2007 ISUZU KB P190 sensor

7D-18 TRANSFER CASE
Transfer Disassembly



RTW 67DLF000101
Legend

(1) Transfer Case Speedometer Bushing, Plate and Driven Gear
(2) Companion Flange, O-ring and Nut
(8)
(M/T: MUA, MUX, A/T: JR405E, AW 30-40LE)
(3) Stoneguard (9) Speed sensor (M/T: AR-5, A/T: 4L60-E)

(4) Detent Plug, Spring and Detent Ball (10) Transfer Actuator (Diesel Engine)
(5) 2-4 Switch ASM (11) Transfer Actuator (Gasoline Engine)
(6) Switch Bracket (12) Breather Hose
(7) Neutral Switch ASM (13) Heat Protector (Gasoline Engine)

Removal

1. Remove the stoneguard.
2. Remove the drain plug from the transfer case to drain
the oil.
3. Remove the parts listed below.
• Speedometer bushing, plate, and speedomete
r
driven gear (M/T: MUA, MUX, A/T: JR405E,
AW 30-40LE)
• Speed sensor (M/T: AR-5, A/T: 4L60-E)

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ISUZU KB P190 2007

7D-40 TRANSFER CASE
52. Install the speed sensor to the transfer case and
tighten the specified torque. (M/T: AR-5, A/T: 4L60-E)
Speed sensor torque: 17 N ·m (1.7 kgf ·m/12 lb ·ft)
53. Install the drain plug to the transfer case and tighten it
to the specified torque.
Drain plug torque: 39 N ·m (4.0 kgf ·m/29 lb ·ft)
54. 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 lit. (1.37 US qt)
55. Replace the filler plug and tighten it to the specified
torque.
Filler plug torque: 39 N ·m (4.0 kgf ·m/29 lb ·ft)
56. Install the underguard and tighten the bolts to the
specified torque.
Underguard bolt torque:
39 N ·m (4.0 kgf ·m/29 lb ·ft)




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ISUZU KB P190 2007

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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ISUZU KB P190 2007

7D1-12 TRANSFER CONTROL SYSTEM
Functions of Switch and indicator Lamp
Transfer-related indicator lamp and switch function

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
operation 1,0,1,0 Open Open Open -----
4H start
of
operation Off Off Off Off 4H position
for 0.1
second 1,0,1,0 Open Open Open Switch
operation sensor
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) 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
During
operation (Axle
drive) Blinking
(2HZ) Off Off Off No
operation 0,0,1,1 Closed Open Open Axle drive
Axle
waiting Blinking
(2HZ) Off Off Off No
operation 0,0,1,1 Closed Open Open Axle drive
4H On Off Off Off No
operation 0,0,1,1 Closed Open Closed -----
4L start
of
operation On Off Off Off 4L position
for 0.1
second 0,0,1,1 Closed Open Closed Switch
operation sensor
Start of
operation On Blinking
(2HZ) Off Off No
operation 0,0,0,1
0,1,0,1 Closed Open Closed 4H to 4L
while
driving
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 0,0,0,1
0,1,0,1 Closed Closed Closed 4H to 4L
through neutral
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Closed Closed 4H to 4L
through neutral
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 1,1,0,0 Closed Closed Closed 4H to 4L
through neutral
4L
waiting On Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Closed Closed 4H to 4L
while
waiting
4L On On Off Off No
operation 1,1,0,1 Closed Open Closed -----
4H start of
operation On Off Off Off 4H position
for 0.1
second 1,1,0,1 Closed Open Closed Switch
operation sensor

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ISUZU KB P190 2007

TRANSFER CONTROL SYSTEM 7D1-13
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
During
operation On Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Open Closed 4L to 4H
while
driving
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 1,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation Off Blinking
(2HZ) Off Off No
operation 0,1,0,1
0,0,0,1 Closed Closed Closed 4L to 4H
while
driving
4H
waiting Off Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Closed Closed
4L to 4H
while
waiting
4H On Off Off Off No
operation 0,0,1,1 Closed Open Closed -----
2H start of
operation On Off Off Off 2H position
for 0.1
second 0,0,1,1 Closed Open Closed Switch
operation sensor
Start of
operation Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
2H to 4H
while
driving
During
operation (Axle) Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Open Open Closed Axle drive
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation 1,0,1,0 Open Open Closed Axle
waiting
2H Off Off Off Off No
operation 1,0,1,0 Open Open Open -----


