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WORKSHOP MANUAL

TF SERIES

TRANSFER

SECTION 7D

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TRANSFER CASE 7D-1SECTION 7D

TRANSFER CASETABLE OF CONTENTS

PAGE

Service Precaution .......................................................................................................... 7D 2General Description ........................................................................................................ 7D 3Transfer Rear Oil Seal .................................................................................................... 7D 4

Transfer Rear Oil Seal and Associated Parts ............................................................ 7D 4Removal ........................................................................................................................ 7D 4Installation .................................................................................................................... 7D 4

Transfer Case Assembly ................................................................................................ 7D 6Transfer Case Assembly and Associated Parts ........................................................ 7D 6Removal ........................................................................................................................ 7D 7Installation .................................................................................................................... 7D 7

Transfer Control Unit ...................................................................................................... 7D 10Removal ........................................................................................................................ 7D 10Installation .................................................................................................................... 7D 10

Transfer Disassembly ..................................................................................................... 7D 11Removal ........................................................................................................................ 7D 11Inspection and Repair .................................................................................................. 7D 20Inspection and Repair (Transfer Case Assembly) ..................................................... 7D 20Reassembly .................................................................................................................. 7D 24

Main Data and Specifications ........................................................................................ 7D 33Special Tools ................................................................................................................ 7D 36

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7D-2 TRANSFER CASEService PrecautionWARNING: THIS VEHICLE HAS A SUPPLEMENTAL

RESTRAINT SYSTEM (SRS). REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN

ORDER TO DETERMINE WHETHER YOU ARE

PERFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING. WHEN YOU

ARE PERFORMING SERVICE ON OR NEAR THE

SRS COMPONENTS OR THE SRS WIRING, REFER

TO THE SRS SERVICE INFORMATION. FAILURE TO

FOLLOW WARNINGS COULD RESULT IN

POSSIBLE AIR BAG DEPLOYMENT, PERSONAL

INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM

REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

ISUZU will call out those fasteners that require a

replacement after removal. ISUZU will also call out

the fasteners that require thread lockers or thread

sealant. UNLESS OTHERWISE SPECIFIED, do not

use supplemental coatings (Paints, greases, or

other corrosion inhibitors) on threaded fasteners or

fastener joint interfaces. Generally, such coatings

adversely affect the fastener torque and the joint

clamping force, and may damage the fastener.

When you install fasteners, use the correct

tightening sequence and specifications. Following

these instructions can help you avoid damage to

parts and systems.

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TRANSFER CASE 7D-3General Description

RUW34DLF000701

The transfer case is used to provide a means of

providing power flow to the front axle. The transfer case

also provides a means of disconnecting the front axle,

providing better fuel economy and quieter operation

when the vehicle is driven on improved roads where

four wheel drive is not required. In addition, the transfer

case provides an additional gear reduction when placed

in low range, which is useful when difficult off-road

conditions are encountered.

Use the 4WD switch on the center cluster panel to

select the drive range. The 4WD indicator lamp will be

lit when 4WD is selected.

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7D-4 TRANSFER CASETransfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts

220R300018

Legend(1)Rear Propeller Shaft

(2)Oil Seal

Removal1. Disconnect the rear propeller shaft (1) from the

transfer case side.

2. Remove the oil seal from the transfer case.Installation1. Install oil seal and apply engine oil to the oil seal

outer surfaces.

2.Apply the recommended grease (BESCO L2) orequivalent to the oil seal lip.

3. Use the oil seal installer 5-8840-2786-0 to install therear seal (2) to the transfer rear case.

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TRANSFER CASE 7D-5

220R300021

4. Connect the rear propeller shaft.

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7D-6 TRANSFER CASETransfer Case Assembly

Transfer Case Assembly and Associated Parts

RTW47DLF000501

Legend(1)Rear Propeller Shaft (4)Center Exhaust Pipe (6VE1 only)(2)Front Propeller Shaft(3)Transfer Case Assembly

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TRANSFER CASE 7D-7RemovalNOTE: Before removing transmission and transfer

assembly from vehicle, change the transfer mode to

2WD using the 4WD push button switch on dash panel.

1. Disconnect battery ground cable.2. Raise and support vehicle with suitable stands. Drain

transfer case fluid.

3. Remove the center exhaust pipe(5). (6VE1 only)

4. Remove rear propeller shaft (1) and front propellershaft (2)(3).

NOTE: Apply alignment marks on the flange at both

front and rear sides.5. Disconnect harness connectors and clip.

Connector: transfer switch, 2WD-4WD actuator,

speed sensor.

NOTE: Avoid turning the vehicle ignition switch to the

ON position when the 2WD-4WD connector is removed

(battery connected).If the ignition switch must be turned to the ON position,

the controller must first be removed (memory must be

cleared because the CHECK 4WD INDICATOR will

light).6. Remove transfer case (4) from the vehicle.

Installation1.Apply a thin coat of molybdenum disulfide grease to

the input shaft spline as shown in the figure.

260R300001

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7D-8 TRANSFER CASE2. Install transfer case (4) to the transmission. Tighten

transfer bolts as shown in the figure.For M/T

261R300001

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TRANSFER CASE 7D-9For A/T

261R300002

3. Connect harness connectors and clip.Connector: transfer switch, 2WD-4WD actuator,

speed sensor.

4. Install center exhaust pipe(5). (6VE1 only)

5. Install rear propeller shaft (1) and front propellershaft (2)(3).

Torque: 63 Nm (6.4 kgm/46 lb ft)

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7D-10 TRANSFER CASETransfer Control Unit

RTW37DLF000401

Legend(1)Transfer Control Unit (3) Bolt(2)Protector

Removal1. Disconnect the battery ground cable.

Remove the drivers seat.

2. Peel back the floor carpet on the driver's side of thevehicle to expose the transfer control unit.

3. Disconnect the harness connector from the Transfercontrol unit.

4. Remove the Transfer control unit.

Installation1. Install the Transfer control unit.2. Connect the harness connector to the Transfer

control unit.

3. Connect the battery ground cable.

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TRANSFER CASE 7D-137. 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

260R300001

8. Remove the oil pump strainer fixing bolts from therear cover.

9. 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.

226R30001

Legend(1)Sun Gear Needle Bearing(2)H-L Sleeve

(3)2-4sleeve, synchronizer key, and frontsynchronizer spring

(4)2-4 Shift ASM

(5)Shift Shaft

(6)H-L Shift ASM

(7)Shift Drum

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TRANSFER CASE 7D-1515.Remove the snap ring from the main shaft.16Use a press to remove the 2-4 hub from the main

shaft.

17.Spread the edges of the retaining ring while lightlytapping on the sun gear input shaft end. Remove the

carrier and gear assembly from the transfer case.

226R300020

18Remove the dog teeth snap ring from the carrier and

gear assembly.19.Remove the planetary dog teeth and the sun gear

input shaft together with the thrust needle bearing.

2260R300021

20.Remove the carrier snap ring.21.Use a press to remove the ball bearings.

22.Use the sliding hammer (5-8840-0084-0) and theneedle bearing replacer (5-8840-0027-0) to remove

the needle bearing from the center of the carrier andgear assembly.

Legend(1)Outer Retaining Ring

(2)Carrier and Gear ASM

(3)Thrust needle Bearing

(4)Sungear Input Shaft

(5)Planetary DogTeeth

(6)Dog Teeth Snap Ring

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7D-16 TRANSFER CASE

23.Remove the retaining ring (spiral type) together withthe internal gear and the damper ring.

226R300004

24.Remove the snap ring.25.Use a press to remove the front output shaft ball

bearings.

26.Remove the oil pump wire snap ring from the rearcover.

27.Use a sliding hammer (5-8840-0084-0) and a needlebearing replacer (5-8840-2788-0) to remove the

needle bearing from the front output shaft.

P1010023

Legend(1)Dumper Ring

(2)Internal Gear

(3)Retaining Ring

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TRANSFER CASE 7D-17Internal Component Disassembly and Reassembly

226R300017

H-L Shift Disassembly1. Remove the guide roller.2. Use a vise to compress the H-L shift spirng (inside

the assembly.

