Isuzu Cars and Trucks 1981-1991

4-Wheel Drive Impulse

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REMOVAL AND INSTALLATION
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the transaxle and transfer fluid.
  4.  
  5. Remove the steering shaft protector, intermediate shaft pinch bolt and steering shaft boot.
  6.  
  7. Raise the vehicle and support with jackstands.
  8.  
  9. Remove the front wheels.
  10.  
  11. Remove the left driveshaft nut and both tie rod ends as outlined in .
  12.  
  13. Disconnect the lower ball joints as outlined in .
  14.  
  15. Remove all undercovers, front exhaust pipe and rear driveshaft.
  16.  
  17. Remove the steering hoses. Place a drain pan under to catch the fluid.
  18.  
  19. Support the engine with an engine hoist.
  20.  
  21. Remove the torque rod bolt at the center beam.
  22.  
  23. Remove the rear rubber mounting bolt, center beam and crossmember with the steering unit and stabilizer.
  24.  
  25. Disconnect the FWD driveshafts as outlined in this Section.
  26.  
  27. Disconnect the speedometer cable and support the transfer case with a jack.
  28.  
  29. Remove the transfer-to-transaxle attaching bolts and remove the assembly.
  30.  

To install:

  1. Install the transfer case and transfer-to-transaxle attaching bolts.
  2.  
  3. Connect the speedometer cable and support the transfer case with a jack.
  4.  
  5. Connect the FWD driveshafts as outlined in this Section.
  6.  
  7. Install the rear rubber mounting bolt, center beam and crossmember with the steering unit and stabilizer.
  8.  
  9. Install the torque rod bolt at the center beam.
  10.  
  11. Install the steering hoses.
  12.  
  13. Install all undercovers, front exhaust pipe and rear driveshaft.
  14.  
  15. Connect the lower ball joints as outlined in .
  16.  
  17. Install the left driveshaft nut and both tie rod ends as outlined in .
  18.  
  19. Install the front wheels.
  20.  
  21. Lower the vehicle.
  22.  
  23. Install the steering shaft protector, intermediate shaft pinch bolt and steering shaft boot.
  24.  
  25. Refill the transaxle and transfer fluid.
  26.  
  27. Connect the negative battery cable and check operation.
  28.  

OVERHAUL
DISASSEMBLY
  1. Remove the transfer case as outlined in this Section. Place the assembly in a holding fixture.
  2.  
  3. Remove the four bolts and pinion case assembly.
  4.  
  5. Remove the six bolts and flange from the case.
  6.  
  7. Remove the front cover and shims by removing the ten bolts. Remove the center differential and shims from the front cover.
  8.  
  9. Remove the front and center differential carrier. Remove the differential ring gear assembly.
  10.  
  11. Remove the countershaft assembly. Remove the countershaft rear bearing outer race and O-ring.
  12.  
  13. Remove the countershaft front bearing, race and shim.
  14.  
  15. Remove the axle shaft seals and speedometer driven gear.
  16.  



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Fig. Transfer case assembly 4WD Impulse



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Fig. Countershaft assembly 4WD Impulse



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Fig. Transfer center differential 4WD Impulse



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Fig. Transfer front differential 4WD Impulse



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Fig. Transfer pinion 4WD Impulse

ASSEMBLY
  1. Install the axle shaft seals and speedometer driven gear.
  2.  
  3. Install the countershaft front bearing, race and shim.
  4.  
  5. Install the countershaft assembly. Install the countershaft rear bearing outer race and O-ring.
  6.  
  7. Install the front and center differential carrier. Install the differential ring gear assembly.
  8.  
  9. Install the front cover and shims by installing the ten bolts. Install the center differential and shims to the front cover.
  10.  
  11. Install the six bolts and flange to the case.
  12.  
  13. Install the four bolts and pinion case assembly.
  14.  
  15. Install the transfer case as outlined in this Section.
  16.  

 
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