This article describes the removal and installation of the transfer cover assembly on Isuzu 2000 models

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Disassembly
1. Using snap ring pliers, remove the snap ring.





2. Strike the speed gear and tone wheel with a rod or
other appropriate tool from the outside of the transfer
cover assembly, and remove the ball bearing and
speed gear and tone wheel.
NOTE: Pay attention not to damage the speed gear
teeth.





3. Remove the stopper plate on the back with a
precision screwdriver or other appropriate tool
starting from the small lock of the plate.
NOTE: Pay attention not to damage the stopper plate
during the work.





4. Using a terminal pull-out tool or an equivalent tool,
push down the lock to unlatch the terminal for the coil
assembly, and pull the terminal out.
NOTE: Pay attention not to damage other terminals.





5. Remove the fixing nuts of the coil assembly from the
outside of the transfer cover assembly. Remove the
coil assembly from the transfer cover.

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6. Using the bearing remover J-42805 and slide
hammer J-2619-01, remove the ball bearing for the
front output shaft.





7. Remove the bolts and front and rear speed sensors.
NOTE: Pay attention not to damage the speed sensors
during the work.







Reassembly
1. Remove the oil seal from the transfer cover assembly.

2. Apply oil to the circumference of the new oil seal and
fill the lip with grease (Besco L2 or equivalent).

3. Using the oil seal installer J-42804, attach the oil seal
to the transfer cover assembly





Rear Output Shaft Oil Seal
Distance between the transfer case end and oil seal.
NOTE: When installing the oil seal to the specified
dimension, be careful not to damage it.
Dimension : 9.85 — 10.35mm (0.39 — 0.41 in)





4. Apply grease to the seal ring of each front and rear
speed sensor, and mount the sensors carefully. 

5. Tighten the bolt with the specified torque.
Torque : 5 N·m (43 lb in)
NOTE: Pay attention not to mount the front (or rear)
sensor to the rear (or front) sensor position.


6. Mount the ball bearing (1) for the front output shaft flat
as shown in the figure.






7. Mount the coil assembly and tighten the set nuts with
the specified torque.
Torque : 10 N·m (87 lb in) 

8. Connect the terminal in the central connector.
NOTE: Be careful not to damage other terminals.

 
9. Set speed gear and tone wheel.
10. Mount the ball bearing (2) flat as shown in the figure.

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11. Using snap ring pliers, install the snap ring to the
transfer cover assembly.
NOTE: Securely mount the snap ring to the groove of the
transfer cover assembly