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Home >> Isuzu >> 2004 >> Axiom Base, 4WD >> Repair and Diagnosis >> Transmission >> Transfer Case >> Transfer Case Tod >> Unit Repair >> Disassembly

Unit Repair: Disassembly

  1. Remove the drain plug from the transfer case and drain the oil.
  2. Remove the speedometer sensor and driven gear.
  3. Remove the front and rear speed sensor of the harness assembly from the transfer cover assembly.
    NOTE: Use care to prevent damage to speed sensor when removing speed sensor.
  4. Disconnect the clutch solenoid coil, 4H and 4L switch harness connector.
    • Remove the harness bracket from the transfer cover.
    Fig 1: Disconnecting Clutch Solenoid Coil Switch Harness Connector
    G02787742Courtesy of ISUZU MOTOR CO.
  5. Remove the connector bracket from the transfer case.
    • Remove the harness assembly and shift motor harness connector from the connector bracket.
    Fig 2: Removing Connector Bracket From Transfer Case
    G02805426Courtesy of ISUZU MOTOR CO.
  6. Remove the 4H and 4L switch from the transfer case.
  7. Remove the shift motor assembly from the transfer cover.
  8. Using the flange holder J-8614-11, remove the end nut.

    Remove the washers, oil seals, front and rear companion flange.

    Fig 3: Removing Washers Oil Seals Front And Rear Companion Flange
    G02805427Courtesy of ISUZU MOTOR CO.
  9. Remove the transfer cover retaining bolts and the transfer cover assembly from the transfer case assembly.
    NOTE: When removing the transfer cover assembly, use care to prevent damage to oil seal.
  10. Remove the breather hose from the transfer case.
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