3. Remove the uter snap ring.4. Remove the shift block assembly from the shift rod.

5. Use a socket and a vise to compress the shift blockspring (inside the assembly.

6. Remove the inner retaining ring.7. Remove the collar (rear.8. Remove the shift block spring.9. Remove the collar (rear.10.Removethe shift block assembly11.Remove the uter snap ring.12.Remove the shift arm.13.Remove the front and rear companion flange.

Legend(1)ARM; SHIFT

(2)BLOCK ASM; SHIFT

(3)RING; RETAINING, INNER

(4)COLLER (FRONT)

(5)SPRING

(6)COLLER (REAR)(7)ROD; SHIFT

(8)RING; SNAP, OUTER

(9)ROLLER; GUIDE

(10)PIN ASM; SPRING

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7D-18 TRANSFER CASEH-L shift reassembly1. Install the shift arm to the shift rod.2. Install the spring pin. The top of the pin must be

flush with the surrounding surface (no projection).3. Install the front collar, the spring, and the rear collar

to the shift block in that order.

4. Use a socket and a vise to compress the shift blockspring.

5. Install the inner retaining ring. Be sure that the armaperture width is within the specified limit.

226R300014

6. Install the shift lock assembly to the shift rod.7. Use a socket and a vise to compress the H-L shift

spring.

8.

Install the outer snap ring.9. Install the guide roller.

2-4 shift ASM

226R300016

2-4 shift disassembly1. Remove the guide roller.2. Compress the spring and remove the snap ring.3. Remove the shift arm.4. Remove the spring.5. Remove the spring pin.6. Remove the shift block assembly.7. Remove the shift rod.

Legend(1)25.62

(2)14.1mm

Legend(1)ROD; SHIFT

(2)ARM; SHIFT

(3)SPRING

(4)BLOCK ARM;SHIFT

(5)PIN ARM; SPRING

(6)ROLLER; GUIDE(7)RING; SNAP

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TRANSFER CASE 7D-192-4 shift reassembly1. Install the shift block assembly to the shift rod.2. Install the spring pin. The head of the pin must not

project beyond the surface (1) of the shift block.

226R300015

3. Install the spring.4. Install the shift arm.5. Compress the spring and install the snap ring.6. Install the guide roller.Oil pump disassembly1. Remove the clamps securing the screen.2. Remove the screen.3. Remove the clamps securing the hose.4. Remove the hose.NOTE: To maintain and porotect oil pump function, the

pump is constructed so that it cannot be disassembled.

Under no conditions attempt to disassemble the pump.

Oil pump reassembly1. Tighten the clamps to secure the hose.2. Tighten the clamps to secure the screen.

NOTE: Be carefull in the direction of clamps.

RTW37DSH000101

Legend(1) OIL PUMP ASM

(2) CLAMP

(3) HOSE

(4) SCREEN ASM

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7D-20 TRANSFER CASEInspection and Repair1. Make the necessary repair or parts replacement if

wear, damage or any other abnormal conditions are

found during inspection.2. Wash all parts thoroughly in clean solvent. Be sure

all old lubricant, metallic particles, dirt, or foreign

material are removed from the surfaces of every

part. Apply compressed air to each oil feed port and

channel in each case half to remove any

obstructions or cleaning solvent residue.Inspection and Repair (TransferCase Assembly)When wear, damage, or any other defects are observed

during the inspection, the part or parts must be repairedor replaced. Wash all the parts with clean detergent,

and check that old oil, metallic particles, dirt, or foreign

materials are completely removed. Blow the air into oil

holes and grooves to remove foreign materials or

residual detergent.Chain Check whether the face that contacts the sprocket is

free from excessive wear or damage. If defects are

observed, replace the part.

If the chain interference mark is found on the insidewall of the transfer cover or the chain is so slack that

a skipped engagement occurs between the chain

and sprocket, replace the chain.Sprocket Check whether the sprocket tooth surface is

excessively worn or damaged, and there is evidence

of burrs, chipping, wear, or damage on the gear

spline. Remove minor flaws or scratches with oil

stone. If excessive wear or damage is observed,

replace the part.

If excessive wear or damage is observed on thesprocket inside sliding surface, replace the part.

Gear Check whether the gear tooth surface is excessively

worn or damaged, and there is evidence of burrs,

chipping, wear, or damage on the gear spline.

Remove minor flaws or scratches with oil stone. Ifexcessive wear or damage is observed, replace the

part.

2-4 and Neutral Switch Check the continuity of 2-4 and Neutral switch.

If defects are observed, replace the 4H and 4L

switch.

221R300001

261R300003

Switch

Stroke

2-4 Switch

Signal

Neutral Switch

Signal

Terminal

1 to 2

Terminal

1 to2

1 Open Close

2 Close Open

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7D-22 TRANSFER CASEBlock Ring and Insert Clearance1. Use a vernier caliper to measure the clearance

between the block ring and the insert.

2. If the measured value exceeds the specified limit,the block ring and the insert must be replaced.

Block ring and insert clearanceStandard : 3.864.14 mm (0.1520.163 in)

Limit : 4.9 mm (0.193 in)

226RS037

2WD-4WD Synchronizer (3-Cone)1. Use a thickness gauge to measure the clearance

between the block ring and the dog teeth.

2. If the measured value exceeds the specified limit,the 2WD-4WD synchronizer assembly must be

replaced.

Block ring and dog teeth clearanceStandard : 1.5 mm (0.059 in)

Limit : 0.8 mm (0.031 in)

226R300019

Clutch Hub and Insert Clearance1. Clutch Hub and Insert Clearance2. Use a thickness gauge to measure the clearance

between the clutch hub and the insert.

3. If the measured value exceeds the specified limit, theclutch hub and the insert must be replaced.

Clutch hub and insert clearance

Standard : 0.01-0.19 mm (0.0004-0.0075 in)

Limit : 0.3 mm (0.012 in)

226RS038

Detent Springs1. Inspect the springs for distortion, cracks or wear.

Replace if these conditions are present.

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TRANSFER CASE 7D-23Detent Spring Free Length1. Use a vernier caliper to measure the detent spring

free length.

2. If the measured value is less than the specified limit,the detent spring must be replaced.

Detent spring free length

Detent ballStandard :23.4 mm (0.92 in)

Limit :22.8 mm (0.90 in)

220RW035

Detent Spring Tension1. Use a spring tester to measure the detent spring

tension.

2. If the measured value is less than the specified limit,the detent spring must be replaced.

Detent ballCompressed height : 18.7 mm (0.736 in)

Standard : 68.6 ~ 88.2 N (7.0 ~ 9.0 kg/ 15.4 ~ 19.8

lb)

220RS013

Shift Arm1. Inspect the shift arms for wear, distortion or scoring.

Replace if these conditions are present.Shift Arm Thickness1. Use a micrometer to measure the shift arm

thickness.

2. If the measured value is less than the specified limit,the shift arm must be replaced.H-L Shift arm thickness

Standard : 7.6-7.85 mm (0.299-0.309 in)

Limit : 7.0 mm (0.276 in)2-4 Shift arm thickness

Standard : 9.6-9.85 mm (0.378-0.388 in)

Limit : 9.0 mm (0.354 in)

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7D-24 TRANSFER CASEReassemblyTransfer ReassemblyThe rear cover oil seals and the rear output shaft ball

bearings cannot be reused. They must be replaced withnew ones when the transfer is reassembled.1. Use the oil seal installer (5-8840-2785-0) to press

the new input shaft and/or front output shaft oil seals

into place (If replacement is required).

2. Use a press to install the ball bearings to the frontoutput shaft. Be sure that the bearings are fully

inserted and then install the snap ring.

3. Install the damper ring and the internal gear to thetransfer case. Be sure that the damper ring is

between the internal gear and the case.

226R300004

Note the direction of the dumper ring installation as

figure.

226R300025

Legend(1)Dumper Ring

(2)Internal Gear

(3)Retaining Ring

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TRANSFER CASE 7D-254. Use a press and the special tool (5-8840-2784-0) to

hold the internal gear against the damper ring. Install

the retaining ring (spiral type).

