & INSTALLATION



1981-87 Models

See Figures 1, 2 and 3



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Fig. Fig. 1: Remove the output shaft cover to gain access to the output retaining nut



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Fig. Fig. 2: Use the flange holder tool J-8614-01, or equivalent, to hold the flange steady while loosening the retaining nut



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Fig. Fig. 3: Use the oil seal installer J-29037 and handle J-8092, or their equivalents, to tap a new oil seal into the transfer case housing-shown with the transfer case removed from the vehicle, however it can be performed while on the vehicle

  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Drain the transmission fluid. For more information on servicing the transmission fluid, refer to General Information & Maintenance .
  4.  
  5. Matchmark the front driveshaft flange to the front transmission flange for reassembly.
  6.  
  7. Remove the 4 driveshaft retaining bolts from the front differential.
  8.  
  9. Remove the 4 driveshaft retaining bolts from the transmission front flange.
  10.  
  11. Lower the driveshaft assembly out of the vehicle.
  12.  
  13. Remove the 4 front output shaft rear cover attaching bolts, then remove the cover. Make sure to retain the distance piece under the cover.
  14.  
  15. Use a flange holding tool J-8614-01, or its equivalent, to hold the front transmission flange steady while loosening the flange retaining nut.
  16.  
  17. Remove the flange retaining nut, the spring washer and the flat washer.
  18.  
  19. Carefully pull the front output shaft out of the transfer case.
  20.  
  21. Using a seal remover tool, pry the old front output shaft oil seal from the transfer case.
  22.  

To install:
  1. Using the front output shaft oil seal installer J-29037, tap a new oil seal into the transfer case.
  2.  
  3. Carefully slide the output shaft into the transfer case, then use the flange holding tool to hold the flange stationary while tightening the flange nut to 101-116 ft. lbs. (137-158 Nm). Make sure to install the spring washer and the flat washer before installing the retaining nut.
  4.  
  5. Install the distance piece in the transfer case, then install the output shaft cover with a new gasket. Tighten the cover attaching bolts to 18-22 ft. lbs. (24-30 Nm).
  6.  
  7. Position the driveshaft assembly under the vehicle, then lift the rear end of the driveshaft up and hold it against the transmission flange so the matchmarks align. Install the driveshaft-to-transmission flange bolts and nuts finger-tight.
  8.  
  9. Position the front driveshaft flange against the differential flange so the matchmarks align and install the attaching bolts and nuts finger-tight. Make sure the driveshaft-to-differential bolts are installed from the backside of the differential flange (the threaded portion of the bolt should be toward the transmission).
  10.  
  11. Tighten the driveshaft-to-differential flange and driveshaft-to-transmission flange bolts and nuts to 46 ft. lbs. (63 Nm).
  12.  
  13. Install the transmission drain plug, then fill the transmission with the proper amount and type of fluid. For more information, refer to General Information & Maintenance .
  14.  
  15. Lower the vehicle.
  16.  
  17. Start the engine and test drive the transmission. After driving the vehicle, look for transmission fluid leaks from the front oil seal.
  18.  

1988-96 Models

See Figures 4 and 5



Click image to see an enlarged view

Fig. Fig. 4: Use the flange holding tool J-37221, or equivalent, to hold the flange steady while loosening or tightening the flange retaining nut



Click image to see an enlarged view

Fig. Fig. 5: After tightening the flange retaining nut, stake the nut in one spot to prevent it from loosening

  1. Raise and safely support the vehicle on jackstands.
  2.  
  3. Drain the transmission fluid. For more information on transmission fluid service, refer to General Information & Maintenance .
  4.  
  5. Matchmark the front driveshaft flange to the front transmission flange for reassembly.
  6.  
  7. Remove the 4 driveshaft retaining bolts from the front differential.
  8.  
  9. Remove the 4 driveshaft retaining bolts from the transmission front flange.
  10.  
  11. Lower the driveshaft assembly out of the vehicle.
  12.  
  13. Use a flange holding tool to hold the front flange steady while loosening the flange retaining nut.
  14.  
  15. Remove the flange retaining nut and the old O-ring. Discard the O-ring.
  16.  
  17. Using an oil seal removal tool, pry the old oil seal out of the extension housing.
  18.  

To install:
  1. Apply a film of clean engine oil to the inner lip of the oil seal, then install it into the transmission extension housing with an oil seal installation tool.
  2.  
  3. Install a new O-ring onto the transmission rear flange and install the flange nut.
  4.  
  5. Use the flange holding tool to hold the flange stationary while tightening the flange nut to 101 ft. lbs. (137 Nm). Use a punch to stake the retaining nut at one spot.
  6.  
  7. Position the driveshaft assembly under the vehicle, then lift the driveshaft up and hold it against the transmission flange so the matchmarks align. Install the driveshaft-to-transmission flange bolts and nuts finger-tight.
  8.  
  9. Position the front driveshaft flange against the differential flange so the matchmarks align and install the attaching bolts and nuts finger-tight. Make sure the driveshaft-to-differential bolts are installed from the backside of the differential flange (the threaded portion of the bolt should be toward the transfer case).
  10.  
  11. Tighten the driveshaft-to-differential flange and driveshaft-to-transmission flange bolts and nuts to 46 ft. lbs. (63 Nm).
  12.  
  13. Fill the transmission with the proper type and amount of fluid. For more details, refer to General Information & Maintenance .
  14.  
  15. Lower the vehicle.
  16.  
  17. Start the engine and test drive the transmission. After driving the vehicle, look for transmission fluid leaks from the rear oil seal.
  18.  

 
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