Transfer Disassembly: Removal: Notes

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.

Remove the stoneguard.
Remove the drain plug from the transfer case to drain the oil.
Remove the parts listed below.
- Speedometer bush, plate, and speedometer driven gear
- Breather hose (Between the transfer case and the transfer actuator assembly)
- Transfer actuator assembly
- Switch bracket
- 2-4 switch assembly (Gray harness cover)
- Neutral switch assembly (Black harness cover)
- Detent plugs, detent springs, and detent balls (2 parts each)
Use the companion flange holder (J-8614-11) to remove the end nut from the front companion flange.

Fig 1: Removing End Nut From Front Companion Flange
Courtesy of ISUZU MOTOR CO.
Remove the bolts attaching the rear cover to the transfer case.
Strike the area around the front output shaft head and the rear cover bolt holes with a plastic hammer to remove the rear cover.

Fig 2: Removing Rear Cover
Courtesy of ISUZU MOTOR CO.
Remove the parts listed below from the rear cover.
- H-L sleeve
- H-L shift assembly
- 2-4 sleeve, synchronizer key, and front synchronizer spring (do not remove the rear spring)
- 2-4 shift assembly
- Shift drum and shift shaft
- Sun gear needle bearing
Fig 3: Removing Parts From Rear Cover
Courtesy of ISUZU MOTOR CO.
Remove the oil pump strainer fixing bolts from the rear cover.
Compress the retaining ring at the rear of the chain. Strike the rear end of the main shaft with a plastic hammer to remove the main shaft, transfer chain, and front output shaft assembly from the rear cover. Be careful not to damage the oil pump strainer.

Fig 4: Striking The Rear End Of The Main Shaft With A Plastic Hammer
Courtesy of ISUZU MOTOR CO.
Remove the transfer chain and the front output shaft from the main shaft.
Remove the main shaft snap ring.
Remove the speedometer drive gear, the ball bearings, the retaining ring, and the oil pump assembly.
Remove the sprocket snap ring.
Remove the thrust washer, the drive sprocket, the inside ring, the outside ring, the block ring, and the rear synchronizer spring.

Fig 5: Removing Thrust Washer, Drive Sprocket, Inside Ring, Outside Ring, Block Ring, And Rear Synchronizer Spring
Courtesy of ISUZU MOTOR CO.
Remove the snap ring from the main shaft.
Use a press to remove the 2-4 hub from the main shaft.

Fig 6: Removing The 2-4 Hub From The Main Shaft
Courtesy of ISUZU MOTOR CO.
Spread the edges of the retaining ring while lightly tapping on the sun gear input shaft end. Remove the carrier and gear assembly from the transfer case.

Fig 7: Lightly Tapping On The Sun Gear Input Shaft End
Courtesy of ISUZU MOTOR CO.
Remove the dog teeth snap ring from the carrier and gear assembly.
Remove the planetary dog teeth and the sun gear input shaft together with the thrust needle bearing.

Fig 8: Identifying Sun Gear Input Shaft With Thrust Needle Bearing
Courtesy of ISUZU MOTOR CO.
Remove the carrier snap ring.
Use a press to remove the ball bearings.

Fig 9: Removing The Ball Bearings
Courtesy of ISUZU MOTOR CO.
Use the sliding hammer (J-2619-1) and the needle bearing replacer (J-29369-2) to remove the needle bearing from the center of the carrier and gear assembly.

Fig 10: Removing The Needle Bearing From Center Of Carrier And Gear Assembly
Courtesy of ISUZU MOTOR CO.
Remove the retaining ring (spiral type) together with the internal gear and the damper ring.

Fig 11: Removing Retaining Ring
Courtesy of ISUZU MOTOR CO.
Remove the snap ring.
Use a press to remove the front output shaft ball bearings.
Remove the oil pump wire snap ring from the rear cover.
Use a sliding hammer (J-2619-01) and a needle bearing replacer (J-26941) to remove the needle bearing from the front output shaft.

Fig 12: Removing Snap Ring
Courtesy of ISUZU MOTOR CO.