Transfer Reassembly

WARNING: This page is about a different car, the 2003 Isuzu Rodeo Sport, 2003 Isuzu Rodeo, 2002 Isuzu Rodeo Sport, and 2002 Isuzu Rodeo. However, it is still accessible from the selected car via links, so may be relevant.

The rear cover oil seals and the rear output shaft ball bearings cannot be reused. They must be replaced with new ones when the transfer is reassembled.

Use the oil seal installer (J-46201) to press the new input shaft and/or front output shaft oil seals into place (If replacement is required).

Fig 1: Installing New Input Shaft Oil Seal (1 Of 2)
Courtesy of ISUZU MOTOR CO.

Fig 2: Installing New Input Shaft Oil Seal (2 Of 2)
Courtesy of ISUZU MOTOR CO.
Use a press to install the ball bearings to the front output shaft. Be sure that the bearings are fully inserted and then install the snap ring.
Install the damper ring and the internal gear to the transfer case. Be sure that the damper ring is between the internal gear and the case.

Fig 3: Installing Damper Ring And The Internal Gear To The Transfer Case
Courtesy of ISUZU MOTOR CO.

Note the direction of the damper ring installation as figure.

Fig 4: Identifying Direction Of Damper Ring
Courtesy of ISUZU MOTOR CO.
Use a press and the special tool (J-46200) and grip (J-8092) to hold the internal gear against the damper ring. Install the retaining ring (spiral type).

Fig 5: Holding The Internal Gear Against The Damper Ring
Courtesy of ISUZU MOTOR CO.
Use a press and the installer (J-46198) and grip (J-8092) to force the needle bearing fully into the carrier and gear assembly.

Fig 6: Forcing Needle Bearing Fully Into Carrier And Gear Assembly
Courtesy of ISUZU MOTOR CO.
Use a press and an appropriate special tool to force the ball bearings fully into the carrier and gear assembly.

Fig 7: Forcing Ball Bearings Fully Into Carrier And Gear Assembly
Courtesy of ISUZU MOTOR CO.
Install the carrier snap ring.
Install the thrust needle bearing, the sun gear input shaft, the needle bearing, the planetary dog teeth, and the dog teeth snap ring to the carrier and gear assembly in that order.
Install the outer retaining ring to the transfer case.
Use a pair of snap ring pliers to install the carrier and gear assembly.
NOTE: Be sure that the outer retaining ring fits snugly in its groove.

Fig 8: Installing The Carrier And Gear Assembly
Courtesy of ISUZU MOTOR CO.
Use a press to install the 2-4 hub.

Fig 9: Installing 2-4 Hub
Courtesy of ISUZU MOTOR CO.
Install the hub snap ring.
Install the synchronizer key springs (2), the synchronizer key, and the 2-4 sleeve to the 2-4 hub. The key and the open end of the springs must be facing in the opposite direction.
Insert the H-L sleeve into the main shaft.

Fig 10: Installing H-L Sleeve Into The Main Shaft
Courtesy of ISUZU MOTOR CO.
Install the sleeve to the H-L shift assembly.
Install the sleeve to the 2-4 shift assembly.
Coat the area around each of the shift assembly insertion holes (transfer case) with transfer oil.
Install the main shaft together with the H-L shift assembly and the 2-4 shift assembly to the shift drum.
Align the shift shaft splines with the shift drum and install the shafts to the drum.

Fig 11: Installing The Shafts To The Drum
Courtesy of ISUZU MOTOR CO.

NOTE: Be careful in the direction of an assembly.

Fig 12: Identifying Direction Of Assembly
Courtesy of ISUZU MOTOR CO.
Coat the main shaft with oil.
Align the block ring, the outside ring, and the inside ring with the 2-4 hub assembly and install them.
Assemble the sprocket, transfer chain, and front output shaft.
Install the sprocket, transfer chain, and front output shaft to the main shaft and the transfer case.
Align the sprocket thrust washer with the main shaft groove and install it.

Fig 13: Aligning Sprocket Thrust Washer With Main Shaft Groove
Courtesy of ISUZU MOTOR CO.

Select a snap ring that will allow minimum axial play. Insert it to the main shaft installation groove.

SNAP RING THICKNESS SPECIFICATION

Snap ring thickness	Identification color Item no.
2.15 mm (0.085 in)	Red
2.10 mm (0.083 in)	Not colored
2.05 mm (0.081 in)	Blue
2.00 mm (0.079 in)	White

Fig 14: Installing Snap Ring

Courtesy of ISUZU MOTOR CO.

