TRANSFER CASE 7D-41
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 US qt)
Type of lubricant BESCO GEAR OIL TRANSAXLE (5W -30)
Refer to Section 0B
Torque Specifications
N⋅m (kgf ⋅m/lb ⋅ft)
RTW 67DLF000201
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ISUZU KB P190 2007
7D-44 TRANSFER CASE
Special Tools
ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION PART NO.
PART NAME
5-8840-2786-0
(J-46202)
Transfer case oil seal installer
5-8840-2784-0
(J-46200)
Ring gear installer
5-8840-0084-0
(J-2619-01)
Sliding hammer
5-8840-0133-0
(J-8614-01)
Flange holder
5-8840-0027-0
(J-26941)
Rear output shaft needle bearing replacer
5-8840-2782-0
(J-46198)
Needle bearing installer
5-8840-2293-0
(J-39209)
Punch; end nut
5-8840-2783-0
(J-46199)
Needle bearing installer
5-8840-2788-0
Front output shaft needle bearing replacer
9-8522-1268-0
Rear output shaft ball bearing installer
5-8840-2785-0
(J-46201)
Input shaft and/or front
output shaft oil seal installe
r
5-8840-2787-0
(J-46203)
Snap ring installer
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TRANSFER CONTROL SYSTEM 7D1-5
System Components
Parts Location
RTW 57DLF000401
Speed sensor
Revolutions of the rear output shaft are decreased and taken
out by the speed/drive/driven gears installed in the transfer
case. The number of revolutions is detected with a speed
sensor.
About 4/3 pulses per revolution of the shaft are output.
4WD switch
The 4W D switch detects the movement of the shift rod driving
the 4 ×2 - 4 ×4 sleeve.
PUSH open is achieved with the PUSH open switch when the
shift rod is at the 4 ×2 position.
4 ×
××
×
2 - 4 ×
××
×
4 sleeve & Arm
The 4 ×2 - 4 ×4 sleeve moves directly in the 4 ×4 direction with
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7D1-6 TRANSFER CONTROL SYSTEM
the 4×2 - 4 ×4 shift rod. W hen moving in 4 ×2 direction, a 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.
This mechanism is provided to protect the shift mechanism
from the force and to prevent movement of the sleeve
(torsional torque etc. of the drive system). By releasing the
preventive force, the sleeve can move to the 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, 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. Therefore,
the rod position and the actual sleeve position may be offset in
some cases.
This system is provided to protect the shift mechanism from a
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 that is provided to the actuator at 4 positions.
These 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 (2W D-4W D)
Operating condition (2Hz: Actuator in operation, mechanism
standby)
Restrictions on operation (4Hz, including indication of
interrupted operation due
to excessive load)
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7D1-10 TRANSFER CONTROL SYSTEM
Transfer Actuator
Method of confirming the actuator position detection
(limit) switch
The actuator indicates the continuity condition of combinations,
as shown in the list below between the 4 detection (limit) switch
pins and the 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
the 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) -54
° to
-29 ° -29
° to 74 ° 74
° to
11 0 ° 11 0
° to 179 ° 179
° to
215 ° 215
° to
285 ° 285
° to
300 °
LS1 Close Close Open Open Open Open Open Open Open Close Close
LS2 Open Close OpenCloseCloseOpen OpenCloseClose Close Close
LS3 Close Close CloseCloseCloseCloseOpen Open Open Open Open
LS4 Open Open Open OpenCloseCloseCloseCloseOpen Open Close
Continuity between each pin and GND pin. (Continuity also exists between CLOSE pins.)
Transfer Actuator Connector
7B4-PDF6
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7D1-14 TRANSFER CONTROL SYSTEM
2H to 4H retrial
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches
LS1, LS2, LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
2H Off Off Off Off No
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 -----
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
Abandoned
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 Off No
operation1,0,1,0 Open Open Open -----
• Completion of transfer case H-L area and axle shift timing may cause some variation in the 2Hz blinking pattern.
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