5. Use a press and the installer (5-8840-2782-0) toforce the needle bearing fully into the carrier and

gear assembly.

6. Use a press and an appropriate special tool to force

the ball bearings fully into the carrier and gear

assembly.

7. Install the carrier snap ring.8. Install the thrust needle bearing, the sun gear input

shaft, the needle bearing, the planetary dog teeth,

and the dog teeth snap ring to the carrier and gear

assembly in that order.

9. Install the outer retaining ring to the tansfer case10. Use a pair of snap ring pliers to install the carrier and

gear assembly.NOTE: Be sure that the outer retaining ring fits snugly in

its groove.

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7D-26 TRANSFER CASE

226R300003

11.Use a press to install the 2-4 hub.

12.Install the hub snap ring.13.Install the synchronizer key springs (2), the

synchronizer key, and the 2-4 sleeve to the 2-4 hub.

The key and the open end of the springs must be

facing in the opposite direction.

Legend(1)Retaining Ring

(2)Carrier and Gear ASM

(3)Thrust Needle Bearing

(4)Sungear Input Shaft

(5)Planetary Dog Teeth

(6)Dog Teeth Snapring

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TRANSFER CASE 7D-2714.Insert the H-L sleeve into the main shaft.

226R300023

Legend(1)H-L Sleeve (3)Synchronizer Key and Key Spring(2)2-4 Sleeve

15.Install the sleeve to the H-L shift assembly.16.Install the sleeve to the 2-4 shift assembly.17.Coat the area around each of the shift assembly

insertion holes (transfer case) with transfer oil.18.Install the main shaft together with the H-L shift

assembly and the 2-4 shift assembly to the shift

drum.

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7D-28 TRANSFER CASE19.Align the shift shaft splines with the shift drum and

install the shafts to the drum.

RTW320MF000201

Legend(1)H-L Sleeve and Shift ASM (3)Shift Shaft(2)2-4 Sleeve ASM with Main Shaft and Shift ASM (4)Shift Drum

NOTE: Be careful in the direction of an assembly.

P1010041/020124

20.Coat the main shaft with oil.21.Align the block ring, the outside ring, and the inside

ring with the 2-4 hub assembly and install them.

22.Assemble the sprocket, transfer chain, and frontoutput shaft.

23.Install the sprocket, transfer chain, and front outputshaft to the main shaft and the transfer case.

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TRANSFER CASE 7D-2924.Align the sprocket thrust washer with the main shaft

groove and install it.

226R300009

25. Select a snap ring that will allow minimum axial play.

Insert it to the main shaft installation groove.mm (in

Snap ring thickness Identification color2.15 (0.085) Red2.10 (0.083) Not colored2.05 (0.081) Blue2.00 (0.079) White

226R300008

Legend(1)Block Ring

(2)Outside Ring(3)Inside Ring

(4)Sprocket

(5)Chain

(6)Front Output Shaft

(7)Thrust Washer

(8)Snap Ring

26.Measure the snap ring external diameter. If themeasured diameter is outside the specified range, a

larger or smaller snap ring must be used.

Snap ring outside diameter (Standard):

53.0 0.5 mm27.Position the rear cover so that its mating surfaces

are facing up.

28.Use a press and the installer (5-8840-2783-0) toinstall the front output shaft needle bearing. The

installer must be aligned with the bearing

manufacturer's name (stamped into the bearing).

29.Install the oil pump wire snap ring to the rear cover.

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7D-30 TRANSFER CASE

226R300005

30.Temporarily install the speedometer drive gear to theinside of the rear cover. Pay close attention to

installation direction.

31.Use a press and the installer (9-8522-1268-0) toinstall the rear output shaft ball bearings. Do not

drive the ball bearings into place with a hammer.

32.Install the rear output shaft retaining ring.33.Place the oil pump in its specified position.34.Secure the pump strainer to the rear cover and

tighten the bolts to the specified torque.

Rear cover and transfer case bolt torque:

15 Nm (1.5 kgm/11 lb ft)

226R300010

35.Apply Loctite FMD 127 to the mating surfaces of therear cover and the transfer case. Be sure that the

Loctite is evenly applied to the inside surfaces of thebolt holes with no gaps.

Legend(1)Oil Pump ASM

(2)Wire Snapring

(3)Retaining Ring

(4)Ball Bearing

(5)Speedometer Gear Drive Gear

(6)Rear Cover

Legend(1)Wire Snapring

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TRANSFER CASE 7D-31

226R300011

36.Install the rear cover to the transfer case and tightenthe bolts to the specified torque.

Rear cover and transfer case bolt torque:

22 Nm (2.2 kgm/16 lbft)37.Apply engine oil to the companion flange O-ring.38.Install the O-ring to the front output shaft.39.Secure the front companion flange with the

companion flange holder (5-8840-0133-0).

40.Install the end nuts and tighten them to the specifiedtorque.

Front companion flange end nut torque:

137 Nm (14 kgm/101 lbft)

41.Use a cold chisel to caulk the front companionflange end nuts.

226R300012

RUW34DSH000301

Legend(1) MAX 26mm (1.02 in)

(2) MIN 4mm (0.16 in)

42.Apply Loctite 575 to the threaded portion of thedetenteplugs.

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7D-32 TRANSFER CASE43.Use the installer (5-8840-2787-0) to install the main

shaft end snap ring to the rear output shaft (from the

back end of the shaft). Be absolutely sure that the

snap ring is seated in the groove.

226R300022

44.Use the installer (5-8840-2786-0) to install the rear

output oil seal to the rear case.

45.Install the detent balls, the detent springs, and thedetent plugs (2 parts each) to the transfer case.

Tighten the plugs to the specified torque.

Detent plug torque: 19 Nm (1.9 kgm/14 lbft)

46.Install the neutral switch (black harness cover) to thetransfer case and tighten the bolts to the specified

torque.

Neutral start switch bolt torque:

39 Nm (4 kgm/29 lbft)

47.Install the 2-4 switch (gray harness cover) to thetransfer case and tighten the bolts to the specified

torque.

2-4 switch bolt torque: 39 Nm (4 kgm/29 lbft)

48.Install the switch bracket to the transfer case andtighten the bolts to the specified torque.

Switch bracket bolt torque:

15 Nm (1.5 kgm/11 lbft)49.Install the transfer actuator assembly to the transfer

case and tighten the bolts to the specified torque.

The actuator must be installed in the same direction

as the shaft.

Transfer actuator assembly bolt torque:

22 Nm (2.2 kgm/16 lbft)

50.Install the breather hose between the transferactuator and the transfer case.

51.Install the speedometer driven gear, thespeedometer bush, and the speedometer stay to thetransfer case. Tighten the bolts to the specified

torque.

Speedometer bolt torque:

15 Nm (1.5 kgm/11 lbft)52.Install the drain plug to the transfer case and tighten

it to the specified torque.

Drain plug torque: 39 Nm (4 kgm/29 lbft)

53.Loosen and remove the filler plug. Add the specifiedvolume of transfer oil (5W-30) or the equivalent to

the transfer through the filler hole.

Transfer oil volume: 1.3 liters

54.Replace the filler plug and tighten it to the specifiedtorque.

Filler plug torque: 39 Nm (4 kgm/29 lbft)

55.Install the underguard and tighten the bolts to thespecified torque.

Underguard bolt torque: 39 Nm (4 kgm/29 lbft)

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TRANSFER CASE 7D-33Main Data and SpecificationsGeneral SpecificationsType Synchronized type gears shifting between the 2 and 4 wheel drive mode.

Planetary type gears shifting between low" and high".Control method Remote control with the button switch on the instrument panel for gears

shifting among 2H" , 4H" and 4L".Gear ratio High; 1.000

Low; 2.482

Oil capacity 1.3 lit. (1.37 U.S. quart)

Type of lubricant BESCO GEAR OIL TRANSAXLE (5W-30)

Refer to chart in Section 0

Torque SpecificationsNm (kgm/lb ft)

RTW47DLF000201

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7D-34 TRANSFER CASENm (kgm/lb ft)

RTW47DLF000401

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TRANSFER CASE 7D-35Nm (kgm/lb ft)

E07R300008

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7D-36 TRANSFER CASESpecial Tools

ILLUSTRATIONPART NO.

