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

Transfer Case Assembly

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REMOVAL & INSTALLATION



1981-87 Models
TRANSFER SIDE CASE

See Figure 1



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the transfer side case, found in 1981-87 4WD models

Only the transfer side case can be removed without dismantling the entire transmission.

  1. Disconnect the negative battery cable.
  2.  
  3. Place the shift lever in the 2H position.
  4.  
  5. Remove the boot and the shift lever from the transfer case from inside the vehicle.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Drain the transmission and the transfer case.
  10.  
  11. Matchmark the driveshafts to the flanges and remove the driveshafts.
  12.  
  13. Position a jack under the transfer case and remove the transfer case mounting bolts.
  14.  
  15. Pull the transfer case away from the transmission and remove the transfer case.
  16.  

To install:
  1. Clean the sealing surfaces on the transmission and the transfer case. Align the shift forks and the sleeve in the 2H position, using a new gasket, install the transfer case to the transmission. Tighten the mounting bolts to 27 ft. lbs. (37 Nm).
  2.  
  3. Align the matchmarks and install the driveshafts.
  4.  
  5. Refill the transmission and the transfer case with 5W-30 engine oil.
  6.  
  7. Lower the vehicle to the floor.
  8.  
  9. Install the shift lever and the boot.
  10.  
  11. Connect the negative battery cable.
  12.  

1988-96 Models
EXCEPT 1995-96 TROOPER AND RODEO MODELS WITH AUTOMATIC TRANSMISSIONS

The transfer case is an integral part of the transmission housing. Although the 2 cases can be separated, the transfer case should be removed with the transmission.

1995-96 TROOPER AND RODEO MODELS WITH AUTOMATIC TRANSMISSIONS

See Figure 2



Click image to see an enlarged view

Fig. Fig. 2: When installing the transfer case, make sure to install the bolts in their proper locations-1995-96 Trooper and Rodeo models with 4WD automatic transmissions

  1. Shift the transfer case into the 2H position. Drive the vehicle forward and backward for a few feet/meters to make sure the front axle and hubs are disengaged. Shift the transmission to the N position.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the center console.
  6.  
  7. Remove the shift knob and boot from the transfer case shift lever. Unbolt the shift lever from the transfer case.
  8.  
  9. Disconnect the shift lock cable from the transmission shift lever.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the transmission and transfer case skid plates.
  14.  
  15. Disconnect the oxygen sensor from the front exhaust pipe.
  16.  
  17. Unbolt the front exhaust pipe from the exhaust manifolds and the catalytic converter. Remove the exhaust pipe and converter assembly.
  18.  
  19. Matchmark the front and rear driveshafts to the differential and transfer case flanges.
  20.  
  21. Unbolt and remove the front driveshaft.
  22.  
  23. Unbolt the rear driveshaft from the rear differential and transfer case flanges.
  24.  
  25. Unbolt the center bearing and remove the rear driveshaft.
  26.  
  27. Drain the transfer case oil.
  28.  
  29. Disconnect the transmission shift linkage from the shift lever rod.
  30.  
  31. Disconnect the 2 wiring harnesses from the transfer case.
  32.  
  33. Support the transfer case with a transmission jack.
  34.  
  35. Remove the transfer case-to-transmission bolts.
  36.  
  37. Separate the transfer case from the transmission output shaft. Lower the transfer case from the vehicle.
  38.  

To install:

Use new self-locking nuts when installing the exhaust pipe and converter.

  1. Apply a thin coating of molybdenum grease to transfer case input shaft splines.
  2.  
  3. Raise the transfer case to the level of the transmission and align the output and input shaft splines.
  4.  
  5. Install the transfer case-to-transmission case bolts, and tighten them to 34 ft. lbs. (46 Nm).
  6.  
  7. Remove the transmission jack.
  8.  
  9. Fill the transfer case with fresh engine oil.
  10.  
  11. Connect the 2 wiring harnesses. Connect the shift lever rod to the shift linkage.
  12.  
  13. Align the matchmarks and install the front and rear driveshafts. Tighten the flange bolts to 46 ft. lbs. (63 Nm).
  14.  
  15. Install the exhaust pipe and catalytic converter. Tighten the nuts to 32 ft. lbs. (43 Nm).
  16.  
  17. Install the skid plates and tighten their bolts to 27 ft. lbs. (37 Nm).
  18.  
  19. Lower the vehicle.
  20.  
  21. Install the transfer case shift lever.
  22.  
  23. Install the console, shift boot, and shift knob.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Check to make sure the transmission, transfer case, and front axle engage correctly.
  28.  

 
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