Transfer Luv Dmax

WORKSHOP MANUAL
TF SERIES
TRANSFER
SECTION 7D
TRANSFER CASE 7D-1
SECTION 7D
TRANSFER CASE
TABLE OF CONTENTS
PAGE Service Precaution .......................................................................................................... 7D General Description ........................................................................................................ 7D Transfer Rear Oil Seal .................................................................................................... 7D Transfer Rear Oil Seal and Associated Parts ............................................................ 7D Removal ........................................................................................................................ 7D Installation .................................................................................................................... 7D Transfer Case Assembly ................................................................................................ 7D Transfer Case Assembly and Associated Parts ........................................................ 7D Removal ........................................................................................................................ 7D Installation .................................................................................................................... 7D 2 3 4 4 4 4 6 6 7 7
Transfer Control Unit ...................................................................................................... 7D 10 Removal ........................................................................................................................ 7D 10 Installation .................................................................................................................... 7D 10 Transfer Disassembly ..................................................................................................... 7D 11 Removal ........................................................................................................................ 7D 11 Inspection and Repair .................................................................................................. 7D 20 Inspection and Repair (Transfer Case Assembly) ..................................................... 7D 20 Reassembly .................................................................................................................. 7D 24 Main Data and Specifications ........................................................................................ 7D 33 Special Tools ................................................................................................................ 7D 36
7D-2 TRANSFER CASE
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.
TRANSFER CASE 7D-3
General Description
RUW34DLF000701
The transfer case is used to provide a means of providing power flow to the front axle. The transfer case also provides a means of disconnecting the front axle, providing better fuel economy and quieter operation when the vehicle is driven on improved roads where four wheel drive is not required. In addition, the transfer case provides an additional gear reduction when placed in low range, which is useful when difficult off-road conditions are encountered. Use the 4WD switch on the center cluster panel to select the drive range. The 4WD indicator lamp will be lit when 4WD is selected.
7D-4 TRANSFER CASE
Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts
220R300018
Legend (1)Rear Propeller Shaft (2)Oil Seal
Removal
1. Disconnect the rear propeller shaft (1) from the transfer case side. 2. Remove the oil seal from the transfer case.
Installation
1. Install oil seal and apply engine oil to the oil seal outer surfaces. 2. Apply the recommended grease (BESCO L2) or equivalent to the oil seal lip. 3. Use the oil seal installer 5-8840-2786-0 to install the rear seal (2) to the transfer rear case.
TRANSFER CASE 7D-5
220R300021
4. Connect the rear propeller shaft.
7D-6 TRANSFER CASE
Transfer Case Assembly

Transfer Case Assembly and Associated Parts
RTW47DLF000501
Legend (1)Rear Propeller Shaft (2)Front Propeller Shaft (3)Transfer Case Assembly (4) Center Exhaust Pipe (6VE1 only)
TRANSFER CASE 7D-7
Removal
NOTE: Before removing transmission and transfer assembly from vehicle, change the transfer mode to 2WD using the 4WD push button switch on dash panel. 1. Disconnect battery ground cable. 2. Raise and support vehicle with suitable stands. Drain transfer case fluid. 3. Remove the center exhaust pipe(5). (6VE1 only) 4. Remove rear propeller shaft (1) and front propeller shaft (2)(3). NOTE: Apply alignment marks on the flange at both front and rear sides. 5. Disconnect harness connectors and clip. Connector: transfer switch, 2WD-4WD actuator, speed sensor. NOTE: Avoid turning the vehicle ignition switch to the ON position when the 2WD-4WD connector is removed (battery connected). If the ignition switch must be turned to the ON position, the controller must first be removed (memory must be cleared because the CHECK 4WD INDICATOR will light). 6. Remove transfer case (4) from the vehicle.
Installation
1. Apply a thin coat of molybdenum disulfide grease to the input shaft spline as shown in the figure.
260R300001
7D-8 TRANSFER CASE 2. Install transfer case (4) to the transmission. Tighten transfer bolts as shown in the figure. For M/T
261R300001
TRANSFER CASE 7D-9 For A/T
261R300002
3. Connect harness connectors and clip. Connector: transfer switch, 2WD-4WD actuator, speed sensor. 4. Install center exhaust pipe(5). (6VE1 only) 5. Install rear propeller shaft (1) and front propeller shaft (2)(3). Torque: 63 Nm (6.4 kgm/46 lb ft)
7D-10 TRANSFER CASE
Transfer Control Unit
RTW37DLF000401
Legend (1)Transfer Control Unit (2)Protector
(3) Bolt
Removal
1. Disconnect the battery ground cable. Remove the drivers seat. 2. Peel back the floor carpet on the driver's side of the vehicle to expose the transfer control unit. 3. Disconnect the harness connector from the Transfer control unit. 4. Remove the Transfer control unit.
Installation
1. Install the Transfer control unit. 2. Connect the harness connector to the Transfer control unit. 3. Connect the battery ground cable.
TRANSFER CASE 7D-11
Transfer Disassembly
RTW47DLF000101
Legend (1) Transfer Case (2) Companion Flange, O-ring and Nut (3) Stoneguard (4) Detent Plug, Spring and Detent Ball (5) 2-4 Switch ASM (6) Switch Bracket
(7) (8) (9) (10) (11)
Neutral Switch ASM Speedometer Bush, Plate and Driven Gear Transfer Actuator Breather Hose Heat Protector (Except Diesel 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 bush, plate, and speedometer driven gear Breather hose (Between the transfer case and the transfer actuator assembly) Transfer actuator assembly Switch bracket
7D-12 TRANSFER CASE 2-4 switch assembly (Gray harness cover) Neutral switch assembly (Black harness cover) Detent plugs, detent springs, and detent balls (2 parts each) 4. Use the companion flange holder (5-8840-0133-0) to remove the end nut from the front companion flange. 6. Strike the area around the front output shaft head and the rear cover bolt holes with a plastic hammer to remove the rear cover.
5. Remove the bolts attaching the rear cover to the transfer case.
220R300022
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 rear spring) 2-4 shift assembly Shift drum and shift shaft Sun gear needle bearing Legend (1)Sun Gear Needle Bearing (2)H-L Sleeve (3)2-4sleeve, synchronizer key, and front synchronizer spring (4)2-4 Shift ASM (5)Shift Shaft (6)H-L Shift ASM (7)Shift Drum 8. Remove the oil pump strainer fixing bolts from the rear cover. 9. Compress the retaining ring at the rear of the chain. Strike the rear end of the main shaft with a plastic hammer to remove the main shaft, transfer chain, and front output shaft assembly from the rear cover. Be careful not to damage the oil pump strainer.
226R30001
260R300001
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 bearings, the retaining ring, and the oil pump assembly. 13. Remove the sprocket snap ring. 14. Remove the thrust washer, the drive sprocket, the inside ring, the outside ring, the block ring, and the rear synchronizer spring.
RTW37DMF000101
Legend (1)Rear synchronizer spring (2)Block Ring (3)Outside Ring (4)Inside Ring (5)Drive Sprocket (6)Transfer Chain (7)Front Output shaft (8)Thrust Washer
(9)Sprocket Snap Ring (10)Oil Pump ASM (11)Oil Pump Retaining Ring (12)Retaining Ring (13)Ball Bearing (14)Speedometer Drive Gear (15)Main Shaft Snap Ring
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.
2260R300021
17. Spread the edges of the retaining ring while lightly tapping on the sun gear input shaft end. Remove the carrier and gear assembly from the transfer case.
Legend (1)Outer Retaining Ring (2)Carrier and Gear ASM (3)Thrust needle Bearing (4)Sungear Input Shaft (5)Planetary DogTeeth (6)Dog Teeth Snap Ring 20.Remove the carrier snap ring. 21.Use a press to remove the ball bearings.
226R300020
18 Remove the dog teeth snap ring from the carrier and gear assembly. 19. Remove the planetary dog teeth and the sun gear input shaft together with the thrust needle bearing.
22.Use the sliding hammer (5-8840-0084-0) and the needle bearing replacer (5-8840-0027-0) to remove the needle bearing from the center of the carrier and gear assembly.
7D-16 TRANSFER CASE 27.Use a sliding hammer (5-8840-0084-0) and a needle bearing replacer (5-8840-2788-0) to remove the needle bearing from the front output shaft.
23. Remove the retaining ring (spiral type) together with the internal gear and the damper ring.
P1010023
226R300004
Legend (1)Dumper Ring (2)Internal Gear (3)Retaining Ring 24. Remove the snap ring. 25. Use a press to remove the front output shaft ball bearings. 26. Remove the oil pump wire snap ring from the rear cover.
TRANSFER CASE 7D-17 Internal Component Disassembly and Reassembly H-L Shift Disassembly 1. Remove the guide roller. 2. Use a vise to compress the H-L shift spirng (inside the assembly.
226R300017
Legend (1)ARM; SHIFT (2)BLOCK ASM; SHIFT (3)RING; RETAINING, INNER (4)COLLER (FRONT) (5)SPRING (6)COLLER (REAR) (7)ROD; SHIFT (8)RING; SNAP, OUTER (9)ROLLER; GUIDE (10)PIN ASM; SPRING
3. Remove the uter snap ring. 4. Remove the shift block assembly from the shift rod.
5. Use a socket and a vise to compress the shift block spring (inside the assembly. 6. Remove the inner retaining ring. 7. Remove the collar (rear. 8. Remove the shift block spring. 9. Remove the collar (rear. 10.Removethe shift block assembly 11.Remove the uter snap ring. 12.Remove the shift arm. 13.Remove the front and rear companion flange.
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). 3. Install the front collar, the spring, and the rear collar to the shift block in that order. 4. Use a socket and a vise to compress the shift block spring. 5. Install the inner retaining ring. Be sure that the arm aperture width is within the specified limit. 2-4 shift ASM
226R300016
226R300014
Legend (1)ROD; SHIFT (2)ARM; SHIFT (3)SPRING (4)BLOCK ARM;SHIFT (5)PIN ARM; SPRING (6)ROLLER; GUIDE (7)RING; SNAP 2-4 shift disassembly 1. 2. 3. 4. 5. 6. 7. Remove the guide roller. Compress the spring and remove the snap ring. Remove the shift arm. Remove the spring. Remove the spring pin. Remove the shift block assembly. Remove the shift rod.
Legend (1)25.62 (2)14.1mm
6. Install the shift lock assembly to the shift rod. 7. Use a socket and a vise to compress the H-L shift spring. 8. Install the outer snap ring. 9. Install the guide roller.
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 shift block.
Oil pump reassembly