PART NAME

ILLUSTRATION PART NO.PART NAME

5-8840-2786

Transfer case oil seal

installer5-8840-2784-0

Ring gear installer

5-8840-0084-0Sliding hammer 5-8840-0133-0Flange holder

5-8840-0027-0Rear output shaft needle

bearing replacer5-8840-2782-0

Needle bearing installer

5-8840-2293-0

Punch; end nut5-8840-2783-0

Needle bearing installer

5-8840-2788-0Front output shaft needle

bearing replacer5-8840-0007-0

Driver handle

5-8840-2785-0

Input shaft and/or front

output shaft oil sealinstaller

5-8840-1268-0Rear output shaft ball

bearing installer

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7D-38 TRANSFER CASEMEMO

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TRANSFER CONTROL SYSTEM 7D1-1

SECTION 7D1

TRANSFER CONTROL SYSTEM

TABLE OF CONTENTS

PAGE

Service Precaution .................................................................................................... 7D1 - 2

General Description ................................................................................................... 7D1 - 3

System Components ................................................................................................. 7D1 - 5

Parts Location ...................................................................................................... 7D1 - 5

Functions of Switch and Indicator Lamp ................................................................. 7D1 - 11

Parts Location ............................................................................................................ 7D1 - 23

Circuit Diagram .......................................................................................................... 7D1 - 27

Connector List ........................................................................................................... 7D1 - 31

Diagnosis .................................................................................................................... 7D1 - 34

Before determining trouble ................................................................................. 7D1 - 34

Memory erasing procedure ....................................................................................... 7D1 - 40

Diagnosis from symptom .......................................................................................... 7D1 - 41

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7D1-2 TRANSFER CONTROL SYSTEM

Service PrecautionWARNING:

THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT

SYSTEM (SRS). REFER TO THE SRS COMPONENT AND

WIRING LOCATION VIEW IN ORDER TO DETERMINE

WHETHER YOU ARE PERFORMING SERVICE ON OR

NEAR THE SRS COMPONENTS OR THE SRS WIRING.

WHEN YOU ARE PERFORMING SERVICE ON OR NEAR

THE SRS COMPONENTS OR THE SRS WIRING, REFER TO

THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW

WARNINGS COULD RESULT IN POSSIBLE AIR BAG

DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE

UNNEEDED SRS SYSTEM REPAIRS.

CAUTION:

Always use the correct fastener in the proper location.

When you replace a fastener, use ONLY the exact partnumber for that application. ISUZU will call out those

fasteners that require a replacement after removal. ISUZU

will also call out the fasteners that require thread lockers

or thread sealant. UNLESS OTHERWISE SPECIFIED, do

not use supplemental coatings (Paints, greases, or other

corrosion inhibitors) on threaded fasteners or fastener

joint interfaces. Generally, such coatings adversely affect

the fastener torque and the joint clamping force, and may

damage the fastener. When you install fasteners, use the

correct tightening sequence and specifications. Following

these instructions can help you avoid damage to parts

and systems.

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General Description

RTW47DLF000301

Transfer Position and Drive Mode

Three drive modes can be selected through operation of 4WD switch.

Transfer Position 4WD SWITCH Mode Drive mode

2H RWD Rear wheel drive

HIGH4H 4WD (HIGH)

High-speed mechanical

lock-up four wheel drive

LOW 4L 4WD (LOW)Low-speed mechanical

lock-up four wheel drive

NEUTRAL 2H & 4L (10 Sec) NEUTRAL Towed by other vehicle

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Summary of transfer control system

The transfer control system switches between the 2-wheel

drive (2H), 4-wheel drive high-speed (4H), 4-wheel drive low-

speed (4L), and neutral positions electrically when the driver

operate the switches.This system has following functions.

1. Connection or disconnection of drive force distribution to

the front wheel front shaft (axle shaft) (The drive force

distribution to the front propeller is connected or

disconnected with the motor actuator.)

2. Try to repeat the connection or disconnection of the front

wheel drive function as described above.

3. Option: Shift on the fly type only.

Instruction of connection or disconnection of the drive force

transmission between the front wheel axle (axle shaft) and

front wheel

(The motor actuator connects or disconnects the left front

wheel ad front wheel axle (axle shaft).).

4. Shifting of auxiliary transmission gears, connection or

disconnection of wheel and engine drive force (4H, 4L,

neutral).

5. Operation of indicator on the instrument panel.

6. Transmission of position signal to other controllers.

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System Components

Parts Location

Speed sensor

Revolutions of the rear output shaft are decreased and taken

out by the speed/drive/driven gears installed in the transfer

case and the number of revolutions is detected with a speed

sensor.

About 4/3 pulses per revolution of the shaft is output.

4WD switch

The 4WD switch detects the movement of the shift rod driving

the 42 - 44 sleeve.

PUSH open is achieved with the PUSH open switch when the

shift rod is at the 42 position.

42 - 44 sleeve & Arm

The 42 - 44 sleeve moves directly in the 44 direction with

the 42 - 44 shift rod, but, when moving in 42 direction, a

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spring standby mechanism is provided between the rod and

sleeve so that the rod is positioned at the 42 position, while

the sleeve is at the 44 position in sometime.

This mechanism is provided to protect the shift mechanism

from the force to prevent the movement of the sleeve(torsional torque etc. of the drive system). By releasing the

preventive force, the sleeve can move to 42 state by the

spring force.

Neutral switch

The neutral switch detects the movement of the shift rod

driving the high-low sleeve.

PUSH close is achieved with the PUSH close switch when the

shift rod is positioned between the High and the Low, that is,

at the neutral state.

High-Low Sleeve & Arm

The spring standby mechanism is provided for the high-low

sleeve in both directions of the high-low shift rod. For this

reason, the rod position and the actual sleeve position may be

offset in some cases.

This system is provided to protect the shift mechanism from

the collision due to coincidence of the high and low phases of

the engaged splines. By giving rotational force to the

preventing phase coincidence, the splines are moved to the

proper engagement position by the spring force.

Shift actuator

The output shaft is rotated by the built-in motor and the

transfer position is switched.Detection (limit) switches to detect the rotating angle of the

output shaft is provided to the actuator at 4 positions, which

are connected to the transfer controller through the vehicle

harness to constantly transmit the actuator operating angle

and changes in its transfer status.

7B4-PDF2

4WD indicator (in meter panel)

This lamp indicates the following items

Valve check

Drive condition (2WD-4WD)

Operating condition (2Hz: Actuator in operation, mechanism

standby)

Restrictions on operation (4Hz, including indication ofinterrupted operation due

to excessive load)

4L indicator (in meter panel)

This lamp indicates following items.

Valve check

Driving status (High-Low)

Operating status (2Hz: Actuator in operation, mechanism

standby)

Restrictions on operation (4Hz)

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7B4-PDF3

7B4-PDF4

Neutral indicator (in operation switch panel)

This LED indicates following items.

LED check

Driving status (Neutral)Operating status (2Hz: Actuator in operation, mechanism

standby)

Restrictions on operation (4Hz)

7B4-PDF5

Check 4WD warning light (in meter panel)

This light indicates following items.

Valve check

Faulty actuator limit SW, and fault of circuit related with the

limit switch

825R300018

4WD switch

Switch to transmit a switching command to the 2H, 4H,

Neutral, or 4L position.

It comprises 3 PUSH momentary switches. By keeping to push

the 2H and 4L switches for 10 seconds,

operation is instructed to the neutral position.To shift from the neutral to other position, other required

switches should be pushed for 10 seconds.

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Transfer controllerLocated below the right seat.

RTW37DLF000401

Legend1. Transfer controller

2. Protector

3. Bolt

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Transfer Acutuator

Method of confirming the actuator position detection

(limit) switch

The actuator indicates the continuity condition of combinationsas shown in the list below between the 4 detection (limit)

switch pins and GND pin along the direction of the notch of the

output shaft spline. Check that these combinations are as

specified.

The middle condition between these positions (4 patterns in

case of 2H-4H) is either of the combinations shown below

depending upon manufacturing variations of the switch plate.

