2004 ISUZU TF SERIES torque

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)
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 specified
torque.

Front companion flange end nut torque:
137 Nm (14 kgm/101 lbft)












41.
Use a cold chisel to caulk the front companion
flange 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 the
detenteplugs.

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)

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" 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 Specifications
Nm (kgm/lb ft)

RTW47DLF000201

7D1-2 TRANSFER CONTROL SYSTEM

Service Precaution
WARNING:
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.

7D1-6 TRANSFER CONTROL SYSTEM
spring standby mechanism is provided between the rod and
sleeve so that the rod is positioned at the 4

2 position, while
the sleeve is at the 4
4 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 4

2 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 of
interrupted 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)

7D1-34 TRANSFER CONTROL SYSTEM

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.

TRANSFER CONTROL SYSTEM 7D1-35
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.

7D1-36 TRANSFER CONTROL SYSTEM
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: Don’t’ accelerate 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 procedure
as 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.