1. Tighten the clamps to secure the hose. 2. Tighten the clamps to secure the screen. NOTE: Be carefull in the direction of clamps.
RTW37DSH000101 226R300015
3. 4. 5. 6.
Install the spring. Install the shift arm. Compress the spring and install the snap ring. Install the guide roller.
Legend (1) OIL PUMP ASM (2) CLAMP (3) HOSE (4) SCREEN ASM
Oil pump disassembly

1. Remove the clamps securing the screen. 2. Remove the screen. 3. Remove the clamps securing the hose. 4. Remove the hose. NOTE: To maintain and porotect oil pump function, the pump is constructed so that it cannot be disassembled. Under no conditions attempt to disassemble the pump.
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.
2-4 and Neutral Switch

Check the continuity of 2-4 and Neutral switch. If defects are observed, replace the 4H and 4L switch.
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.
221R300001
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.
261R300003
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. If excessive wear or damage is observed, replace the part.
Switch Stroke
1 2
2-4 Switch Signal Terminal 1 to 2 Open Close
Neutral Switch Signal Terminal 1 to2 Close Open
TRANSFER CASE 7D-21
Oil Pump
Remove foreign materials from the strainer. If the strainer is damaged, replace it. If the area into which the shaft is inserted is excessively worn or damaged, replace the oil pump assembly.
Ball Bearing Play

1. Use a dial indicator to measure the ball bearing play. 2. If the measured value exceeds the specified limit, the ball bearing must be replaced. Limit : 0.2 mm (0.008 in)
Clutch Hub Spline Play

Set a dial indicator to the clutch hub to be measured. Move the clutch hub as far as possible to both the right and the left. Note the dial indicator reading. If the measured value exceeds the specified limit, the clutch hub must be replaced. Clutch hub spline play Standard : 0 0.1 mm (0 0.004 in) Limit : 0.2 mm (0.008 in)
226R3043
Synchronizers
The synchronizer hubs and sliding sleeves are a selected assembly and should be kept together as originally assembled. Clean synchronizer components with clean solvent and air dry. Inspect the components for the following: Teeth for wear, scuffs, nicks, burrs or breaks. Keys and springs for wear, cracks or distortion, replace if these conditions are present. If scuffed, nicked or burred conditions cannot be corrected with a soft stone or crocus cloth, replace the component.
226RS042
Bearings
1. Inspect the condition of all the needles and ball bearings. Wash bearings thoroughly in a cleaning solvent. Apply compressed air to the bearings. NOTE: Do not allow the bearings to spin. Turn them slowly by hand. Spinning bearings may damage the rollers. 2. Lubricate the bearings with a light oil and check them for roughness by slowly turning the race by hand.
7D-22 TRANSFER CASE
Block Ring and Insert Clearance

1. Use a vernier caliper to measure the clearance between the block ring and the insert. 2. If the measured value exceeds the specified limit, the block ring and the insert must be replaced. Block ring and insert clearance Standard : 3.86 4.14 mm (0.152 0.163 in) Limit : 4.9 mm (0.193 in)
226R300019
Clutch Hub and Insert Clearance

1. Clutch Hub and Insert Clearance 2. Use a thickness gauge to measure the clearance between the clutch hub and the insert. 3. If the measured value exceeds the specified limit, the clutch hub and the insert must be replaced.
226RS037
Clutch hub and insert clearance Standard : 0.01-0.19 mm (0.0004-0.0075 in) Limit : 0.3 mm (0.012 in)
2WD-4WD Synchronizer (3-Cone)

1. Use a thickness gauge to measure the clearance between the block ring and the dog teeth. 2. If the measured value exceeds the specified limit, the 2WD-4WD synchronizer assembly must be replaced. Block ring and dog teeth clearance Standard : 1.5 mm (0.059 in) Limit : 0.8 mm (0.031 in)
226RS038
Detent Springs
1. Inspect the springs for distortion, cracks or wear. Replace if these conditions are present.
TRANSFER CASE 7D-23
Detent Spring Free Length

1. Use a vernier caliper to measure the detent spring free length. 2. If the measured value is less than the specified limit, the detent spring must be replaced. Detent spring free length Detent ball Standard :23.4 mm (0.92 in) Limit :22.8 mm (0.90 in)
220RS013
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring. Replace if these conditions are present.
Shift Arm Thickness

1. Use a micrometer to measure the shift arm thickness. 2. If the measured value is less than the specified limit, the shift arm must be replaced.
220RW035
Detent Spring Tension

1. Use a spring tester to measure the detent spring tension. 2. If the measured value is less than the specified limit, the detent spring must be replaced. Detent ball Compressed height : 18.7 mm (0.736 in) Standard : 68.6 ~ 88.2 N (7.0 ~ 9.0 kg/ 15.4 ~ 19.8 lb)
H-L Shift arm thickness Standard : 7.6-7.85 mm (0.299-0.309 in) Limit : 7.0 mm (0.276 in) 2-4 Shift arm thickness Standard : 9.6-9.85 mm (0.378-0.388 in) Limit : 9.0 mm (0.354 in)
7D-24 TRANSFER CASE
Reassembly
Transfer Reassembly
The rear cover oil seals and the rear output shaft ball bearings cannot be reused. They must be replaced with new ones when the transfer is reassembled. 1. Use the oil seal installer (5-8840-2785-0) to press the new input shaft and/or front output shaft oil seals into place (If replacement is required).
226R300004
Legend (1)Dumper Ring (2)Internal Gear (3)Retaining Ring Note the direction of the dumper ring installation as figure.
226R300025
2. Use a press to install the ball bearings to the front output shaft. Be sure that the bearings are fully inserted and then install the snap ring. 3. Install the damper ring and the internal gear to the transfer case. Be sure that the damper ring is between the internal gear and the case.
TRANSFER CASE 7D-25 4. Use a press and the special tool (5-8840-2784-0) to hold the internal gear against the damper ring. Install the retaining ring (spiral type).
5. Use a press and the installer (5-8840-2782-0) to force the needle bearing fully into the carrier and gear assembly.
7. Install the carrier snap ring. 8. Install the thrust needle bearing, the sun gear input shaft, the needle bearing, the planetary dog teeth, and the dog teeth snap ring to the carrier and gear assembly in that order. 9. Install the outer retaining ring to the tansfer case 10.Use a pair of snap ring pliers to install the carrier and gear assembly. NOTE: Be sure that the outer retaining ring fits snugly in its groove.
6. Use a press and an appropriate special tool to force the ball bearings fully into the carrier and gear assembly.
7D-26 TRANSFER CASE 11.Use a press to install the 2-4 hub.
12.Install the hub snap ring. 13.Install the synchronizer key springs (2), the synchronizer key, and the 2-4 sleeve to the 2-4 hub. The key and the open end of the springs must be facing in the opposite direction.
226R300003
Legend (1)Retaining Ring (2)Carrier and Gear ASM (3)Thrust Needle Bearing (4)Sungear Input Shaft (5)Planetary Dog Teeth (6)Dog Teeth Snapring
TRANSFER CASE 7D-27 14. Insert the H-L sleeve into the main shaft.
226R300023
Legend (1)H-L Sleeve (2)2-4 Sleeve 15. Install the sleeve to the H-L shift assembly. 16. Install the sleeve to the 2-4 shift assembly. 17. Coat the area around each of the shift assembly insertion holes (transfer case) with transfer oil. 18. Install the main shaft together with the H-L shift assembly and the 2-4 shift assembly to the shift drum.
(3)Synchronizer Key and Key Spring
7D-28 TRANSFER CASE 19. Align the shift shaft splines with the shift drum and install the shafts to the drum.
RTW320MF000201
Legend (1)H-L Sleeve and Shift ASM (2)2-4 Sleeve ASM with Main Shaft and Shift ASM NOTE: Be careful in the direction of an assembly.
(3)Shift Shaft (4)Shift Drum 20.Coat the main shaft with oil. 21.Align the block ring, the outside ring, and the inside ring with the 2-4 hub assembly and install them. 22.Assemble the sprocket, transfer chain, and front output shaft. 23.Install the sprocket, transfer chain, and front output shaft to the main shaft and the transfer case.
P1010041/020124
TRANSFER CASE 7D-29 24. Align the sprocket thrust washer with the main shaft groove and install it.
Legend (1)Block Ring (2)Outside Ring (3)Inside Ring (4)Sprocket (5)Chain (6)Front Output Shaft (7)Thrust Washer (8)Snap Ring 26.Measure the snap ring external diameter. If the measured diameter is outside the specified range, a larger or smaller snap ring must be used. Snap ring outside diameter (Standard): 53.0 0.5 mm 27.Position the rear cover so that its mating surfaces are facing up. 28.Use a press and the installer (5-8840-2783-0) to install the front output shaft needle bearing. The installer must be aligned with the bearing manufacturer's name (stamped into the bearing).
226R300009
25. Select a snap ring that will allow minimum axial play. Insert it to the main shaft installation groove. mm (in) Snap ring thickness Identification color 2.15 (0.085) Red 2.10 (0.083) Not colored 2.05 (0.081) Blue 2.00 (0.079) White
29.Install the oil pump wire snap ring to the rear cover.
226R300008
7D-30 TRANSFER CASE
226R300005
Legend (1)Wire Snapring 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 installer (9-8522-1268-0) to install the rear output shaft ball bearings. Do not drive the ball bearings into place with a hammer. Legend (1)Oil Pump ASM (2)Wire Snapring (3)Retaining Ring (4)Ball Bearing (5)Speedometer Gear Drive Gear (6)Rear Cover 35.Apply Loctite FMD 127 to the mating surfaces of the rear cover and the transfer case. Be sure that the Loctite is evenly applied to the inside surfaces of the bolt holes with no gaps.
226R300010
32. Install the rear output shaft retaining ring. 33. Place the oil pump in its specified position. 34. Secure the pump strainer to the rear cover and tighten the bolts to the specified torque. Rear cover and transfer case bolt torque: 15 Nm (1.5 kgm/11 lb ft)
TRANSFER CASE 7D-31
226R300011
226R300012
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)
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.
41. Use a cold chisel to caulk the front companion flange end nuts.
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. 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 transfer 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:
226R300022
22 Nm (2.2 kgm/16 lbft) 50.Install the breather hose between the transfer 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)
44. Use the installer (5-8840-2786-0) to install the rear 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)
TRANSFER CASE 7D-33
Main Data and Specifications