2H 2H-4H 4H 4H-N N N-L 4L

Direction of output

shaft notch (outline)

-54to

-29-29to 74

74to

110110to 179

179to

215

215to

285

285to

300

LS1 Close Close Open Open Open Open Open Open Open Close Close

LS2 Open Close Open Close Close Open Open Close Close Close Close

LS3 Close Close Close Close Close Close Open Open Open Open Open

LS4 Open Open Open Open Close Close Close Close Open Open Close

Continuity between each pin and GND pin. (Continuity also exists between CLOSE pins.)

Transfer Actuator Connector

7B4-PDF6

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Method of checking the position detection switch harness

Disconnect the vehicle harness connector on the transfer

controller side and the vehicle harness connector on the

transfer actuator side as shown in the wiring diagram, and

check the continuity between the following connector pins andthat there is no continuity between those pins and GND or

power source.

Check that there is continuity between the GND pin and vehicle

GND on the transfer actuator and there is no continuity

between the GND pin and other power source.

RTW47DSF000301

Vehicle harness connector pin No. (connector of mating parts of the harness is shown in this figure)

Name of pin T/F controller side T/F actuator side Remarks

LS1 R-14, 17 5

LS2 R-14, 6 4

LS3 R-14, 15 7

LS4 R-14, 14 6

GND R-15, 1, 9 8

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Function of Switch and indicator Lamp

Transfer-related indicator lamp and switch function

Item4WD

lamp4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuatordetection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

2H Off Off Off OffNo

operation1,0,1,0 Open Open Open -----

4H start

of

operation

Off Off Off Off

4H position

for 0.1

second

1,0,1,0 Open Open Open

Switch

operation

sensor

Start of

operation

Blinking

(2HZ)Off Off Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

while

driving

During

operation

(Synchro)

Blinking

(2HZ)Off Off Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

using

synchro

and

retrial

During

operation

(Axledrive)

Blinking

(2HZ)

Off Off OffNo

operation

0,0,1,1 Closed Open Open Axle drive

Axle

waiting

Blinking

(2HZ)Off Off Off

No

operation0,0,1,1 Closed Open Open Axle drive

4H On Off Off OffNo

operation0,0,1,1 Closed Open Closed -----

4L start

of

operation

On Off Off Off

4L position

for 0.1

second

0,0,1,1 Closed Open Closed

Switch

operation

sensor

Start of

operationOn

Blinking

(2HZ)Off Off

No

operation

0,0,0,1

0,1,0,1Closed Open Closed

4H to 4L

while

driving

During

operation

(N)

Off Blinking(2HZ)

Off Off Nooperation

0,0,0,10,1,0,1

Closed Closed Closed

4H to 4L

through

neutral

During

operation

(N)

OffBlinking

(2HZ)Off Off

No

operation0,1,0,0 Closed Closed Closed

4H to 4L

through

neutral

During

operation

(N)

OffBlinking

(2HZ)Off Off

No


4H to 4L

through

neutral

4L

waitingOn

Blinking

(2HZ)Off Off

No


4H to 4L

while

waiting

4L On On Off OffNo

operation

1,1,0,1 Closed Open Closed -----

4H start

of

operation

On Off Off Off

4H position

for 0.1

second


Switch

operation

sensor

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Item 4WDlamp

4L lamp Neutrallamp

Check

4WDwarning

light

4WDswitch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switchOr

Axle

dummy

Remarks

During

operationOn

Blinking

(2HZ)Off Off

No

operation1,1,0,1 Closed Open Closed

4L to 4H

while

driving

During

operation

(N)

OffBlinking

(2HZ)Off Off

No


4L to 4H

through

neutral

During

operation Off

Blinking

(2HZ) Off Off

No

operation

0,1,0,1

0,0,0,1 Closed Closed Closed

4L to 4H

whiledriving

4H

waitingOff

Blinking

(2HZ)Off Off

No


4L to 4H

while

waiting

4H On Off Off OffNo


2H start

of

operation

On Off Off Off

2H position

for 0.1

second


Switch

operation

sensor

Start of

operation

Blinking

(2HZ)Off Off Off

No

operation

0,1,1,1

0,1,1,0

0,0,1,0

1,1,1,0

Closed Open Closed

2H to 4H

while

driving

During

operation

(Axle)

Blinking

(2HZ)Off Off Off

No

operation

0,1,1,1

0,1,1,0

0,0,1,0

1,1,1,0

Open Open Closed Axle drive

Axle

waiting

Blinking

(2HZ)Off Off Off

No

operation1,0,1,0 Open Open Closed

Axle

waiting



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2H to 4H retrial

Item4WD

lamp4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOFactuator

switch

Or

Axle

dummy

Remarks



4H start

of

operation

Off Off Off Off

4H

position

for 0.1

second

1,0,1,0 Open Open Open -----

Start of

operation

Blinking

(2HZ)Off Off Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

while

driving

During

operation

(Synchro)

(Go to 4H

if synchro

complete)

Blinking

(2HZ)Off Off Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

using

synchro

and retrial

X 2

Abandon

ed

operation

(2H)

Blinking

(4HZ) Off Off Off

No

operation 1,0,1,0 Open Open Open

Return to

2H

2H

indication

after

10second

s

Off Off Off OffNo


Completion of transfer case H-L area and axle shift timing may cause some variation in 2Hz blinking pattern.

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Operational limits (4H4L) (Vehicle speed, engine speed, and transmission position not specified)

Item4WD

lamp4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOFactuator

switch

Or

Axle

dummy

Remarks

4H On Off Off Off Open 0,0,1,1 Closed Open Closed -----

4H start

of

operation

On Off Off Off

4L

position

for 0.1

second


10second

display

during

limitation

OnBlinking

(4HZ)Off Off Open 0,0,1,1 Closed Open Closed

No

operation

during

limitation

Go to 4H

after 10

seconds

On Off Off Off Open 0,0,1,1 Closed Open Closed -----

Operational limits (4L4H) (Vehicle speed, engine speed, and transmission position not specified)

Item4WD

lamp4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOFactuator

switch

Or

Axle

dummy

Remarks

4L On On Off OffNo


4L start of

operationOn On Off Off

4H

position

for 0.1

second


10

second

display

during

limitation

OnBlinking

(4HZ)Off Off Open 1,1,0,1 Closed Open Closed

No

operation

during

limitation

Go to 4L

after 10

seconds

On On Off OffNo


Under some conditions, a secondary operational indication may be received when the 4Hz operational indication

is present.

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Transfer-related indicator lamp and switch functionSkip operation

Item4WD

lamp4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection (limit)

switches

LS1,

LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks



4L start of

operationOff Off Off Off

4L

position

for 0.1second


Switch

operation

sensor

Start of

operation

Blinking

(2HZ)

Blinking

(2HZ)Off Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

while

driving

During

operation

(Synchro)

Blinking

(2HZ)

Blinking

(2HZ)Off Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

using

synchro

and retrial

During

operation

(Passing

through

4H)

OffBlinking

(2HZ)Off Off

No

operation0,0,1,1 Closed Open Open -----

During

operation

(Passing

through

4H)

OffBlinking

(2HZ)Off Off

No

operation

0,0,1,1

0,1,0,1Closed Open Open -----

During

operation

(N)

OnBlinking

(2HZ)Off Off

No

operation

0,0,1,1

0,1,0,1Closed Open Closed -----

During

operation

(N)

OnBlinking

(2HZ)Off Off

No


Switch

operation

sensorDuring

operation

(N)

OnBlinking

(2HZ)Off Off

No


4H to 4L

while

driving

During

operation

(Axle

drive)

Blinking

(2HZ)

Blinking

(2HZ)Off Off

No


Axle

waiting

Blinking

(2HZ)

Blinking

(2HZ)Off Off

No


4L waiting OnBlinking

(2HZ)Off Off

No


4H to 4L

while

waiting

4L On On Off OffNo


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Item4WD

lamp4L lamp

Neutral

lamp

Check4WD

lamp

4WD

switch

Actuator

detectio

n (limit)

switches

LS1,

LS2,

LS3. and

LS4

1 = on

2 = off

Transfer4WD

switch

Transferneutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

2H start of

operationOn On Off Off

2H

position

for 0.1

second


Switch

operation

sensor

During

operation

Blinking

(2HZ)

