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Transfer Case: Reassembly

  1. Apply engine oil onto all seals on outer diameter. Install transfer case input shaft oil seal with Oil Seal Installer (J-38592). Install transfer case front output shaft oil seal with Oil Seal Installer (J-38594). Apply light multipurpose grease to seal lips.
  2. Apply grease onto gear thrust surfaces. Assemble counter gear and sub-gear assembly. Using press, install ball bearing onto counter gear shaft. Select and install appropriate snap ring to allow minimal axial play. See COUNTER GEAR SNAP RING SPECIFICATIONS  table.
    COUNTER GEAR SNAP RING SPECIFICATIONS

    Application In. (mm)
    Snap Ring Clearance 0-.004 (0-.10)
    Snap Ring Thickness
    White .059 (1.50)
    Yellow .061 (1.55)
    Blue .063 (1.60)
  3. Using spring pull type gauge, check sub-gear preload. See Fig 1. Preload should be 13-22 lbs. (18-30 N.m). Install bearing, snap ring and counter gear assembly into transfer case. Install bearing snap ring into transfer case.
  4. Press ball bearing onto front output shaft. Install front output shaft. Install NEW stopper plate. Coat all clutch sleeve and hub assembly parts with transmission oil. Assemble clutch sleeve and hub assembly. Engage springs in insert with ends away from each other. See Fig 2.
    Fig 1: Measuring Sub-Gear Preload
    G96C31593Courtesy of ISUZU MOTOR CO.
    Fig 2: Assembling Clutch Sleeve & Hub Assembly
    G96D31594Courtesy of ISUZU MOTOR CO.
  5. Install NEW stopper plate, and clutch sleeve and hub assembly onto front output shaft. Ensure heavy boss of clutch hub face is toward front output gear side. See Fig 3. Using press, slowly force clutch sleeve and hub assembly together with stopper plate into place.
  6. Align inserts with block ring insert grooves and install onto clutch sleeve and hub assembly. Install outside ring, inside ring and needle bearing onto front output gear and bearing collar. See Figure.
  7. On M/T models, assemble sub-gear, anti-lash plate, Belleville spring, spacer and snap ring onto front output gear. Coat all parts with transmission fluid. On all models, insert needle bearing into front output gear.
  8. Press needle bearing collar and front output gear onto front output shaft. Press ball bearing onto front output shaft and secure with snap ring. See Fig 4. Select and install appropriate snap ring to allow minimal axial play. See OUTPUT SHAFT SNAP RING SPECIFICATIONS  table.
    Fig 3: Installing Clutch Hub & Stopper Plate
    G96E31595Courtesy of ISUZU MOTOR CO.
    Fig 4: Assembling Needle Bearing Collar & Front Output Gear
    G96F31596Courtesy of ISUZU MOTOR CO.
    OUTPUT SHAFT SNAP RING SPECIFICATIONS

    Application In. (mm)
    Snap Ring Clearance 0-.004 (0-.10)
    Snap Ring Thickness
    White .061 (1.55)
    Yellow .063 (1.60)
    Blue .065 (1.65)
    Pink .067 (1.70)
    Green .069 (1.75)
    Brown .071 (1.80)
    Red .073 (1.85)
    Orange .075 (1.90)
  9. Check for proper sub-gear preload on front output gear assembly, following procedure for counter gear in step  3. Install front output gear assembly into transfer case and secure with ball bearing snap ring.
  10. Press ball bearing onto input shaft. Install plate, ball, bearing collar, needle bearing and transfer input gear. Install high-low clutch hub and sleeve (clutch hub face with heavy boss must face transfer input gear side). Install input shaft assembly with snap ring into transfer case.
    NOTE: Clutch hub face with heavy boss must face transfer input gear side. See Fig 5. On M/T models, clutch hub groove "A" must align with key groove of sleeve. See Fig 6.
    Fig 5: High-Low Hub Assembly Position
    G96G31597Courtesy of ISUZU MOTOR CO.
    Fig 6: Clutch Hub Groove & Sleeve Alignment
    G96H31598Courtesy of ISUZU MOTOR CO.
  11. Temporarily install front companion flange. Using Companion Flange Holder (J-8614-11) and Lock Nut Wrench (J-37219), tighten lock nut to specification. See TORQUE SPECIFICATIONS .
  12. Using punch, stake lock nut in one place. Using drift and hammer, install ball bearing and secure with snap ring. To complete reassembly, see REASSEMBLY under TRANSFER SHIFT ARM ASSEMBLY  and TRANSFER CASE HALVES  . Tighten fasteners to specification. See TORQUE SPECIFICATIONS .
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