Measure the snap ring external diameter. If the measured diameter is outside the specified range, a larger or smaller snap ring must be used.
1. Snap ring outside diameter (Standard):
2. 53.0+/-0.5 mm (2.09+/-0.02 in)
Position the rear cover so that its mating surfaces are facing up.
Use a press and the installer (J-46199) and grip (J-8092) to install the front output shaft needle bearing. The installer must be aligned with the bearing manufacturer's name (stamped into the bearing).

Fig 15: Installing The Front Output Shaft Needle Bearing
Courtesy of ISUZU MOTOR CO.
Install the oil pump wire snap ring to the rear cover.

Fig 16: Installing Oil Pump Wire Snap Ring To Rear Cover
Courtesy of ISUZU MOTOR CO.
Temporarily install the speedometer drive gear to the inside of the rear cover. Pay close attention to installation direction.
Use a press and the installer (J-24259) to install the rear output shaft ball bearings. Do not drive the ball bearings into place with a hammer.

Fig 17: Installing Rear Output Shaft Ball Bearings
Courtesy of ISUZU MOTOR CO.
Install the rear output shaft retaining ring.
Place the oil pump in its specified position.
Secure the pump strainer to the rear cover and tighten the bolts to the specified torque. Rear cover and transfer case bolt torque:
15 N.m (11 lb ft)

Fig 18: Placing Oil Pump In Its Specified Position
Courtesy of ISUZU MOTOR CO.
Apply Loctite FMD 127 to the mating surfaces of the rear cover and the transfer case. Be sure that the Loctite is evenly applied to the inside surfaces of the bolt holes with no gaps.

Fig 19: Applying Loctite FMD 127 To Mating Surfaces Of Rear Cover And Transfer Case
Courtesy of ISUZU MOTOR CO.
Install the rear cover to the transfer case and tighten the bolts to the specified torque.
Rear cover and transfer case bolt torque:

22 N.m (16 lb ft)
Apply engine oil to the companion flange O-ring.
Install the O-ring to the front output shaft.
Secure the front companion flange with the companion flange holder (J-8614-11).
Install the end nuts and tighten them to the specified torque.
Front companion flange end nut torque:

137 N.m (101 lb ft)

Fig 20: Installing Front Companion Flange End Nut
Courtesy of ISUZU MOTOR CO.
Use a cold chisel to caulk the front companion flange end nuts.

Fig 21: Using A Cold Chisel To Caulk Front Companion Flange End Nuts
Courtesy of ISUZU MOTOR CO.

Fig 22: Locating Dimension Of Caulk Front Companion Flange
Courtesy of ISUZU MOTOR CO.
Apply Loctite 575 to the threaded portion of the detent plugs.
Use the installer (J-46203) to install the main shaft end snap ring to the rear output shaft (from the back end of the shaft). Be absolutely sure that the snap ring is seated in the groove.

Fig 23: Installing Main Shaft End Snap Ring To Rear Output Shaft
Courtesy of ISUZU MOTOR CO.
Use the installer (J-46202) to install the rear output oil seal to the rear case.

Fig 24: Installing Rear Output Oil Seal To Rear Case
Courtesy of ISUZU MOTOR CO.
Install the detent balls, the detent springs, and the detent plugs (2 parts each) to the transfer case.
Tighten the plugs to the specified torque.

Detent plug torque: 19 N.m (14 lb ft)
Install the neutral switch (black harness cover) to the transfer case and tighten the bolts to the specified torque.
Neutral start switch bolt torque:

39 N.m (29 lb ft)
Install the 2-4 switch (gray harness cover) to the transfer case and tighten the bolts to the specified torque.
2-4 switch bolt torque: 39 N.m (29 lb ft)
Install the switch bracket to the transfer case and tighten the bolts to the specified torque.
Switch bracket bolt torque:

15 N.m (11 lb ft)
Install the transfer actuator assembly to the transfer case and tighten the bolts to the specified torque. The actuator must be installed in the same direction as the shaft.
Transfer actuator assembly bolt torque:

22 N.m (16 lb ft)
Install the breather hose between the transfer actuator and the transfer case.
Install the speedometer driven gear, the speedometer bush, and the speedometer stay to the transfer case. Tighten the bolts to the specified torque.
Speedometer bolt torque:

15 N.m (11 lb ft)
Install the drain plug to the transfer case and tighten it to the specified torque.
Drain plug torque: 39 N.m (29 lb ft)
Loosen and remove the filler plug. Add the specified volume of transfer oil (5W-30) or the equivalent to the transfer through the filler hole.
Transfer oil volume: 1.3 liters (1.37 U.S. quart)
Replace the filler plug and tighten it to the specified torque.
Filler plug torque: 39 N.m (29 lb ft)
Install the underguard and tighten the bolts to the specified torque.
Underguard bolt torque: 39 N.m (29 lb ft)