General Specifications
Type Control method Gear ratio Oil capacity Type of lubricant Synchronized type gears shifting between the 2 and 4 wheel drive mode. Planetary type gears shifting between low" and high". Remote control with the button switch on the instrument panel for gears shifting among 2H" , 4H" and 4L". High; 1.000 Low; 2.482 1.3 lit. (1.37 U.S. quart) BESCO GEAR OIL TRANSAXLE (5W-30) Refer to chart in Section 0
Torque Specifications
Nm (kgm/lb ft)
RTW47DLF000201
7D-34 TRANSFER CASE Nm (kgm/lb ft)
RTW47DLF000401
TRANSFER CASE 7D-35 Nm (kgm/lb ft)
E07R300008
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
5-8840-0084-0 Sliding hammer
5-8840-0133-0 Flange holder
5-8840-0027-0 Rear output shaft needle bearing replacer
5-8840-2782-0 Needle bearing installer
5-8840-2293-0 Punch; end nut
5-8840-2783-0 Needle bearing installer
5-8840-2788-0 Front output shaft needle bearing replacer
5-8840-0007-0 Driver handle
5-8840-2785-0 Input shaft and/or front output shaft oil seal installer
5-8840-1268-0 Rear output shaft ball bearing installer
TRANSFER CASE 7D-37 ILLUSTRATION PART NO. PART NAME
5-8840-2787-0 Snapring installer
7D-38 TRANSFER CASE
MEMO
TRANSFER CONTROL SYSTEM 7D1-1
SECTION 7D1
TRANSFER CONTROL SYSTEM

TABLE OF CONTENTS
PAGE Service Precaution .................................................................................................... 7D1 General Description ................................................................................................... 7D1 System Components ................................................................................................. 7D1 Parts Location ...................................................................................................... 7D1 2 3 5 5
Functions of Switch and Indicator Lamp ................................................................. 7D1 - 11 Parts Location ............................................................................................................ 7D1 - 23 Circuit Diagram .......................................................................................................... 7D1 - 27 Connector List ........................................................................................................... 7D1 - 31 Diagnosis .................................................................................................................... 7D1 - 34 Before determining trouble ................................................................................. 7D1 - 34 Memory erasing procedure ....................................................................................... 7D1 - 40 Diagnosis from symptom .......................................................................................... 7D1 - 41
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.
General Description
RTW47DLF000301
Transfer Position and Drive Mode

Three drive modes can be selected through operation of 4WD switch. Transfer Position HIGH LOW NEUTRAL 4WD SWITCH 2H 4H 4L 2H & 4L (10 Sec) Mode RWD 4WD (HIGH) 4WD (LOW) NEUTRAL Drive mode Rear wheel drive High-speed mechanical lock-up four wheel drive Low-speed mechanical lock-up four wheel drive Towed by other vehicle
7D1-4 TRANSFER CONTROL SYSTEM Summary of transfer control system The transfer control system switches between the 2-wheel drive (2H), 4-wheel drive high-speed (4H), 4-wheel drive lowspeed (4L), and neutral positions electrically when the driver operate the switches. This system has following functions. 1. Connection or disconnection of drive force distribution to the front wheel front shaft (axle shaft) (The drive force distribution to the front propeller is connected or disconnected with the motor actuator.) 2. Try to repeat the connection or disconnection of the front wheel drive function as described above. 3. Option: Shift on the fly type only. Instruction of connection or disconnection of the drive force transmission between the front wheel axle (axle shaft) and front wheel (The motor actuator connects or disconnects the left front wheel ad front wheel axle (axle shaft).). 4. Shifting of auxiliary transmission gears, connection or disconnection of wheel and engine drive force (4H, 4L, neutral). 5. Operation of indicator on the instrument panel. 6. Transmission of position signal to other controllers.
System Components
Parts Location
Speed sensor Revolutions of the rear output shaft are decreased and taken out by the speed/drive/driven gears installed in the transfer case and the number of revolutions is detected with a speed sensor. About 4/3 pulses per revolution of the shaft is output. 4WD switch The 4WD switch detects the movement of the shift rod driving the 42 - 44 sleeve. PUSH open is achieved with the PUSH open switch when the shift rod is at the 42 position. 42 - 44 sleeve & Arm The 42 - 44 sleeve moves directly in the 44 direction with the 42 - 44 shift rod, but, when moving in 42 direction, a
7D1-6 TRANSFER CONTROL SYSTEM spring standby mechanism is provided between the rod and sleeve so that the rod is positioned at the 42 position, while the sleeve is at the 44 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 42 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. 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)
7B4-PDF2
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)

7B4-PDF3
Neutral indicator (in operation switch panel) This LED indicates following items. LED check Driving status (Neutral) Operating status (2Hz: Actuator in operation, mechanism standby) Restrictions on operation (4Hz)
7B4-PDF4
Check 4WD warning light (in meter panel) This light indicates following items. Valve check Faulty actuator limit SW, and fault of circuit related with the limit switch
7B4-PDF5
4WD switch Switch to transmit a switching command to the 2H, 4H, Neutral, or 4L position. It comprises 3 PUSH momentary switches. By keeping to push the 2H and 4L switches for 10 seconds, operation is instructed to the neutral position. To shift from the neutral to other position, other required switches should be pushed for 10 seconds.
825R300018
Transfer controller
Located below the right seat.
RTW37DLF000401
Legend
1. Transfer controller 2. Protector 3. Bolt
Transfer Acutuator
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 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 case of 2H-4H) is either of the combinations shown below depending upon manufacturing variations of the switch plate.
2H Direction of output shaft notch (outline) LS1 LS2 LS3 LS4 -54 to -29 Close Open Close Open
2H-4H -29 to 74 Close Close Close Open Open Open Close Open Open Close Close Open Open Close Close Close
4H 74 to 110 Open Open Close Close
4H-N 110 to 179 Open Open Open Close Open Close Open Close
N 179 to 215 Open Close Open Open
N-L 215 to 285 Close Close Open Open
4L 285 to 300 Close Close Open Close
Continuity between each pin and GND pin. (Continuity also exists between CLOSE pins.) Transfer Actuator Connector
7B4-PDF6
7D1-10 TRANSFER CONTROL SYSTEM Method of checking the position detection switch harness Disconnect the vehicle harness connector on the transfer controller side and the vehicle harness connector on the transfer actuator side as shown in the wiring diagram, and check the continuity between the following connector pins and that there is no continuity between those pins and GND or power source. Check that there is continuity between the GND pin and vehicle GND on the transfer actuator and there is no continuity between the GND pin and other power source.
RTW47DSF000301
Vehicle harness connector pin No. (connector of mating parts of the harness is shown in this figure)
Name of pin
LS1 LS2 LS3 LS4 GND
T/F controller side R-14, 17 R-14, 6 R-14, 15 R-14, 14 R-15, 1, 9
T/F actuator side 5 4 7 6 8
Remarks
Function of Switch and indicator Lamp

