How do you change the transfer case on a 1994 Isuzu Trooper?

Answer 1

Manual transmission - built into the transmission

Automatic: This is what I did on my 95. 94 should be similar:

1:unscrew xfer shift knob.

2:remove center console - 4 Philips screws near carpet

3:remove ignition lockout cable from shifter (cable that comes from front of shifter assembly). It is on passenger sidt of main shifter mechanism. Compress plastic tangs with needle nose and pull off brass cable end - knda tricky. Do not break plastic tangs.

4: remove electrical connectors from shifter assembly

5:underneath vehicle, disconnect shifter linkage from tranny - should have a wave washer and a clip. You can remove either side - shifter or tranny.

6:remove 4 hex bolts and 2 Philips screws that mount the shifter assemply to hump in floor. Remove shifter assembly.

7:remove 2 bolts that mount xfer case shift lever - note alignment while removing. Remove xfer case shift lever.

8:disconnect front driveshaft from xfer case - DO NOT allow driveshafts to slide apart!

9:remove rear drive shaft from xfer case. Tie front of driveshaft up to chassis to get it out of the way or remove it entirely.

10:loosen bolts that hold xfer case to transmission. 2 are hidden just above transmission mount.

11:slide xfer case rearward to remove. It is awkward and weighs about 100-120 lbs and will kill you if it falls on any vital part of your person.

There you go.

When installing, replace transmission rear seal and put new grease on xfer shift lever mechanism. Put thin coating of grease on xfer case shaft that goes into transmission. Pay attention to 'rust' pattern of flanges when installing driveshafts. Also grease bolts that mount the shifter assembly to floor. Change fluid as well.

Good luck.