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ISUZU KB P190 2007

7D1-16 TRANSFER CONTROL SYSTEM
Transfer-related indicator lamp and switch function
Skip operation
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 -----
4L start of
operation Off Off Off Off 4L
position for 0.1
second 1,0,1,0 Open Open Open
Switch
operation sensor
Start of
operation Blinking
(2HZ) Blinking
(2HZ) 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) Blinking
(2HZ) Blinking
(2HZ) 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
During
operation (Passing through 4H) Off
Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Open -----
During
operation (Passing through 4H) Off
Blinking
(2HZ) Off Off No
operation 0,0,1,1
0,1,0,1 Closed Open Open -----
During
operation
(N)
On Blinking
(2HZ) Off Off No
operation
0,0,1,1
0,1,0,1 Closed Open Closed -----
During
operation (N) On
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Open Closed Switch
operation sensor
During
operation (N) On
Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Closed 4H to 4L
while
driving
During
operation (Axle
drive) Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Open
-----
Axle
waiting Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Open Open -----
4L waiting On Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Closed Closed 4H to 4L
while
waiting
4L On On Off Off No
operation1,1,0,1 Closed Open Closed -----

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ISUZU KB P190 2007

TRANSFER CONTROL SYSTEM 7D1-17
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
lamp 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 start
of
operation On On Off Off 2H
position for 0.1
second 1,1,0,1 Closed Open Closed
Switch
operation sensor
During
operation Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Open Closed 4L to 4H
while
driving
During
operation (Passing through N) On
Blinking
(2HZ) Off Off No
operation 1,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation (Passing through N) Off
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation (4H
waiting) Off
Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Closed Closed 4L to 4H
while
waiting
During
operation (Axle) Off while
waiting for start of H shift Blinking
(2HZ) while
waiting for start of H shift Off Off
No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
2H to 4H
while
driving
During
operation (Axle) Blinking
(2HZ) at
end of H shift Off at end
of H shift Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
Axle
driving
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation1,0,1,0 Open Open Closed -----
2H 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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ISUZU KB P190 2007

TRANSFER CONTROL SYSTEM 7D1-19
Transfer-related indicator lamp and switch function
2H→Neutral →2H
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 -----
Neutral
start of
operation Off Off Off Off Neutral
position for 10
seconds 1,0,1,0 Open Open Open
Switch
operation sensor
Start of
operation Off Off Blinking
(2HZ) 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) Off Off
Blinking
(2HZ) 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
During
operation (Passing through 4H) Off Off
Blinking
(2HZ) Off No
operation 0,0,1,1 Closed Open Closed -----
During
operation (Passing through 4H) Off Off
Blinking
(2HZ) Off No
operation 0,0,0,1
0,1,0,1 Closed Open Closed 4H to 4L
while
driving
During
operation
(N)
Off Off Blinking
(2HZ) Off No
operation
0,0,0,1
0,1,0,1 Closed Closed Closed
4H to 4L
through
neutral
During
operation (N) Off Off
Blinking
(2HZ) Off No
operation 0,1,0,0 Closed Closed Closed Switch
operation sensor
Neutral Off Off On Off No
operation0,1,0,0 Closed Closed Open -----
2H start of
operation Off Off On Off 2H
position for 10
seconds 0,1,0,0 Closed Open Closed
Switch
operation sensor
During
operation (Passing through N) Off
Blinking
(2HZ) Off Off No
operation 0,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation Off Blinking
(2HZ) Off Off No
operation 0,1,0,1
0,0,0,1 Closed Closed Closed 4L to 4H
while
driving

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ISUZU KB P190 2007