Transfer-related indicator lamp and switch function
Actuator detection Check Item 4WD lamp 4L lamp Neutral lamp 4WD warning light 4WD switch (limit) switches LS1, LS2, LS3. and LS4 1 = on 2 = off 2H 4H start of operation Start of operation Off Off Off Off Off Off Off Off No operation 4H position for 0.1 second No operation 1,0,1,0 1,1,1,0 Blinking (2HZ) Off Off Off 0,0,1,0 0,1,1,0 0,1,1,1 1,1,1,0 0,0,1,0 0,1,1,0 0,1,1,1 Open Open Open Open Open Open 1,0,1,0 Open Open Open ----Switch operation sensor 2H to 4H while driving 2H to 4H Open Open Open using synchro and retrial Transfer 4WD switch Transfer neutral switch
SOF actuator switch Or Axle dummy Remarks
During operation (Synchro) During operation (Axle drive) Axle waiting 4H 4L start of operation Start of operation During operation (N) During operation (N) During operation (N) 4L waiting 4L 4H start of operation
Blinking (2HZ)
Off
Off
Off
No operation
Blinking (2HZ) Blinking (2HZ) On
Off
Off
Off
No operation No operation No operation 4L position for 0.1 second No operation No operation No operation No operation No operation No operation 4H position for 0.1 second
0,0,1,1
Closed
Open
Open
Axle drive
Off Off
Off Off
Off Off
0,0,1,1 0,0,1,1
Closed Closed
Open Open
Open Closed
Axle drive ----Switch
On
Off
Off
Off
0,0,1,1
Closed
Open
Closed
operation sensor 4H to 4L while driving 4H to 4L through neutral 4H to 4L through neutral 4H to 4L through neutral 4H to 4L while waiting ----Switch
On
Blinking (2HZ) Blinking (2HZ) Blinking (2HZ) Blinking (2HZ) Blinking (2HZ) On
Off
Off
0,0,0,1 0,1,0,1 0,0,0,1 0,1,0,1
Closed
Open
Closed
Off
Off
Off
Closed
Closed
Closed
Off
Off
Off
0,1,0,0
Closed
Closed
Closed
Off
Off
Off
1,1,0,0
Closed
Closed
Closed
On
Off
Off
1,1,0,1
Closed
Closed
Closed
On
Off
Off
1,1,0,1
Closed
Open
Closed
On
Off
Off
Off
1,1,0,1
Closed
Open
Closed
operation sensor

Actuator detection (limit) switches LS1, LS2, LS3. and LS4 1 = on 2 = off During operation During operation (N) During operation 4H waiting 4H 2H start of operation Start of operation On Off Off Off Off On Blinking (2HZ) Blinking (2HZ) Blinking (2HZ) Blinking (2HZ) Off Off Off No operation No operation No operation No operation No operation 2H position for 0.1 second No operation 0,0,1,1 0,1,1,1 0,1,1,0 0,0,1,0 1,1,1,0 0,1,1,1 Blinking (2HZ) Blinking (2HZ) Off Off Off Off No operation No operation No operation 0,1,1,0 0,0,1,0 1,1,1,0 1,0,1,0 1,0,1,0 Open Open Closed Axle drive Closed Open Closed 1,1,0,1 Closed Open SOF Transfer 4WD switch Transfer neutral switch actuator switch Or Axle dummy
Item
4WD lamp
4L lamp
Neutral lamp
Check 4WD warning light
4WD switch
Remarks
Closed
4L to 4H while driving 4L to 4H through neutral 4L to 4H while driving 4L to 4H while waiting ----Switch operation sensor 2H to 4H while driving
Off
Off
Off
1,1,0,0
Closed
Closed
Closed
Off
Off
0,1,0,1 0,0,0,1
Closed
Closed
Closed
Off
Off
Off
0,0,1,1
Closed
Closed
Closed
On
Off
Off
0,0,1,1
Closed
Open
Closed
Blinking (2HZ)
Off
Off
Off
Closed
Open
Closed
During operation (Axle) Axle waiting 2H
Off Off
Off Off
Off Off
Open Open
Open Open
Closed Open
Axle waiting -----
2H to 4H retrial
Actuator detection (limit) switches LS1, LS2, LS3. and LS4 1 = on 2 = off 2H 4H start of operation Off Off Off Off No operation 4H position for 0.1 second No operation 1,0,1,0 Open Open SOF Transfer 4WD switch Transfer neutral switch actuator switch Or Axle dummy
Item
4WD lamp
4L lamp
Neutral lamp
4WD switch
Remarks
Open
-----
Off
Off
Off
Off
1,0,1,0
Open
Open
Open
-----
Start of operation During operation (Synchro) (Go to 4H if synchro complete) Abandon ed operation (2H) 2H indication after 10second s
Blinking (2HZ)
Off
Off
Off
1,1,1,0 0,0,1,0 0,1,1,0 0,1,1,1 1,1,1,0 0,0,1,0 0,1,1,0 0,1,1,1
Open
Open
Open
2H to 4H while driving 2H to 4H using
Blinking (2HZ)
Off
Off
Off
No operation
Open
Open
Open
synchro and retrial X2
Blinking (4HZ)
Off
Off
Off
No operation
1,0,1,0
Open
Open
Open
Return to 2H
Off
Off
Off
Off
No operation
1,0,1,0
Open
Open
Open
-----
Completion of transfer case H-L area and axle shift timing may cause some variation in 2Hz blinking pattern.
7D1-14 TRANSFER CONTROL SYSTEM Operational limits (4H4L) (Vehicle speed, engine speed, and transmission position not specified)
Actuator detection Check Item 4WD lamp 4L lamp Neutral lamp 4WD warning light 4WD switch (limit) switches LS1, LS2, LS3. and LS4 1 = on 2 = off 4H 4H start of operation 10 second display during limitation Go to 4H after 10 seconds On Off Off Off Open 0,0,1,1 Closed Open Closed On Blinking (4HZ) Off Off Open 0,0,1,1 Closed Open Closed On Off Off Off Open 4L position for 0.1 second 0,0,1,1 Closed Open Closed ----Transfer 4WD switch Transfer neutral switch
On
Off
Off
Off
0,0,1,1
Closed
Open
Closed
-----
No operation during limitation
-----
Operational limits (4L4H)
(Vehicle speed, engine speed, and transmission position not specified)

Actuator detection (limit) 4WD switch switches LS1, LS2, LS3. and LS4 1 = on 2 = off No operation 4H position for 0.1 second 1,1,0,1 Closed Open Transfer 4WD switch Transfer neutral switch
Item
4WD lamp
4L lamp
Neutral lamp
SOF actuator switch Or Axle dummy
Remarks
4L
On
On
Off
Off
Closed
-----
4L start of operation 10 second display during limitation Go to 4L after 10 seconds
On
On
Off
Off
1,1,0,1
Closed
Open
Closed
-----
On
Blinking (4HZ)
Off
Off
Open
1,1,0,1
Closed
Open
Closed
No operation during limitation
On
On
Off
Off
No operation
1,1,0,1
Closed
Open
Closed
-----
Under some conditions, a secondary operational indication may be received when the 4Hz operational indication is present.

Skip operation
Actuator detectio Check 4WD warning light n (limit) switches LS1, LS2, LS3. and LS4 1 = on 2 = off 2H Off Off Off Off No operation 4L position for 0.1 second Start of operation Blinking (2HZ) Blinking (2HZ) No operation 1,1,1,0 0,0,1,0 0,1,1,0 0,1,1,1 1,1,1,0 Blinking (2HZ) Blinking (2HZ) Off Off No operation 0,0,1,0 0,1,1,0 0,1,1,1 Open Open Open 1,0,1,0 Open Open Open ----Switch 1,0,1,0 Open Open Open operation sensor 2H to 4H while driving 2H to 4H using synchro and retrial SOF actuator switch Or Axle dummy
Item
4WD lamp
4L lamp
Neutral lamp
4WD switch
Transfer 4WD switch
Transfer neutral switch
Remarks
4L start of operation
Off
Off
Off
Off
Off
Off
Open
Open
Open
During operation (Synchro) During operation (Passing through 4H) During operation (Passing through 4H) During operation (N) During operation (N) During operation (N) During operation (Axle drive) Axle waiting 4L waiting
Off
Blinking (2HZ)
Off
Off
No operation
0,0,1,1
Closed
Open
Open
-----
Off
Blinking (2HZ)
Off
Off
No operation
0,0,1,1 0,1,0,1
Closed
Open
Open
-----
On
Blinking (2HZ) Blinking (2HZ) Blinking (2HZ)
Off
Off
No operation No operation No operation
0,0,1,1 0,1,0,1
Closed
Open
Closed
----Switch
On
Off
Off
0,1,0,0
Closed
Open
Closed
operation sensor 4H to 4L while driving
On
Off
Off
0,0,1,1
Closed
Open
Closed
Blinking (2HZ) Blinking (2HZ) Blinking (2HZ) On
Off
Off
No operation No operation No operation No operation
0,0,1,1
Closed
Open
Open
-----
Off
Off
0,0,1,1
Closed
Open
Open
----4H to 4L while waiting
Off
Off
1,1,0,1
Closed
Closed
Closed
4L
On
Off
Off
1,1,0,1
Closed
Open
Closed
-----

