2004 ISUZU TF SERIES Workshop Manual

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Page 3617 of 4264

ISUZU TF SERIES 2004 Workshop Manual TRANSFER CASE 7D-29

24.
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 ma

Page 3618 of 4264

ISUZU TF SERIES 2004 Workshop Manual 7D-30 TRANSFER CASE

226R300005

30.
Temporarily install the speedometer drive gear to the
inside of the rear cover. Pay close attention to
installation direction.
31.
Use a press and the

Page 3619 of 4264

ISUZU TF SERIES 2004 Workshop Manual TRANSFER CASE 7D-31

226R300011
36.
Install the rear cover to the transfer case and tighten
the bolts to the specified torque.
Rear cover and transfer case bolt torque:
22 Nm (2.2 kgm/16 lbft)

Page 3620 of 4264

ISUZU TF SERIES 2004 Workshop Manual 7D-32 TRANSFER CASE

43.
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 rin

7D-32 TRANSFER CASE

43.
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 rea
r
output oil seal to the rear case.
45.
Install the detent balls, the detent springs, and the
detent 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 the
transfer 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 the
transfer 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 and
tighten 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 transfe
r
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 transfe
r
actuator and the transfer case.
51.
Install the speedometer driven gear, the
speedometer bush, and the speedometer stay to the
transfer 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 specified
volume 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 specified
torque.
Filler plug torque: 39 Nm (4 kgm/29 lbft)
55.
Install the underguard and tighten the bolts to the
specified torque.
Underguard bolt torque: 39 Nm (4 kgm/29 lbft)

Page 3621 of 4264

ISUZU TF SERIES 2004 Workshop Manual TRANSFER CASE 7D-33

Main Data and Specifications
General Specifications
Type Synchronized type gears shifting between the 2 and 4 wheel drive mode.
Planetary type gears shifting between “low"

Page 3622 of 4264

ISUZU TF SERIES 2004 Workshop Manual 7D-34 TRANSFER CASE

N
m (kg
m/lb ft)

RTW47DLF000401

Page 3623 of 4264

ISUZU TF SERIES 2004 Workshop Manual TRANSFER CASE 7D-35

N
m (kg
m/lb ft)
E07R300008

Page 3624 of 4264

ISUZU TF SERIES 2004 Workshop Manual 7D-36 TRANSFER CASE

Special Tools

ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION
PART NO.
PART NAME

5-8840-2786
Transfer case oil seal
installer 5-8840-2784-0

Ring gear installer
5

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