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Removal and Installation of Transfer Case Assembly: Installation

  1. Apply grease (Besco L2 or its equivalent) to the input shaft spline.
    Fig 1: Identifying Input Shaft Spline
    G02787732Courtesy of ISUZU MOTOR CO.
  2. Install the transfer case assembly to the transmission assembly.
  3. Install the transfer bolts to the specified torque.

    Torque:  46 N.m (34 lb ft)

  4. Connect the engine harness connector to the transfer harness connector.
  5. Install the breather hose up to bottom of the transfer case breather and clip them firmly.
  6. Securely insert the breather hose into the cutout portion of the transfer case.
    Fig 2: Inserting Breather Hose Into Cutout Portion Of Transfer Case
    G02787733Courtesy of ISUZU MOTOR CO.
  7. Install the speedometer harness clamp to the connector bracket of the transfer case, and then connect the harness connector to the speedometer sensor.
    Fig 3: Installing Speedometer Harness Clamp To Connector Bracket Of Transfer Case
    G02787734Courtesy of ISUZU MOTOR CO.
  8. Install the center exhaust pipe.

    Torque:  43 N.m (32 lb ft)

  9. Connect the front and rear propeller shaft assembly to the transfer case.

    Torque:  63 N.m (46 lb ft)

  10. Install the transfer protector.

    Torque:  37 N.m (27 lb ft)

  11. Connect the battery ground cable.
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