Blinking

(2HZ)Off Off

No


4L to 4H

while

drivingDuring

operation

(Passing

through

N)

OnBlinking

(2HZ)Off Off

No


4L to 4H

through

neutral

During

operation

(Passing

through

N)

OffBlinking

(2HZ)Off Off

No


4L to 4H

through

neutral

During

operation

(4H

waiting)

Off

Blinking

(2HZ) Off Off

No

operation 0,0,1,1 Closed Closed Closed

4L to 4H

whilewaiting

During

operation

(Axle)

Off while

waiting for

start of H

shift

Blinking

(2HZ)

while

waiting for

start of H

shift

Off OffNo

operation

0,1,1,1

0,1,1,0

0,0,1,0

1,1,1,0

Closed Open Closed

2H to 4H

while

driving

During

operation

(Axle)

Blinking

(2HZ) at

end of H

shift

Off at end

of H shiftOff Off

No

operation

0,1,1,1

0,1,1,0

0,0,1,0

1,1,1,0

Closed Open ClosedAxle

driving

Axle

waiting

Blinking

(2HZ)Off Off Off

No

operation1,0,1,0 Open Open Closed -----



Completion of transfer case H-L area and axle shift timing may cause some variation in 2Hz blinking pattern.

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Skip operation limitations (4L2H) (Vehicle speed, engine speed, and transmission position not

specified)

Item4WD

lamp4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

4L Off On Off Off Open 1,1,0,1 Closed Open Closed -----

4L start of

operationOff On Off Off

2H

position

for 0.1

second


10

second

display

during

limitation

Blinking

(4HZ)Off Off Off Open 1,1,0,1 Closed Open Closed

No

operation

during

limitation

Go to 4L

after 10

seconds

Off ON Off Off Open 1,1,0,1 Closed Open Closed -----

Skip operation limitations (2H4L) (Vehicle speed, engine speed, and transmission position not

specified)

Item4WD

lamp4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

2HL Off Off Off Off Open 1,0,1,0 Open Open Open -----

4L start of

operationOff Off Off Off

2H

position

for 0.1

second

1,0,1,0 Open Open Open -----

10

second

display

during

limitation

Blinking

(4HZ)

Blinking

(4HZ)Off Off Open 1,0,1,0 Open Open Open

No

operation

during

limitation

Go to 2H

after 10

seconds

Off Off Off Off Open 1,0,1,0 Open Open Open -----

Under some conditions, a secondary operational indication may be received when the 4Hz operational

indication is present.

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Transfer-related indicator lamp and switch function2HNeutral2H

Item4WD

lamp4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detectio

n (limit)

switches

LS1,

LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks



Neutral

start of

operation

Off Off Off Off

Neutral

position

for 10seconds


Switch

operation

sensor

Start of

operationOff Off

Blinking

(2HZ)Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

while

driving

During

operation

(Synchro)

Off OffBlinking

(2HZ)Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

using

synchro

and retrial

During

operation

(Passing

through

4H)

Off OffBlinking

(2HZ)

OffNo

operation


During

operation

(Passing

through

4H)

Off OffBlinking

(2HZ)Off

No

operation

0,0,0,1

0,1,0,1Closed Open Closed

4H to 4L

while

driving

During

operation

(N)

Off OffBlinking

(2HZ)Off

No

operation

0,0,0,1

0,1,0,1Closed Closed Closed

4H to 4L

through

neutral

During

operation

(N)

Off OffBlinking

(2HZ)Off

No


Switch

operation

sensor

Neutral Off Off On OffNo

operation0,1,0,0 Closed Closed Open -----

2H start of

operationOff Off On Off

2H

position

for 10

seconds


Switch

operation

sensor

During

operation

(Passing

through

N)

OffBlinking

(2HZ)Off Off

No


4L to 4H

through

neutral

Duringoperation

Off Blinking(2HZ)

Off Off Nooperation

0,1,0,10,0,0,1

Closed Closed Closed

4L to 4H

while

driving

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Item4WD

lamp4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detectio

n (limit)

switches

LS1,

LS2,

LS3. and

LS4

1 = on

2 = off

Transfer4WD

switch

Transferneutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

During

operation

(4H

waiting)

OffBlinking

(2HZ)Off Off

No


4L to 4H

while

waiting

During

operation

(Axle)

Blinking

(2HZ)

Off Off OffNo

operation

0,1,1,1

0,1,1,0

0,0,1,01,1,1,0

Closed Open Closed

2H to 4H

while

driving

During

operation

(Axle)

Blinking

(2HZ)Off Off Off

No

operation

0,1,1,1

0,1,1,0

0,0,1,0

1,1,1,0

Open Open ClosedAxle

driving

Axle

waiting

Blinking

(2HZ)Off Off Off

No




Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer

shifts in both directions (HNeutralL).

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4HNeutral4H

Item4WD

lamp4L lamp

Neutral

lamp

Check4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuatorswitch

Or

Axle

dummy

Remarks

4H On Off Off OffNo


Neutral

start of

operation

On On Off Off

Neutral

position

for 10

seconds


Start of

operationOff Off

Blinking

(2HZ)Off

No


4L to Nwhile

driving

During

operation

(N)

Off OffBlinking

(2HZ)Off

No


4L to N

with axle

driving

During

operation

(N)

Off OffBlinking

(2HZ)Off

No


4L to 4N

with axle

removed

During

operation

(Axle)

Blinking

(2HZ)Off Off Off

No

operation

0,1,1,1

0,1,1,0

0,0,1,0

1,1,1,0

Open Open ClosedAxle

driving

Axle

waiting

Blinking

(2HZ)Off Off Off

No




4H start

of

operation

Off Off Off Off

2H

position

for 10

seconds


Switch

operation

sensor

During

operation

(N)

OffBlinking

(2HZ)Off Off

No

operation1,1,0,0 Closed Closed Open

4L to 4H

through

neutral

During

operation(N)

Off

Blinking

(2HZ) Off Off

No

operation 0,1,0,0 Closed Closed Open

4L to 4H

throughneutral

During

operationOff

Blinking

(2HZ)Off Off

No

operation

0,1,0,1

0,0,0,1Closed Closed Open

4L to 4H

while

driving

4H

waiting

Blinking

(2HZ)Off) Off Off

No


4L to 4H

while

waiting

During

operation

(Axle)

Blinking

(2HZ)Off Off Off

No

operation0,0,1,1 Closed Open Open

Axle

driving

Axle

waiting

Blinking

(2HZ)Off Off Off

No


4H On Off Off OffNo


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4LNeutral4L

Item4WD

lamp4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOFactuator

switch

Or

Axle

dummy

Remarks

4L On On Off OffNo


Neutral

start of

operation

On On Off Off

Neutral

position

for 10

seconds


Start of

operationOff Off

Blinking

(2HZ)Off

No


4L to N

while

driving

During

operation

(N)

Off OffBlinking

(2HZ)Off

No


4L to N

with axle

driving

During

operation

(N)

Off OffBlinking

(2HZ)Off

No


4L to 4N

with axle

removed

During

operation

(Axle)

Blinking

(2HZ)Off Off Off

No


Axle

driving

Axle

waiting

Blinking

(2HZ)Off Off Off

No

operation0,1,0,0 Closed Closed Closed -----



4L start of

operationOff Off On Off

4L

position

for 10

seconds


Switch

operation

sensor

During

operation

(N)

OffBlinking

(2HZ)Off Off

No


4H to 4L

through

neutral

During

operation(N)

Off

Blinking

(2HZ) Off Off

No

operation 1,1,0,0 Closed Closed Open

4H to 4L

throughneutral

During

operation

(N)

OffBlinking

(2HZ)Off Off

No


4H to 4L

through

neutral

4H

waitingOn

Blinking

(2HZ)Off Off

No


4L while

waiting

During

operation

(Axle)

Blinking

(2HZ)Off Off Off

No

operation1,1,0,1 Closed Open Open

Axle

driving

Axle

waiting

Blinking

(2HZ)Off Off Off

No


4H On On Off OffNo




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Parts Location (RHD)