Actuator detectio n (limit) switches 4WD switch LS1, LS2, LS3. and LS4 1 = on 2 = off 2H 2H start of operation On On Off Off position for 0.1 second No operation 1,1,0,1 Closed Open Closed SOF actuator switch Or Axle dummy Remarks
Item
4WD lamp
4L lamp
Neutral lamp
Check 4WD lamp
Transfer 4WD switch
Switch operation sensor 4L to 4H while driving 4L to 4H through neutral
During operation During operation (Passing through N) During operation (Passing through N) During operation (4H waiting)
Blinking (2HZ)
Blinking (2HZ)
Off
Off
1,1,0,1
Closed
Open
Closed
On
Blinking (2HZ)
Off
Off
No operation
1,1,0,0
Closed
Closed
Closed
Off
Blinking (2HZ)
Off
Off
No operation
4L to 4H 0,1,0,0 Closed Closed Closed through neutral
Off
Blinking (2HZ) Blinking (2HZ) while waiting for start of H shift
Off
Off
No operation
4L to 4H 0,0,1,1 Closed Closed Closed while waiting
During operation (Axle)
Off while waiting for start of H shift Blinking (2HZ) at end of H shift Blinking (2HZ) Off
0,1,1,1 Off Off No operation 0,1,1,0 0,0,1,0 1,1,1,0 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) Axle waiting 2H
Off at end of H shift
Off
Off
Closed
Open
Closed
Axle driving
Off Off
Off Off
Off Off
1,0,1,0 1,0,1,0
Open Open
Open Open
Closed Open
---------
Completion of transfer case H-L area and axle shift timing may cause some variation in 2Hz blinking pattern.
TRANSFER CONTROL SYSTEM 7D1-17 Skip operation limitations (4L2H) specified) (Vehicle speed, engine speed, and transmission position not
Actuator detection (limit) switches LS1, LS2, LS3. and LS4 1 = on 2 = off 4L 4L start of operation 10 second display during limitation Go to 4L after 10 seconds Off On Off Off Open 2H Off On Off Off position for 0.1 second 1,1,0,1 Closed Open Closed ----1,1,0,1 Closed Open SOF Transfer 4WD switch Transfer neutral switch actuator switch Or Axle dummy
Item
4WD lamp
4L lamp
Neutral lamp
4WD switch
Remarks
Closed
-----
No Blinking (4HZ) Off Off Off Open 1,1,0,1 Closed Open Closed operation during limitation
Off
ON
Off
Off
Open
1,1,0,1
Closed
Open
Closed
-----
Skip operation limitations (2H4L) specified)
(Vehicle speed, engine speed, and transmission position not
Actuator detection (limit) switches LS1, LS2, LS3. and LS4 1 = on 2 = off 2HL 4L start of operation 10 second display during limitation Go to 2H after 10 seconds Off Off Off Off Open 2H Off Off Off Off position for 0.1 second 1,0,1,0 Open Open Open ----1,0,1,0 Open Open SOF Transfer 4WD switch Transfer neutral switch actuator switch Or Axle dummy
Item
4WD lamp
4L lamp
Neutral lamp
4WD switch
Remarks
Open
-----
No Blinking (4HZ) Blinking (4HZ) Off Off Open 1,0,1,0 Open Open Open operation during limitation
Off
Off
Off
Off
Open
1,0,1,0
Open
Open
Open
-----
Under some conditions, a secondary operational indication may be received when the 4Hz operational indication is present.

2HNeutral2H
Actuator detectio n (limit) switches 4WD switch LS1, LS2, LS3. and LS4 1 = on 2 = off 2H Neutral start of operation Off Off Off Off No operation Neutral position for 10 seconds No operation 1,0,1,0 Open Open SOF actuator switch Or Axle dummy Remarks
Check Item 4WD lamp 4L lamp Neutral lamp 4WD warning light
Transfer 4WD switch
Open
----Switch operation sensor 2H to 4H while driving 2H to 4H using synchro and retrial
Off
Off
Off
Off
1,0,1,0
Open
Open
Open
1,1,1,0 Start of operation Off Off Blinking (2HZ) Off 0,0,1,0 0,1,1,0 0,1,1,1 1,1,1,0 0,0,1,0 0,1,1,0 0,1,1,1 Open Open Open
During operation (Synchro) During operation (Passing through 4H) During operation (Passing through 4H) During operation (N) During operation (N) Neutral Off Off Off Off Off Off Off Off
Blinking (2HZ)
Off
No operation
Open
Open
Open
Off
Off
Blinking (2HZ)
Off
No operation
0,0,1,1
Closed
Open
Closed
-----
Blinking (2HZ)
Off
No operation
0,0,0,1 0,1,0,1
Closed
Open
Closed
4H to 4L while driving 4H to 4L through neutral Switch operation sensor ----Switch operation sensor
Off
No operation No operation No operation 2H position for 10 seconds
0,0,0,1 0,1,0,1
Closed
Closed
Closed
Off
0,1,0,0
Closed
Closed
Closed
Off
Off
Off
0,1,0,0
Closed
Closed
Open
2H start of operation During operation (Passing through N) During operation
Off
Off
On
Off
0,1,0,0
Closed
Open
Closed
Off
Blinking (2HZ)
Off
Off
No operation
0,1,0,0
Closed
Closed
Closed
4L to 4H through neutral 4L to 4H while driving
Off
Blinking (2HZ)
Off
Off
No operation
0,1,0,1 0,0,0,1
Closed
Closed
Closed

Actuator detectio n (limit) switches 4WD switch LS1, LS2, LS3. and LS4 1 = on 2 = off During operation (4H waiting) During operation (Axle) During operation (Axle) Axle waiting 2H Off Blinking (2HZ) Off Off No operation 0,0,1,1 Closed Closed Closed SOF actuator switch Or Axle dummy Remarks
Check Item 4WD lamp 4L lamp Neutral lamp 4WD warning light
Transfer 4WD switch
4L to 4H while waiting
Blinking (2HZ)
Off
Off
Off
No operation
0,1,1,1 0,1,1,0 0,0,1,0 1,1,1,0 0,1,1,1 0,1,1,0 0,0,1,0 1,1,1,0 1,0,1,0 1,0,1,0
2H to 4H Closed Open Closed while driving
Blinking (2HZ) Blinking (2HZ) Off
Off
Off
Off
Open
Open
Closed
Axle driving
Off Off
Off Off
Off Off
Open Open
Open Open
Closed Open
---------
Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer shifts in both directions (HNeutralL).
7D1-20 TRANSFER CONTROL SYSTEM 4HNeutral4H

Actuator detection (limit) 4WD switch switches LS1, LS2, LS3. and LS4 1 = on 2 = off No operation Neutral position for 10 seconds No operation No operation No operation 0,0,1,1 Closed Open Transfer 4WD switch Transfer neutral switch SOF actuator switch Or Axle dummy
Item
4WD lamp
4L lamp
Neutral lamp
Remarks
4H Neutral start of operation Start of operation During operation (N) During operation (N) During operation (Axle) Axle waiting Neutral 4H start of operation During operation (N) During operation (N) During operation
On
Off
Off
Off
Closed
-----
On
On
Off
Off
1,1,0,1
Closed
Open
Closed
-----
Off
Off
Blinking (2HZ) Blinking (2HZ) Blinking (2HZ)
4L to N 1,1,0,0 Closed Open Closed while driving 4L to N with axle driving 0,1,0,0 0,1,1,1 0,1,1,0 0,0,1,0 1,1,1,0 1,0,1,0 0,1,0,0 Closed Closed Closed 4L to 4N with axle removed Axle driving
Off
Off
Off
Off
1,1,0,0
Closed
Closed
Closed
Off
Off
Off
Off
Off
Off
No operation No operation No operation 2H position for 10 seconds No operation No operation
Open
Open
Closed
Off Off
Off On
Off Off
Open Closed
Open Closed
Closed Open
--------Switch operation sensor 4L to 4H
Off
Off
Off
Off
0,1,0,0
Open
Open
Open
Off
Blinking (2HZ) Blinking (2HZ)
Off
Off
1,1,0,0
Closed
Closed
Open
through neutral 4L to 4H through neutral 4L to 4H
Off
Off
Off
0,1,0,0
Closed
Closed
Open
Off
Blinking (2HZ)
Off
Off
No operation
0,1,0,1 0,0,0,1
Closed
Closed
Open
while driving 4L to 4H while waiting
4H waiting During operation (Axle) Axle waiting 4H
Blinking (2HZ) Blinking (2HZ) Blinking (2HZ) On
Off)
Off
Off
No operation No operation No operation No operation
0,0,1,1
Closed
Closed
Open
Off
Off
Off
0,0,1,1
Closed
Open
Open
Axle driving ---------
Off Off
Off Off
Off Off
0,0,1,1 0,0,1,1
Closed Closed
Open Open
Open Closed
TRANSFER CONTROL SYSTEM 7D1-21 Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer shifts in both directions (HNeutralL).
7D1-22 TRANSFER CONTROL SYSTEM 4LNeutral4L

