Isuzu Ascender 2003-05

Transfer Case Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle. Drain the transfer case.
  6.  
  7. Remove or disconnect the following:

    Fuel tank shield mounting bolts and shield
     
    Front and rear propeller shaft. Matchmark the shafts prior to removal.
     
    Fuel lines from the retainer
     
    Electrical harness from the retainers on the right and left sides
     
    Speed sensor electrical connectors
     
    Motor/encoder electrical connector
     
    Transfer case wiring harness
     
    Vent hose
     

  8.  
  9. Install a transmission jack to support the transfer case.

    Transfer case mounting bolts
     
    Transfer case from the vehicle
     
    Transfer case gasket and discard if damaged
     

  10.  

To install:

  1. Install or connect the following:
  2.  


NOTE
You must replace the transfer case gasket if it is damaged. Never use silicone sealant in place of, or with the transfer case gasket.



Transfer case, using a new gasket if necessary
 
Transfer case mounting bolts and tighten to 35 ft. lbs. (47 Nm)
 

  1. Remove the transmission jack.
  2.  
  3. The remainder of installation is the reverse of removal.
  4.  
  5. Refill the transfer case.
  6.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle. Drain the transfer case.
  6.  
  7. Remove or disconnect the following:

    Fuel tank shield mounting bolts and shield
     
    Front and rear propeller shaft. Matchmark the shafts prior to removal.
     
    Fuel lines from the retainer
     
    Electrical harness from the retainers on the right and left sides
     
    Speed sensor electrical connectors
     
    Motor/encoder electrical connector
     
    Transfer case wiring harness
     
    Vent hose
     

  8.  
  9. Install a transmission jack to support the transfer case.

    Transfer case mounting bolts
     
    Transfer case from the vehicle
     
    Transfer case gasket and discard if damaged
     

  10.  

To install:

  1. Install or connect the following:
    NOTE
    You must replace the transfer case gasket if it is damaged. Never use silicone sealant in place of, or with the transfer case gasket.






    Transfer case, using a new gasket if necessary
     
    Transfer case mounting bolts and tighten to 35 ft. lbs. (47 Nm).
     

  2.  
  3. Remove the transmission jack.
  4.  
  5. The remainder of installation is the reverse of removal.
  6.  
  7. Refill the transfer case.
  8.  

 
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