RTW48AXF021701&RTW48AXF021801

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Parts Location (LHD)

RTW48AXF021901&RTW48AXF022001

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RTW48AXF021601

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PARTS LOCATION

RTW48AXF031701

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CIRCUIT DIAGRAM (6VE1)

RTW48AXF007201

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CIRCUIT DIAGRAM (C24SE)

RTW48AXF031601

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CIRCUIT DIAGRAM (4JA1-TC/4JH1-TC)

RTW48AXF007101

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CIRCUIT DIAGRAM (4JA1-L)

RTW48AXF028601

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CONNECTOR LIST

No. Connector face No. Connector face

B-24

GreenMeter-B

C-57

(4JH1-

TC)

ECM

B-54

White J/B I2

C-67

BlackEHCU

B-62

White Ignition switch (IGSUB : G1)

C-94

(4JH1-TC)

GrayTCM

B-63

White Ignition switch (IGSUB : G2)

C-95

(6VE1)

White TCM

B-64

Silver Weld splice 1(Illumination)

C-107

White J/B E2

B-65

Silver Weld splice 2 (Ground)

C-108

White J/B E1

B-66

White 4WD switch

C-109

Silver Body-LH ; ground

C-2

SilverEngine room-RH ; Ground

C-118(4JH1-

TC)

White A/C Resister & Neutral switch

C-36

SilverEngine room-LH ; Ground

C-119

(6VE1)

Black Auto cruise actuator

C-56

(4JH1-

TC)Gray ECM

R-15

BlackTransfer controller

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R-14

BlackTransfer controller

H-3

(4JH1-

A/T)

White Battery (+) Engine room

E-10

Silver Engine ground

H-4

(4JH1)

White Engine Engine room

E-11(4JH1)

(C24SE)

Natural

GreenNeutral switch

H-6

WhiteEngine room INST

E-12(4JH1)

(C24SE)

Natural

Green Neutral switch

H-7

WhiteEngine room INST

E-35

(4JH1-TC

C24SE)Black Motor actuator

H-22

(4JA1/H

1-M/T)

Gray Engine Engine room C

E44

Gray Vehicle speed sensor

H-23

(4JA1-L)

Engine room B T/mission

E-45

White 4WD switch

H-29

(4JH1-

M/T)

White Battery (+)

Engine room CE-46

Brown H-L neutral switch

H-31

(6VE1)

WhiteEngine room T/mission

E-51

BlackInhibiter switch

H-32

WitheEngine room Rear body

E-61

(6VE1)

BlackECM

P-1

Silver Battery (+)

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P-2

Silver Relay & Fuse box

P-5

Silver Battery (-)

P-6

SilverBody earth (Ground)

P-10

SilverEngine ground

P-13

(4JH1)

Gray Shift on the fly actuator

R-14

Black 2-4WD Control unit

R-15

Black 2-4WD Control unit

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Diagnosis

Before determining a trouble (Non-trouble mode)1. When shifting from 2H to 4H:

1-1-1 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Shft on the fly)

If the load is too large to shift the gears synchronously, the operation is repeated up to 3 times. If the shifting

is not effected after being repeated 3 times, the indicator frequency is changed from 2Hz to 4Hz and, at the

same time, the actuator condition is changed to 2H, indicator flashes at 4Hz for 10 seconds, and then goes

out.

Cause of excessive synchronous shifting load

Extremely low temperature (the oil viscosity of the front differential increases requiring a large load for

synchronization)

High speed (since the difference of relative revolutions of gears to be shifted synchronously is too large,

required work load per unit time becomes larger).Step 1-1-1:

Stop the vehicle or decrease the speed and operate as required again.

1-1-2 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Rigid and free wheel

Hub) / Block out of meshing spline.

Step 1-1-2:

Run the vehicle forward and backward several meters and operate as required again.

1-2 When the flashing of 4WD indicator at 2Hz continues more than 11.5 seconds (repetition of 3 times of

above No.1 is counted) (Shift on the fly)

If there is difference of revolutions and phases between the front wheel and axle, connecting the front wheel

and axle is difficult.

Until shifting in the transfer and connection of the front wheel and axle are completed, the indicator flashes

at a frequency of 2Hz. In the above case, the indicator continues flashing at a frequency of 2Hz until the

connection of the front axle is completed. (If the shifting in the transfer is not completed, the flashing

frequency is changed to 4Hz (above No.1).)

By correcting the difference of relative revolutions and deviation of phases, the shifting can be completed.

Step 1-2:

While the vehicle is running, make sure of safety around the vehicle and accelerate or decelerate the

vehicle while going straight.

When the vehicle is at a stop, run the vehicle forward and backward several meters.

2. When shifting from 4H to 2H

2-1 When 4WD indicator continues flashing at 2Hz

When shifting from 4H to 2H, the 4WD indicator continues flashing at 2Hz until separation in the transfer and

the separation of the front wheel axle are completed. When torsional torque is accumulated in the drive

system, separation in the transfer and separation of the front axle is difficult. In such a case, they can be

separated by removing the torsional torque of the drive system.

Step 2-1:

While the vehicle is running, make sure of safety around the vehicle and accelerate or decelerate the

vehicle while going straight.

When the vehicle is in stop, run the vehicle several meters forward and backward.

: Shift on the fly only.

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3. Shifting from 4H to 4L

3-1 When the 4L indicator flashes at 2Hz

When shifting from 4H to 4L, the 4L indicator continues flashing at 2Hz until shifting in the transfer case is

completed. The phases of the engaged splines may sometimes deviated preventing completion of shifting.

By correcting the deviation of phases, shifting is completed.

Step 3-1:

(In case of AT): Set the select bar of the transmission to the D position.

(In case of MT): Set the lever of the transmission to a position allowing running and engage the clutch

gently.

At this time, some rotating force acts on the engaged splines, phase is corrected and the engagement is

completed.

3-2 When the 4L indicator flashes at 2Hz for 10 seconds and then keeps ON again (AT vehicle)

This condition occurs when torsional torque has been generated between the transmission and road surface

and the transfer standby mechanism cannot absorb it completely.

Step 3-2:

Set the select lever of the transmission to the N position. (Stepping on the brake pedal is effective at

this time.)

3-3 When the 4L indicator flashes at a frequency of 4Hz

Shifting from 4H to 4L is restricted.

When the vehicle is running, the transmission lever is at the running range and the engine speed is high (L4:

3000rpm or more V6: 2000rpm), the transfer cannot be shifted from 4H to 4L (restriction on operation).

Restriction on operation (Except 4JA1-LT)

The 4H, neutral and 4L shifting mechanism has no synchronization function. Therefore, if relative rotations in the

mechanism become excessive, shifting exerts adverse influence on the internal mechanism of the transfer. To

avoid such a trouble, vehicle condition is detected to restrict the operation (vehicle speed, engine speed and TM

position).

Requirement to restrict the speed: Vehicle should be in stop.

For the reason of the detection logic, time to wait for start of operation may be required.

A/T: If the vehicle is in stop for a long time at the TM running range (D, 1, 2) before operating the AT, waiting

time becomes longer (from 1 second to 3 minutes at the maximum).

M/T: If the vehicle is at stop with the clutch stepped on at the T/M running position (1 R), the time to wait

becomes longer.

Waiting time means the time commencing from when other requirements (engine speed and T/M position) are

met to permission of the speed restriction. Operation during the waiting time is not permissible.

The waiting time is 1 second at the minimum and increases up to 5 seconds if the above condition continues 3

minutes. After that, the waiting time increases up to 3 minutes in 2 minutes.

When it is clear that the above condition has continued and reduction of waiting time is desirable, turn on or off

the ignition or start and stop the vehicle several meters.

Requirements for permission of restriction on engine speed: Engine speed should be decreased.

The engine speed of 3000rpm (V6: 2000rpm) or below is advisable.

Requirements for permission of restriction on T/M position restriction:

(AT) N range is recommendable

(MT) should be at the neutral.

These requirements for permission should be all met before the switch is operated. If the requirements are met

after operation, operation is not automatically effected but re-operation is required after permission is given.

