Isuzu Cars and Trucks 1981-1991

Transfer Side Case

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OVERHAUL
1981 and 1987 P'up and Trooper
DISASSEMBLY
  1. Remove the detent spring and balls.
  2.  
  3. Remove the screw plugs.
  4.  
  5. Remove the screw plug.
  6.  
  7. Remove the shift rod.
  8.  
  9. Remove the 4x2/4x4 shift arm and block.
  10.  
  11. Remove the shift rod by removing the pin.
  12.  
  13. Remove the high/low shift arm.
  14.  
  15. Remove the dowel pin.
  16.  
  17. Remove the idler gear shaft.
  18.  
  19. Remove the idler gear and needle bearings.
  20.  
  21. Remove the thrust washer.
  22.  
  23. Remove the thrust washer.
  24.  
  25. Remove the front output shaft cover.
  26.  
  27. Remove the Distance piece.
  28.  
  29. Remove the front output shaft.
  30.  
  31. Remove the front output gear.
  32.  
  33. Remove the front output shaft front bearing.
  34.  
  35. Remove the front output shaft rear bearing.
  36.  



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Fig. Transfer side case 1981 and 1987 P'up and Trooper



Click image to see an enlarged view

Fig. Shift rod and idler gear removal for transfer side case 1981 and 1987 P'up and Trooper

ASSEMBLY
  1. Install the front output shaft rear bearing.
  2.  
  3. Install the front output shaft front bearing.
  4.  
  5. Install the front output gear.
  6.  
  7. Install the front output shaft.
  8.  
  9. Install the Distance piece.
  10.  
  11. Install the front output shaft cover.
  12.  
  13. Install the thrust washer.
  14.  
  15. Install the thrust washer.
  16.  
  17. Install the idler gear and needle bearings.
  18.  
  19. Install the idler gear shaft.
  20.  
  21. Install the dowel pin.
  22.  
  23. Install the high/low shift arm.
  24.  
  25. Install the shift rod by removing the pin.
  26.  
  27. Install the 4x2/4x4 shift arm and block.
  28.  
  29. Install the shift rod.
  30.  
  31. Install the screw plug.
  32.  
  33. Install the screw plugs.
  34.  
  35. Install the detent spring and balls.
  36.  

 
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