Actuator detection Check Item 4WD lamp 4L lamp Neutral lamp 4WD warning light 4WD switch (limit) switches LS1, LS2, LS3. and LS4 1 = on 2 = off 4L Neutral start of operation Start of operation During operation (N) During operation (N) During operation (Axle) Axle waiting Neutral Off Off Off Off Blinking (2HZ) Blinking (2HZ) Blinking (2HZ) On On Off Off No operation Neutral On On Off Off position for 10 seconds No operation No operation No operation No operation No operation No operation 4L 4L start of operation During operation (N) During operation (N) During operation (N) 4H waiting During operation (Axle) Axle waiting 4H Off Off Off Off Off On Off position for 10 seconds No operation No operation No operation No operation No operation No operation No operation 0,1,0,0 Open Open Open 1,1,0,1 Closed Open Closed ----1,1,0,1 Closed Open Closed ----Transfer 4WD switch Transfer neutral switch
Off
Off
Off
1,1,0,0
Closed
Open
Closed
4L to N while driving 4L to N with axle driving 4L to 4N with axle removed Axle driving --------Switch operation sensor 4H to 4L
Off
1,1,0,0
Closed
Closed
Closed
Off
0,1,0,0
Closed
Closed
Closed
Off
Off
Off
0,1,0,0
Closed
Closed
Closed
Off Off
Off On
Off Off
0,1,0,0 0,1,0,0
Closed Closed
Closed Closed
Closed Open
Blinking (2HZ) Blinking (2HZ) Blinking (2HZ) Blinking (2HZ) Off
Off
Off
1,1,0,0
Closed
Closed
Open
through neutral 4H to 4L through neutral 4H to 4L through neutral 4L while waiting Axle driving ---------
Off
Off
1,1,0,0
Closed
Closed
Open
Off
Off
1,1,0,0
Closed
Closed
Open
On Blinking (2HZ) Blinking (2HZ) On
Off
Off
1,1,0,1
Closed
Closed
Open
Off
Off
1,1,0,1
Closed
Open
Open
Off On
Off Off
Off Off
1,1,0,1 1,1,0,1
Closed Closed
Open Open
Open Closed
Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer shifts in both directions (HNeutralL).
Parts Location (RHD)
RTW48AXF021701&RTW48AXF021801
Parts Location (LHD)
RTW48AXF021901&RTW48AXF022001
RTW48AXF021601
PARTS LOCATION
RTW48AXF031701
CIRCUIT DIAGRAM (6VE1)
RTW48AXF007201
CIRCUIT DIAGRAM (C24SE)
RTW48AXF031601
CIRCUIT DIAGRAM (4JA1-TC/4JH1-TC)
RTW48AXF007101
CIRCUIT DIAGRAM (4JA1-L)
RTW48AXF028601
CONNECTOR LIST
No. B-24 Connector face No. C-57 (4JH1TC) Meter-B C-67 ECM Connector face
Green B-54
White B-62
J/B I2
Black C-94 (4JH1TC)
EHCU
White B-63
Ignition switch (IGSUB : G1)
TCM Gray C-95 (6VE1)
White B-64
Ignition switch (IGSUB : G2)
White C-107
TCM
Silver B-65
Weld splice 1(Illumination)
White C-108
J/B E2
Silver B-66
Weld splice 2 (Ground)
White C-109
J/B E1
White C-2
4WD switch
Silver C-118 (4JH1TC)
Body-LH ; ground
Silver C-36
Engine room-RH ; Ground
White C-119 (6VE1)
A/C Resister & Neutral switch
Silver C-56 (4JH1TC) Gray
Engine room-LH ; Ground
Black R-15
Auto cruise actuator
ECM
Black
Transfer controller
No. R-14
Connector face
No. H-3 (4JH1A/T)
Connector face
Black E-10
Transfer controller
White H-4 (4JH1) White H-6
Battery (+) ~ Engine room
Silver E-11 (4JH1) (C24SE) Natural Green E-12 (4JH1) (C24SE) Natural Green E-35 (4JH1TC C24SE) Black E44
Engine ground
Engine ~ Engine room
Neutral switch
White H-7
Engine room ~ INST
Neutral switch
White H-22 (4JA1/H 1-M/T)
Engine room ~ INST
Motor actuator
Gray H-23 (4JA1-L)
Engine ~ Engine room C
Gray E-45
Vehicle speed sensor H-29 (4JH1M/T) 4WD switch White H-31 (6VE1) White H-32
Engine room B ~ T/mission
White E-46
Battery (+) ~ Engine room C
Brown E-51
H-L neutral switch
Engine room ~ T/mission
Black E-61 (6VE1) Black
Inhibiter switch
Withe P-1
Engine room ~ Rear body
ECM
Silver
Battery (+)
No. P-2
Connector face
No.
Connector face
Silver P-5
Relay & Fuse box
Silver P-6
Battery (-)
Silver P-10
Body earth (Ground)
Silver P-13 (4JH1) Gray R-14
Engine ground
Shift on the fly actuator
Black R-15
2-4WD Control unit
Black
2-4WD Control unit
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.
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): (In case of MT):
Set the select bar of the transmission to the D position. 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: Dont 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.
TRANSFER CONTROL SYSTEM 7D1-37 Step 4-3: (Same procedure as the step 3-3) Stop the vehicle (close the accelerator and decrease the engine speed to L4: 3000rpm V6: 2000rpm or below). (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 lever is recommendable). Push the 4H button. If the shifting is not completed (indicator flashes at 2Hz), go to the step 4-1.
5. When shifting from 4H or 4L to neutral

(Same procedure is required when shifting from 2H but in such a case, requirements for shifting from 2H to 4H are also applied.) 5-1 Neutral indicator continues flashing at 2Hz The neutral indicator continues flashing at 2Hz until 4H (4L) is completely separated in the transfer. If torsional torque has accumulated between the transmission and road surface, separation may be difficult. Step 5-1: If the operation is not completed, execute the step 7 for confirmation. (In case of AT): Set the transmission select lever to the D position. After confirming that the gears are at the neutral position, return the lever to the N position. Set the transmission lever to a vehicle running position and engage the clutch gently. After confirming that the gears are at the neutral position, return the lever to the neutral position
(In case of MT):
5-2 When the neutral indicator flashes at 4Hz As in the case of shifting from 4L to 4H, restriction is imposed to the operation from 4L or 4H (including 2H). If the transmission lever is at a running range and engine speed is high (L4: 3000rpm, V6: 2000rpm or more) while the vehicle is running, operation from the 4L or 4H (including 2H) of the transfer to the neutral is impossible (restriction on operation). Step 5-2: Stop the vehicle. (In case of AT): (In case of MT): Set the transmission select lever to the N (or P) position. Set the transmission lever to the neutral position (at this time, stepping on the clutch is recommended).
Keep pushing the 2H and 4L button for 10 second. Follow the start procedure for confirmation. (Confirmation of drive force not transferred; same as in the step 5-1) After the confirmation, set the transmission to the neutral position in case of MT or to the neutral position in case of AT.
6. When shifting from neutral to 2H, 4H or 4L

6-1 When the 4L indicator or 4WD indicator flashes at 2Hz Indicator flashing at 2Hz indicates that the engagement of the splines has not completed because of deviation of the spline phases. By eliminating such a deviation, shifting is completed (same as in the step 3-1 and 4-1). 6-2 When the 4L indicator or 4WD indicator flashes at 4Hz As in the case of shifting from 4L to 4H, restriction is imposed to the operation to 4L or 4H (including 2H). If the transmission lever is at a running range and engine speed is high (3000rpm or more) while the vehicle is running, operation from neutral of the transfer to the 4L or 4H (including 2H) is impossible (restriction on operation). Step 6-2: Stop the vehicle. (In case of AT): (In case of MT): Set the transmission select lever to the N (or P) position. Set the transmission lever to the neutral position (at this time, stepping on the clutch is recommended).
Keep pushing the4H or 4L or 2H button for 10 second.
Trouble diagnosis based on the operation switch, transfer indicator lamp and operating sound Check 4WD indicator ON (operation guard based on the transfer actuator position detection error)
This condition indicates a faulty circuit related with the detection (limit) switches of the system actuator. Detection (limit) switches detect the actuator operating angle based on their combinations. The controller monitors transition of the actuator based on the combination of the detection (limit) switch output. If the transition based on the combinations indicates some trouble, it is memorized, shifting operation is stopped when the trouble is counted 5 times, and the Check 4WD indicator lights up. At this time, the system permits operation to 2H only. When such a condition results, inspection of the transfer shift actuator, check of harness related with the detection (limit) switch, and erasure of the memory of the controller are required. (Refer to the memory erasure procedure for the erasure of the memory.) At this time, the position indicator may flash at 4Hz. It means that a detection (limit) switch trouble wad detected in the operation process shown by that position indicator (example: 4WD indicator when shifting from 2H to 4H). Caution: In the course of trouble diagnosis and correction, do not turn ON the ignition with the harness connector of the transfer actuator disconnected. (Do not disconnect the harness connector of the transfer actuator when the ignition is ON.) If the controller is connected at this condition, a limit SW trouble is judged and the above-described Check 4WD condition is brought about. This can be reset by clearing the memory. When it is required to disconnect the harness connector of the actuator and turning the ignition ON, remove the controller at the same time or remove the IG power fuse of the transfer controller.
Memory erasing procedure