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Restriction on operation (4JA1-LT)

The 4H, neutral and 4L shifting mechanism has no synchronization function. Therefore, if relative rotations in the

mechanism become excessive, shifting exerts adverse influence on the internal mechanism of the transfer. To

avoid such a trouble, vehicle condition is detected to restrict the operation (vehicle speed, and TM position).

Requirement to restrict the speed: Vehicle should be in stop.

Requirements for permission of restriction on engine speed: Engine speed should be decreased.

The engine speed of 3000rpm (V6: 2000rpm) or below is advisable.

Requirements for permission of restriction on T/M position restriction:

should be at the neutral.

These requirements for permission should be all met before the switch is operated. If the requirements are met

after operation, operation is not automatically effected but re-operation is required after permission is given.

Note: Dontaccelerate engine speed a the time of this operation.

Step 3-3:Stop the vehicle. (Close the accelerator and decrease the engine speed to below L4: 3000rpm, V6:

2000rpm.)

(In case of AT): Set the transmission select lever to the N position.

(In case of MT): Set the transmission lever to the neutral position. (Stepping on the clutch is

recommendable.) Push the 4L button.

If shifting operation is not completed (the lamp flashes at 2Hz), perform the step 3-1.

4. Shifting from 4L to 4H

4-1 When 4L indicator continues flashing at 2HZ

When shifting from 4L to 4H, the 4L indicator continues flashing at 2Hz until the shifting in the transfer case is

completed. Phases of engaged splines may deviate and the operation may not completed in some cases.

Shifting is completed by correcting the deviation of the splines.

Step 4-1: (same as step 3-1)

(In case of AT): Set the transmission select lever to the D position.

(In case of MT): Shift the transmission lever to a position allowing running and engage the clutch

gently.

4-2 When the indicator continues flashing at 2Hz for 10 seconds and then keeps on at 4L again (AT

vehicle)

This condition occurs when torsional torque has generated between the transmission and the road surface

(use of the parking position on a slope) and resistance against the separation of the driving force cannot be

fully by the waiting mechanism of the transfer.

Shifting is possible by using the brake also at the neutral position of the transmission

Step 4-2: (Same procedureas the step 3-2)

Set the transmission select lever to the N position.

(Leaving the brake lever and stepping it again is recommendable.)

4-3 When the 4L indicator flashes at 4HZ

Shifting from 4L to 4H is restricted.

When the vehicle is running, transmission lever is at the running range, and the engine speed is high, the

transfer 4L cannot be shifted to 4H.

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Step 4-3: (Same procedure as the step 3-3)

Stop the vehicle (close the accelerator and decrease the engine speed to L4: 3000rpm V6: 2000rpm or

below).

(In case of AT): Set the transmission select lever to the N position.(In case of MT): Set the transmission lever to the neutral position (stepping on the clutch lever is

recommendable).

Push the 4H button.

If the shifting is not completed (indicator flashes at 2Hz), go to the step 4-1.

5. When shifting from 4H or 4L to neutral

(Same procedure is required when shifting from 2H but in such a case, requirements for shifting from

2H to 4H are also applied.)

5-1 Neutral indicator continues flashing at 2Hz

The neutral indicator continues flashing at 2Hz until 4H (4L) is completely separated in the transfer. If

torsional torque has accumulated between the transmission and road surface, separation may be difficult.

Step 5-1:

If the operation is not completed, execute the step 7 for confirmation.

(In case of AT): Set the transmission select lever to the D position.

After confirming that the gears are at the neutral position, return the lever to the N

position.

(In case of MT): Set the transmission lever to a vehicle running position and engage the clutch gently.

After confirming that the gears are at the neutral position, return the lever to the

neutral position

5-2 When the neutral indicator flashes at 4HzAs in the case of shifting from 4L to 4H, restriction is imposed to the operation from 4L or 4H (including 2H).

If the transmission lever is at a running range and engine speed is high (L4: 3000rpm, V6: 2000rpm or more)

while the vehicle is running, operation from the 4L or 4H (including 2H) of the transfer to the neutral is

impossible (restriction on operation).

Step 5-2:

Stop the vehicle.

(In case of AT): Set the transmission select lever to the N (or P) position.

(In case of MT): Set the transmission lever to the neutral position (at this time, stepping on the clutch

is recommended).

Keep pushing the 2H and 4L button for 10 second.

Follow the start procedure for confirmation. (Confirmation of drive force not transferred; same as in the

step 5-1)

After the confirmation, set the transmission to the neutral position in case of MT or to the neutral

position in case of AT.

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6. When shifting from neutral to 2H, 4H or 4L

6-1 When the 4L indicator or 4WD indicator flashes at 2Hz

Indicator flashing at 2Hz indicates that the engagement of the splines has not completed because of

deviation of the spline phases. By eliminating such a deviation, shifting is completed (same as in the step 3-1

and 4-1).

6-2 When the 4L indicator or 4WD indicator flashes at 4Hz

As in the case of shifting from 4L to 4H, restriction is imposed to the operation to 4L or 4H (including 2H). If

the transmission lever is at a running range and engine speed is high (3000rpm or more) while the vehicle is

running, operation from neutral of the transfer to the 4L or 4H (including 2H) is impossible (restriction on

operation).

Step 6-2:

Stop the vehicle.

(In case of AT): Set the transmission select lever to the N (or P) position.

(In case of MT): Set the transmission lever to the neutral position (at this time, stepping on the clutch

is recommended).

Keep pushing the4H or 4L or 2H button for 10 second.

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Trouble diagnosis based on the operation switch, transfer indicator lamp and operatingsound Check 4WD indicator ON (operation guard based on the transfer actuatorposition detection error)

This condition indicates a faulty circuit related with the detection (limit) switches of the system actuator.Detection (limit) switches detect the actuator operating angle based on their combinations.

The controller monitors transition of the actuator based on the combination of the detection (limit) switch output.

If the transition based on the combinations indicates some trouble, it is memorized, shifting operation is stopped

when the trouble is counted 5 times, and the Check 4WDindicator lights up. At this time, the system permits

operation to 2H only.

When such a condition results, inspection of the transfer shift actuator, check of harness related with the

detection (limit) switch, and erasure of the memory of the controller are required.

(Refer to the memory erasure procedure for the erasure of the memory.)

At this time, the position indicator may flash at 4Hz. It means that a detection (limit) switch trouble wad

detected in the operation process shown by that position indicator (example: 4WD indicator when shifting from

2H to 4H).

Caution:

In the course of trouble diagnosis and correction, do not turn ON the ignition with the harness connector of

the transfer actuator disconnected. (Do not disconnect the harness connector of the transfer actuator

when the ignition is ON.)

If the controller is connected at this condition, a limit SW trouble is judged and the above-described

Check 4WD condition is brought about.

This can be reset by clearing the memory.

When it is required to disconnect the harness connector of the actuator and turning the ignition ON,

remove the controller at the same time or remove the IG power fuse of the transfer controller.

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Memory erasing procedure

1. Prepare two pieces of short harness with the end sharped

like a needle (bout 20cm(7.9 in) long).

2. Turn OFF the ignition.3. Remove the front left seat ASM.

4. Make the controller under the front left seat ASM (spread

the cut of the floor carpet).

5. Keeping the connector of the transfer controller connected,

set the short harness from the back of the connector as

illustrated.

6. Turn ON the ignition, wait for 2 seconds, and turn OFF the

ignition after confirming the relay sound.

7. Disconnect the short harness, turn ON the ignition again,

and confirm the Check 4WD lamp in the meter panel is

OFF.

8. Before erasing the memory, check that the circuit of the T/Factuator position detection harness, etc. for it are normal.

Transfer Controller Pin Assignment

RTW47DSF000101

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Diagnosis from symptomCheck4WD lighting up

Step Action Yes No

1 Check what was done beforethe trouble occurred.

Was the harness between the

transfer controller and actuator

disconnected with the ignition

kept ON for the purpose of

servicing the vehicle, etc.?

Or, was the ignition turned ON

(power supplied to the transfer

controller) with the harness of

the actuator removed?

If the power is supplied with theactuator not connected, faulty

position detection swi

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