2004 ISUZU TF SERIES Workshop Manual

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Page 3601 of 4264

ISUZU TF SERIES 2004 Workshop Manual TRANSFER CASE 7D-13

7.
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

Page 3602 of 4264

ISUZU TF SERIES 2004 Workshop Manual 7D-14 TRANSFER CASE

10.
Remove the transfer chain and the front output shaft
from the main shaft.
11.
Remove the main shaft snap ring.
12.
Remove the speedometer drive gear, the ball
bearing

Page 3603 of 4264

ISUZU TF SERIES 2004 Workshop Manual TRANSFER CASE 7D-15

15.
Remove the snap ring from the main shaft.
16
Use a press to remove the 2-4 hub from the main
shaft.

17.
Spread the edges of the retaining ring while li

Page 3604 of 4264

ISUZU TF SERIES 2004 Workshop Manual 7D-16 TRANSFER CASE

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

226R300004

24.
Remove the snap ring.
25.
Use a press

Page 3605 of 4264

ISUZU TF SERIES 2004 Workshop Manual TRANSFER CASE 7D-17

Internal Component Disassembly and Reassembly

226R300017

H-L Shift Disassembly

1.
Remove the guide roller.
2.
Use a vise to compress

Page 3606 of 4264

ISUZU TF SERIES 2004 Workshop Manual 7D-18 TRANSFER CASE

H-L shift reassembly

1.
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).

Page 3607 of 4264

ISUZU TF SERIES 2004 Workshop Manual TRANSFER CASE 7D-19

2-4 shift reassembly

1.
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 sh

Page 3608 of 4264

ISUZU TF SERIES 2004 Workshop Manual 7D-20 TRANSFER CASE

Inspection and Repair
1.
Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2.
Wash all parts tho

7D-20 TRANSFER CASE

Inspection and Repair
1.
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 (Transfer
Case Assembly)
When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired
or 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 inside
wall 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 the
sprocket 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. I
f
excessive 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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