1. Prepare two pieces of short harness with the end sharped like a needle (bout 20cm(7.9 in) long). 2. Turn OFF the ignition. 3. Remove the front left seat ASM. 4. Make the controller under the front left seat ASM (spread the cut of the floor carpet).
5. Keeping the connector of the transfer controller connected, set the short harness from the back of the connector as illustrated. 6. Turn ON the ignition, wait for 2 seconds, and turn OFF the ignition after confirming the relay sound. 7. Disconnect the short harness, turn ON the ignition again, and confirm the Check 4WD lamp in the meter panel is OFF. 8. Before erasing the memory, check that the circuit of the T/F actuator position detection harness, etc. for it are normal.
Transfer Controller Pin Assignment
RTW47DSF000101
Diagnosis from symptom

Check4WD lighting up
Step 1 Action Check what was done before the trouble occurred. Was the harness between the transfer controller and actuator disconnected with the ignition kept ON for the purpose of servicing the vehicle, etc.? Or, was the ignition turned ON (power supplied to the transfer controller) with the harness of the actuator removed? Is the ignition switch ON? Yes If the power is supplied with the actuator not connected, faulty position detection switch is considered. Clear the memory and trace this chart from the beginning. No Go to step 2.
Go to step 3.
Does the transfer-related indicators (4WD, 4Lo, Check 4WD, neutral) light up for 2 seconds when the ignition switch is turned ON? Isnt the harness between the Check4WD indicator and transfer controller GND shorted? Check the continuity of harness between the transfer controller and transfer actuator. Check the power short and GND short. Check the GND harness of the transfer actuator. Is a trouble noticed? Check the limit switch of the actuator. Is a trouble noticed?
Go to step 4.
Turn the ignition switch ON and trace this chart from the beginning. Indicator lamp burnt out. Disconnected harness wire . After repairing, trace this chart from the beginning. Go to step 5.
GND (body) short of the indicator harness. After repairing, trace this chart from the beginning. Repair the harness, clear the memory and trace this chart from the beginning.
Go to step 6.
Clear the memory and trace this chart from the beginning. Failed controller. Replace the controller, clear the memory and trace this chart from the beginning. To check the operation after completing the repair and clearing the memory, shift between 2H and 4L 5 times at least. To judge the condition more quickly, ask the customer the situation when the Check4WD lamp lighted up. When the position indicator blinks at a frequency of 4Hz immediately after occurrence of a trouble, position of failure which the indicator shows may be limited. (Since it indicates the situation immediately before detection of failure whether the vehicle is running or standstill so that possibility of failure around that point is high.) Status of the transfer when the Check4WD lights up is not always the same. Immediately after occurrence of the failure, 2H can be operated. 6
Failed actuator. Replace the actuator, clear the memory and trace this chart from the beginning.
Cannot shift from 2WD to 4H or 4L. When shifting from 2H to other position, the indicator (4WD, 4Lo, Check4WD, neutral) does not respond.
Step 1 Action Is the ignition switch ON? Yes Go to step 2. No Turn the ignition switch ON and trace this chart from the beginning. Indicator lamp burnt out. Disconnected harness wire . After repairing, trace this chart from the beginning.
Does the transfer-related indicators (4WD, 4Lo, Check 4WD, neutral) light up for 2 seconds when the ignition switch is turned ON?
Failed operation switch. Only 2H is stuck at ON condition and 4H4L position is internally disconnected. Or, Failed controller
Even after correction step 1-1(*), 4WD indicator blinks at 4Hz and changes to 2H after 10 seconds.
Step 1 Action Is the ignition switch ON? Yes Go to step 2. No Turn the ignition switch ON and trace this chart from the beginning. Indicator lamp burnt out. Disconnected harness wire. After repairing, trace this chart from the beginning. Failed actuator position detection switch (LS1, LS2, LS3, LS4, GND). Short or disconnection of harness of this detection switch. After repairing, trace this chart from the beginning. Failed controller. Replace the controller and trace this chart from the beginning. Failed actuator motor. Disconnected controller motor drive output circuit, GND short circuit. +B fuse blown out. Disconnection of that harness. After repairing, trace this chart from the beginning.
Does the transfer-related indicators (4WD, 4Lo, Check 4WD, neutral) light up for 2 seconds when the ignition switch is turned ON? After 2 seconds, check that the Check4WD lamp is ON or OFF. Is the Check4WD lamp OFF?
Go to step 3.
Go to step 4.
Press the 4H button. Is sound of relay heard from the transfer control? Is the sound of running motor heard?
Go to step 5.
Failed control system of the transfer mechanism. Check and repair and trace this chart from the beginning.
*Before determining a trouble (Non-trouble mode)
Even after the correction step 1-2(*), the 4WD indicator still blinks at 2Hz when shifting from 2H to 4H.
Step 1 Action Check the air pressure and wear of all the tires. Is any trouble noticed? Check the 4WD detection switch on the transfer case, neutral detection switch and each harness. Is a trouble noticed? Yes After adjusting the air pressure and repairing the tire worn away, try the correction step 1-2(*). 4WD detection switch is open or the harness failed. The neutral detection switch is closed or the harness GND is shorted. Replace or repair and then trace this chart from the beginning. Go to step 4. No Go to step 2.
Go to step 3.
Is there continuity in the harness between the transfer controller and front axle actuator? Isnt a body short or disconnection noticed? Is a trouble noticed in the axle detection harness between the axle actuator and transfer controller?
Disconnected harness. After repairing trace this chart from the beginning.
Body short or disconnection of the harness between the transfer controller and front axle actuator. After repairing, trace this chart from the beginning. Malfunction of axle actuator. Refer to the paragraph of the axle disconnect. After repairing, trace this chart from the beginning.
*Before determining a trouble (Non-trouble mode) Note: The vehicle of manual hub and rigid hub dont have axle actuator. When the above-mentioned procedure is followed, check the harness between the axle dummy output terminal and the axle switch input terminal of transfer controller instead of axle actuator.
After operation, indicator of target position blinks for 1.5 sec. at 2Hz, return to 2H condition (4WD indicator going out)
Step 1 Action Keep to press the 4H button (about 10 seconds). Does the 4WD indicator blink at 2Hz for 15 seconds and then blink at 4Hz? Yes Failed actuator motor. Disconnection of controller motor drive output circuit, or GND short. +B fuse blown out. Disconnection of that harness. After repairing, trace this chart from the beginning. Go to step 3. No Go to step 2.
Press the 4H button. Is the sound of relay heard from the transfer controller? Is the sound of running motor heart?
Failed controller. Replace the controller and trace this chart from the beginning. Failed actuator motor. Disconnection or GND short of controller motor drive output circuit. After repairing, trace this chart from the beginning.
Transfer cannot shift to a position other than 4H. When shifting from 4H to other position, indicator (4WD, 4Lo, Check4WD, neutral) does not respond (Only 4WD keeps lighting).
Step 1 Action Is the ignition switch ON? Yes Go to step 2. No Failed 4WD indicator and harness. After repairing, trace this chart from the beginning. Indicator lamps other than the 4WD indicator are burnt out. (Check for GND short circuit between the 4WD indicator and transfer controller.) Disconnected harness wire. After repairing, trace this chart from the beginning. *Failed operation switch. Or disconnected or shorted of the harness for the operation switch.
Does the transfer-related indicators (4WD, 4Lo, Check 4WD, neutral) light up for 2 seconds when the ignition switch is turned ON? Then, only 4H lights up.
Go to step 3.
Press the 2H button. Is the sound of relay heard from under the seat, and the sound of running motor heard?
Failed controller. After replacing the controller, trace this chart from the beginning.
* The operation switch is an analog type switch which reads the internal composite resistance value at the time of operation. If an abnormal value is detected, it is judged to be an instruction to 4H.
Even after the correction step 2-1(*), the 4WD indicator still blinks at 2Hz when shifting from 4H to 2H.
Step 1 Action Check all the tires for air pressure and wear. Is any trouble noticed? Check the 4WD detection switch on the transfer case and neutral detection switch and each harness. Is a trouble noticed? Yes After adjusting the air pressure and repairing the tire worn away, try the correction step 2-1(*). 4WD detection switch is closed or the GND short of harness. The neutral detection switch is closed or the harness GND is shorted. Replace or repair and then trace this chart from the beginning. Go to step 4. No Go to step 2.
Go to step 3.
Is there continuity in the harness between the transfer controller and axle actuator? Isnt short or disconnection noticed? Isnt the connection mistaken? Is a trouble noticed in the axle detection harness between the axle actuator and transfer controller?
GND short of harness
Body short, disconnection or incorrect connection of the harness between the transfer controller and actuator. After repairing, trace this chart from the beginning. Malfunction of axle actuator. Refer to the paragraph of axle disconnect. After repairing, trace this chart from the beginning.
*Before determining a trouble (Non-trouble mode) Note: The vehicle of manual hub and rigid hub dont have axle actuator. When the above-mentioned procedure is followed, check the harness between the axle dummy output terminal and the axle switch input terminal of transfer controller instead of axle actuator.
Though the indicator responds when shifting from 4H to 2H(or other position), it returns to 4H.
Step 1 Action Is the ignition switch ON? Yes Go to step 2. No Turn the ignition switch ON and trace this chart from the beginning. Indicator lamp burnt out. Disconnected harness wire. After repairing, trace this chart from the beginning. Failed actuator position detection (limit) switch (LS1, LS2, LS3, LS4, GND). Short or disconnection of harness of this detection switch. Refer to paragraph of Check4WD. After repairing, trace this chart from the beginning. Failed controller. Replace the controller and trace this chart from the beginning. Failed actuator motor. Disconnection of controller motor drive output circuit or GND short. After repairing, trace this chart from the beginning.
Does the transfer-related indicators (4WD, 4Lo, Check 4WD, neutral) light up for 2 seconds when the ignition switch is turned ON? After 2 seconds, check if the Check4WD lamp lights up. Is the Check4WD lamp OFF?
Go to step 3.
Go to step 4.
Press the 2H button. Is the sound of relay heard from the transfer controller? Is the sound of running motor heart?
Go to step 5.
If the motor does not or cannot run at all (stuck transfer mechanism, disconnected motor, failed drive circuit), the lamp blinks at 4Hz when the position is shifted to other position by pressing the button for more 10 seconds (20 seconds in case of neutral position).
From 4H to 4L; Even after the correction step 3-3(*), 4Lo indicator blinks at 4Hz
Step 1 2 Action Is the ignition switch ON? Turn ON the ignition switch and check the valve. Do not start the engine. Has the valve check for 2 seconds been completed normally? Shift to 2H. Can be shifted to 2H and then to 4H? Yes Turn it OFF once. Go to step 3. No Go to step 2. Refer to the paragraph about the indicator when it does not react when shifted from 2H to 4H. After taking the remedy, trace this chart from the beginning. Refer to the paragraph about shifting from 2H to 4H. In particular, check if not at the Check4WD condition, return to this chart and trace it from the beginning. Shift back to 4H and go to step 5.
Go to step 4.
Set to N position in case of AT and set to the neutral position in case of MT and check if the lamp blinks at 4Hz after operation.
Start the engine and travel the vehicle. Does the speedometer run at this time?
Failed T/M position switch and harness (failure of TM1 and TM2 harness and their related switches shown in the figure). Incorrect wiring. Repair as required and trace this chart from the beginning. Go to step 6.
Check the harness between the Failed harness between the transfer controller and speed transfer controller and speed sensor. sensor. After repairing, trace this chart (Check the engine rotation from the beginning. detection harness at the same (Repair the engine rotation time.) detection unit, if required.) Is any trouble noticed? Failed controller. Travel the vehicle several 7 Replace the controller and trace meters, stop it, meet the this chart from the beginning. permission requirements for operation limits. Did you wait for several seconds after the requirements were met? *Before determining a trouble (Non-trouble mode) 6
Failure of speed sensor or disconnection or short of harness (for the meter). After repairing, trace this chart from the beginning. Go to step 7.
You did not wait for enough time. Optimum waiting time is 1 second or maximum 3 minutes depending on the previous conditions. Refer to the paragraph about operation without failure.
From 4L to 4H: After the correction step 4-3(*), 4Lo indicator blinks at 4H.
Step 1 2 Action Is the ignition switch ON? Turn ON the ignition switch and check the valve. Do not start the engine. Has the valve check for 2 seconds been completed normally? Can be shifted to 2H and then to 4L? Yes Turn it OFF once. Go to step 3. No Go to step 2. Refer to the paragraph about the indicator when it does not react when shifted from 2H to 4H. After taking the remedy, trace this chart from the beginning. In case of Check 4WD, shifting to 2H is possible. Returning to 4L is impossible. Refer to the paragraph about Check4WD. Press the operation switch of 4L and go to step 5.
Go to step 4. (Impossible usually.) Failed controller
Start the engine and travel the vehicle. Does the speedometer run at this time?
Check the harness between the Failed harness between the transfer controller and speed transfer controller and speed sensor. sensor. After repairing, trace this chart (Check the engine rotation from the beginning. detection harness at the same (Repair the engine rotation time.) detection unit, if required.) Is any trouble noticed? Failed transfer controller. Travel the vehicle several 7 Replace the controller and trace meters, stop it, meet the this chart from the beginning. permission requirements for operation limits. Did you wait for several seconds after the requirements were met? *Before determining a trouble (Non-trouble mode) 6
To neutral: After the correction step 5-2(*), neutral indicator blinks at 4Hz. Check the function between H and L according to the chart for 4L to 4H instead of check for the requirements of neutral.
Step 1 2 Action Is the ignition switch ON? Turn ON the ignition switch and check the valve. Do not start the engine. Has the valve check for 2 seconds been completed normally? Can be shifted to 2H and then to 4L? Yes Turn it OFF once. Go to step 3. No Go to step 2. Refer to the paragraph about the indicator when it does not react when shifted from 2H to 4H (7D1-37). After taking the remedy, trace this chart from the beginning. Refer to the paragraph about shifting from 2H to 4H. In particular, check if not at the Check4WD condition, return to this chart and trace it from the beginning. In case of Check4WD, shifting to 2H is possible. Returning to 4H is impossible. Refer to the paragraph about Check4WD. Shift back to 4H and go to step 5.
Go to step 4. (Impossible usually.) Failed controller
Start the engine and travel the vehicle. Does the speedometer run at this time? Check the harness between the transfer controller and speed sensor. (Check the engine rotation detection harness at the same time.) Is any trouble noticed? Travel the vehicle several meters, stop it, meet the permission requirements for operation limits. Did you wait for several seconds after the requirements were met?
Failed harness between the transfer controller and speed sensor. After repairing, trace this chart from the beginning. (Repair the engine rotation detection unit, if required.) Failed controller. Replace the controller and trace this chart from the beginning.
*Before determining a trouble (Non-trouble mode) For shifting to neutral, 2H and 4L switches should be kept pressed at the same time for 10 seconds. For shifting from neutral to other position, 2H, 4H or 4L switch should be kept pressed for 10 seconds. When shifting from neutral to other position, the lamp blinking at 2Hz indicates active condition. When the lamp keeps blinking at 2Hz, follow the step for the case when the lamp keeps blinking at 2Hz when shifting between positions.
No. TFT150-WE-0431

