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Unit Repair: Reassembly

  1. Apply recommended liquid gasket (LOCTITE 598 or its equivalent) uniformly to the transfer case and cover fitting surface.
    Fig 1: Applying Liquid Gasket Uniformly To Transfer Case And Cover Fitting Surface
    G02787745Courtesy of ISUZU MOTOR CO.
  2. Install the plate, bracket, connector bracket and ground cable of the harness assembly, and tighten the transfer cover retaining bolts (16 pieces) to specified torque.

    Torque:  31 N.m (23 lb ft)

    Fig 2: Installing Plate Bracket Connector Bracket And Ground Cable Of Harness Assembly (1 Of 2)
    G02787746Courtesy of ISUZU MOTOR CO.
    Fig 3: Installing Plate Bracket Connector Bracket And Ground Cable Of Harness Assembly (2 Of 2)
    G02805426Courtesy of ISUZU MOTOR CO.
  3. Install the front and rear companion flange.
  4. Install the oil seal and washer, and using the flange holder J-8614-11, install the new end nut to the specified torque.

    Torque:  167 N.m (123 lb ft)

  5. Securely stake the end nut at one spot.
    NOTE: Be sure to confirm that there is no clack at the staked portion of the end nut after staking.
    Fig 4: Installing Front And Rear Companion Flange (1 Of 2)
    G02787748Courtesy of ISUZU MOTOR CO.
    Fig 5: Installing Front And Rear Companion Flange (2 Of 2)
    G02787749Courtesy of ISUZU MOTOR CO.
  6. Apply recommended liquid gasket (LOCTITE 598 or its equivalent) to the transfer cover and shift motor assembly fitting surface.
    Fig 6: Applying Recommended Liquid Gasket To Transfer Cover
    G02805431Courtesy of ISUZU MOTOR CO.
  7. Install the shift motor assembly to the transfer cover assembly.

    Torque:  10 N.m (87 lb in)

  8. Install the 4H and 4L switch.

    Torque:  24 N.m (17 lb ft)

  9. Install the harness assembly and shift motor harness connector to the connector bracket.
  10. Install the front and rear speed sensors to the transfer cover.

    Torque:  5 N.m (43 lb in)

  11. Connect the harness assembly connector to the clutch solenoid coil harness connector and 4H and 4L switch.
    • Fix the harness with harness bracket.
    Fig 7: Connecting Harness Assembly Connector To Clutch Solenoid Coil Harness Connector
    G02787751Courtesy of ISUZU MOTOR CO.
  12. Install the driven gear and speedometer sensor to the transfer case.

    Torque:  25 N.m (19 lb ft)

    Fig 8: Installing Driven Gear And Speedometer Sensor
    G02787752Courtesy of ISUZU MOTOR CO.
  13. Remove the filler plug and fill the transfer case with ATF DEXRON®-II or III.
  14. Wind the sealing tape around the filler plug thread and tighten the plug to the specified torque.

    Torque:  25 N.m (19 lb ft)

    Fig 9: Removing Filler Plug
    G02805434Courtesy of ISUZU MOTOR CO.
  15. Install the breather hose to the transfer case.
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