2004 ISUZU TF SERIES oil

SHIFT ON THE FLY SYSTEM 4C2-7



RTW440SH000101
Inner Shaft Bearing
Inspect the state of inner shaft bearing. If any abnormality
such as smoothlessness is found, replace with a new inner
shaft bearing.
Insert a clutch gear and check the state of needle bearing.
If there is an abnormality such as smoothlessness, replace
the needle bearing.

Sleeve
Visual Check
Check and see that there is not wear, damage, or crecking
in the sleeve.
NOTE:
Close inspection of the groove and inner gear are required
because those are important parts.










412RW011
Functional Check
Operate the sleeve with the inner shaft combined with the
clutch gear.
If smoothlessness is felt, replace the sleeve.
NOTE:
Gear oil should be applied to the contact surface of gear.




412RW022
Dimensional Check
Check the width of sleeve center groove.
Sleeve Center Groove (Limit) mm (in)
7.1 (0.28)

4C2-8 SHIFT ON THE FLY SYSTEM



RTW440SH000201
Clutch Gear
Visual Check
Check and see the there is not wear, damage, crack, or
any other abnormality in the clutch gear.
Functional Check
If there is an abnormality such as soothlessness when
operated in combination with sleeve, replace the clutch
gear.
NOTE:
When inspection, gear oil should be applied to the contact
surface of gear.




RTW440SH000301
Dimensional Check
Make sure of the size illustrated.
Clutch Gear Out Side Diameter (Limit) mm (in)
36.98 (1.46)



RTW440SH000501



RTW440SH000401
Actuator
Visual Check
Check and see that there is no damage, cracking, or other
abnormality.
Functional Check
Make sure of function with voltage (12V) applied to
terminal
3, 4 and set the tester to terminal 1, 2 in
accordance with the table below.
State Port 3Port 4Port 1, 2
Conducting Function
A






C
B







D
If there is an abnormality, replace the actuator as an
assembly.
NOTE:
Be careful not to permit the entry of water or dust into the ports
of the actuator.
Do not open the actuator cover, if the actuator will be reused.

SHIFT ON THE FLY SYSTEM 4C2-9


RTW440SH000601








RTW440SH000801
Dimension Check
Measure illustration sized A, B, and C
Limit mm (in)

A 64.3 (2.53)
B 6.7 (0.26)
C 6.7 (0.26)













RTW440SH000701




REASSEMBLY
15. Oil seal
Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer.
Installer 5-8840-2407-0 (J-41693)
Grip 5-8840-0007-0 (J-8092)
























412RS051



14. Needle Bearing
Force a new needle bearing into inner shaft by using a
special tool.
Installer : 5-8840-2408-0 (J-41694)
Grip : 5-8840-0007-0 (J-8092)

4C2-10 SHIFT ON THE FLY SYSTEM



412RS044





















13. Inner Shaft Bearing


Place a new snap ring in inner shaft.


Force a new inner shaft bearing into the inner shaft.
Installer : 5-8840-2197-0 (J-37452)


12. Snap Ring
NOTE;
Be careful not to damage the inner shaft.

11.inner Shaft


Clean the housing contact surface of the front axle
case.


Insert inner shaft assembly into the front axle case.
NOTE:
Be careful not to damage oil seal.




412RW017

10. Snap Ring
Install snap ring in the groove of front axle case.
NOTE:
Be sure to install the snap ring properly.


9. Clutch Gear
Apply differential gear oil to clutch oil.
8. Sleeve
Apply differential gear oil to sleeve.




412RW023


7. Housing


Clean contact surface with the front axle and sctuator
mounting surface.

Apply liquid gasket to the contact surface on the front
axle case and install in the housing.

6. Bolt
Tighten bolts to specified tightening torque.
Housing Bolt Torque N m (kg m/lb ft)
75 (7.6/55)

SHIFT ON THE FLY SYSTEM 4C2-11






5. Actuator


Clean the actuator contact surface with the housing.


Apply liquid gasket to the contact surface on the
actuator side.


Align shift arm with the groove of sleeve and install the
actuator.

4. Bolt
Tighten bolts to specified torque.
Actuator Bolt Torque N m (kg m/lb ft)
9 (0.95/78)














3. Front Axle Drive Shaft (LH side)
2. Bolt


Install front axle drive shaft and mounting bracket.


Tighten fitting bolts to specified tightening torque.
Bolt Torque N m (kg m/lb ft)
116 (11.8/85)
1. Filler Plug


Pour specified amount of differential gear oil.
Front Differential Oil Capacity liter (US/UK gal)
1.4 (0.37/0.31)
Actuator Housing Oil Capacity liter (US/UK gal)
0.12 (0.03/0.03)


Install filler plug through packing and tighten to
specified torque.
Filler Plug Torque Nm (kgm/lbft)
78 (8.0/58)

SHIFT ON THE FLY SYSTEM 4C2-13
SPECIAL SERVICE TOOL
ILLUSTRATION PART NO. PART NAME

5-8840-0007-0
(J-8092)

Grip


5-8840-2407-0
(J-41693)



Installer: Oil seal



5-8840-2408-0
(J-41694)



Installer: Bearing needle



5-8840-0027-0
(J-26941)

Remover: Bearing needle


5-8840-0084-0
(J-2619-01)

Hammer: Sliding



5-8840-2197-0
(J-37452)

Remover: Bearing inner shaft

BRAKE CONTROL SYSTEM 5A-9

Pressure Isolation (Pressure Maintain)
The electronic-hydraulic control unit is activated when
the brakes are applied.
If the information from the wheel speed sensors
indicates excessive wheel deceleration (imminent
lockup), the first step in the anti-lock sequence is to
isolate the brake pressure being applied by the brake
pedal.
The microprocessor in the Control Unit sends a voltage
to the coil to energize and close the isolation valve.
This prevents any additional fluid pressure applied by
the brake pedal from reaching the wheel. With the
isolation valves closed, unnecessary increase in the
brake pressure is prevented.
C05L300013

5A-28 BRAKE CONTROL SYSTEM

Isolation Valve Test
Purpose: The purpose of this test is to detect brake
pipe and valve line harness wire for wrong connections
and valve trouble.
This test will help you confirm the result of your repair
service including the removal/reinstallation of brake
pipe, valve line harness and valve.
Test conditions: The ignition key is in the “ON” position
with the four wheels lifted up. The brake pedal is
stepped on, released and stepped on again with the
parking brake released.
Test procedure:
1. Connect Tech 2 with the vehicle, and select
Actuaor Test from the menus.
2. Select a Solenoid Valve Test Menu from the
Actuaor Test Menus.

060L300002
3. Select Isolation Valve from the Valve Select Menus.
4. Step on the brake pedal.
5. Release the brake pedal.
6. Make sure that the Isolation Valve “ON” aimed at by
Tech 2 and the wheel locked position are the same.
If different, check brake pipe, valve line harness
wiring and H/UNIT. Repair is needed if abnormality
is found.
7. Conduct Step 2 through Step 5 above on all the
four wheels.

060L300002
CAUTION: When conducting this test, please
observe the following cautions.

1. Do not start the engine.
2. Lift up the vehicle at a level floor.





Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
5. Do not load the vehicle.





When lifting up the vehicle, be sure to
observe the lifting up points. Refer to
vehicle lifting points in 0A section.