Transfer Luv Dmax

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Transfer Luv Dmax

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WORKSHOP MANUAL

TRANSFER CASE 7D-1

7D-2 TRANSFER CASE

TRANSFER CASE 7D-3

7D-4 TRANSFER CASE

Transfer Rear Oil Seal

Legend (1)Rear Propeller Shaft (2)Oil Seal

TRANSFER CASE 7D-5

4. Connect the rear propeller shaft.

7D-6 TRANSFER CASE

Transfer Case Assembly

TRANSFER CASE 7D-7

TRANSFER CASE 7D-9 For A/T

7D-10 TRANSFER CASE

Transfer Control Unit

Legend (1)Transfer Control Unit (2)Protector

TRANSFER CASE 7D-11

(7) (8) (9) (10) (11)

Legend (1)25.62 (2)14.1mm

Oil pump reassembly

Oil pump disassembly

7D-20 TRANSFER CASE

Inspection and Repair

2-4 and Neutral Switch

Inspection and Repair (Transfer Case Assembly)

2-4 Switch Signal Terminal 1 to 2 Open Close

Neutral Switch Signal Terminal 1 to2 Close Open

TRANSFER CASE 7D-21

Ball Bearing Play

Clutch Hub Spline Play

7D-22 TRANSFER CASE

Block Ring and Insert Clearance

Clutch Hub and Insert Clearance

2WD-4WD Synchronizer (3-Cone)

TRANSFER CASE 7D-23

Detent Spring Free Length

Shift Arm Thickness

Detent Spring Tension

7D-24 TRANSFER CASE

7D-26 TRANSFER CASE 11.Use a press to install the 2-4 hub.

(3)Synchronizer Key and Key Spring

7D-30 TRANSFER CASE

TRANSFER CASE 7D-31

42.Apply Loctite 575 to the threaded portion of the detenteplugs.

TRANSFER CASE 7D-33

Main Data and Specifications

7D-34 TRANSFER CASE Nm (kgm/lb ft)

TRANSFER CASE 7D-35 Nm (kgm/lb ft)

7D-36 TRANSFER CASE

5-8840-2786 Transfer case oil seal installer

5-8840-2784-0 Ring gear installer

5-8840-0084-0 Sliding hammer

5-8840-0133-0 Flange holder

5-8840-0027-0 Rear output shaft needle bearing replacer

5-8840-2782-0 Needle bearing installer

5-8840-2293-0 Punch; end nut

5-8840-2783-0 Needle bearing installer

5-8840-2788-0 Front output shaft needle bearing replacer

5-8840-0007-0 Driver handle

5-8840-1268-0 Rear output shaft ball bearing installer

TRANSFER CASE 7D-37 ILLUSTRATION PART NO. PART NAME

5-8840-2787-0 Snapring installer

7D-38 TRANSFER CASE

TRANSFER CONTROL SYSTEM 7D1-1