engine ISUZU TF SERIES 2004 Workshop Manual

3C-2 FRONT SUSPENSION
MAIN DATA AND SPECIFICATIONS
4




2 (EXCEPT HIGH RIDE SUSPENSION) MODEL
Front suspension Type Independent wishbone arms, coil spring
with stabilizer bar.
Coil spring Spring Rate 4JH1-TC / 4JA1-TC / 4JA1-L (ENGINE); 9.62 kg/mm
(94.3 N/mm)
C24SE (ENGINE); 7.94 kg/mm (77.9 N/mm)
Type Gas-sealed. Hydraulic, double acting
Stroke 116.5 mm (4.59 in)
Compressed length 284.0 mm (11.18 in)
Front shock absorber
Extended length 400.5 mm (15.77 in)
Stabilizer bar Diameter 25.0 mm (0.98 in)

4




2 (HIGH RIDE SUSPENSION) MODEL
Front suspension Type Independent wishbone arms, torsion bar spring
with stabilizer bar.
Length 1142 mm (44.96 in) Torsion bar spring
Diameter 29.0 mm (1.14 in)
Type Gas-sealed. Hydraulic, double acting
Stroke 121.0 mm (4.76 in)
Compressed length 257.0 mm (10.12 in)
Front shock absorber
Extended length 378.0 mm (14.88 in)
Stabilizer bar Diameter 26.0 mm (1.02 in)

4




4 MODEL
Front suspension Type Independent wishbone arms, torsion bar spring
with stabilizer bar.
Length 1142 mm (44.96 in) Torsion bar spring
Diameter 29.0 mm (1.14 in)
Type Gas-sealed. Hydraulic, double acting
Stroke 121.0 mm (4.76 in)
Compressed length 257.0 mm (10.12 in)
Front shock absorber
Extended length 378.0 mm (14.88 in)
Stabilizer bar Diameter 26.0 mm (1.02 in)

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-11

Transfer Disassembly

RTW47DLF000101
Legend


(7) Neutral Switch ASM
(1) Transfer Case

(8) Speedometer Bush, Plate and Driven Gear
(2) Companion Flange, O-ring and Nut

(9)Transfer Actuator
(3) Stoneguard

(10)Breather Hose
(4) Detent Plug, Spring and Detent Ball

(11) Heat Protector (Except Diesel Engine)
(5) 2-4 Switch ASM


(6) Switch Bracket



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 speedomete
r
driven gear


Breather hose (Between the transfer case and
the transfer actuator assembly)


Transfer actuator assembly


Switch bracket

TRANSFER CASE 7D-31

226R300011
36.
Install the rear cover to the transfer case and tighten
the bolts to the specified torque.
Rear cover and transfer case bolt torque:
22 Nm (2.2 kgm/16 lbft)
37.
Apply engine oil to the companion flange O-ring.
38.
Install the O-ring to the front output shaft.
39.
Secure the front companion flange with the
companion flange holder (5-8840-0133-0).
40.
Install the end nuts and tighten them to the specified
torque.

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












41.
Use a cold chisel to caulk the front companion
flange end nuts.
226R300012
RUW34DSH000301

Legend
(1) MAX 26mm (1.02 in)
(2) MIN 4mm (0.16 in)

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

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 low-
speed (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 o
r
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 o
r
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.

7D1-14 TRANSFER CONTROL SYSTEM
Operational limits (4H




4L) (Vehicle speed, engine speed, and transmission position not specified)

Item 4WD
lamp 4L lampNeutral
lamp Check
4WD
warning
light 4WD
switch Actuator
detection
(limit)
switches
LS1, LS2,
LS3. and
LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral
switch SOF
actuator
switch
Or
Axle
dummyRemarks
4H On Off Off Off Open 0,0,1,1 Closed Open Closed -----
4H start
of
operation On Off Off Off 4L
position
for 0.1
second 0,0,1,1 Closed Open Closed -----
10
second
display
during
limitation On Blinking
(4HZ) Off Off Open 0,0,1,1 Closed Open Closed No
operation
during
limitation
Go to 4H
after 10
seconds
On Off Off Off Open 0,0,1,1 Closed Open Closed -----

Operational limits (4L





4H) (Vehicle speed, engine speed, and transmission position not specified)

Item 4WD
lamp 4L lampNeutral
lamp Check
4WD
warning
light 4WD
switch Actuator
detection
(limit)
switches
LS1, LS2,
LS3. and
LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral
switch SOF
actuator
switch
Or
Axle
dummyRemarks
4L On On Off Off No
operation1,1,0,1 Closed Open Closed -----
4L start of
operation On On Off Off 4H
position
for 0.1
second 1,1,0,1 Closed Open Closed -----
10
second
display
during
limitation On Blinking
(4HZ) Off Off Open 1,1,0,1 Closed Open Closed No
operation
during
limitation
Go to 4L
after 10
seconds
On On Off Off No
operation1,1,0,1 Closed Open Closed -----


Under some conditions, a secondary operational indication may be received when the 4Hz operational indication
is present.

TRANSFER CONTROL SYSTEM 7D1-17
Skip operation limitations (4L




2H) (Vehicle speed, engine speed, and transmission position not
specified)

Item 4WD
lamp 4L lampNeutral
lamp Check
4WD
warning
light 4WD
switch Actuator
detection
(limit)
switches
LS1, LS2,
LS3. and
LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral
switch SOF
actuator
switch
Or
Axle
dummyRemarks
4L Off On Off Off Open 1,1,0,1 Closed Open Closed -----
4L start of
operation Off On Off Off 2H
position
for 0.1
second 1,1,0,1 Closed Open Closed -----
10
second
display
during
limitation Blinking
(4HZ) Off Off Off Open 1,1,0,1 Closed Open Closed No
operation
during
limitation
Go to 4L
after 10
seconds
Off ON Off Off Open 1,1,0,1 Closed Open Closed -----

Skip operation limitations (2H




4L) (Vehicle speed, engine speed, and transmission position not
specified)

Item 4WD
lamp 4L lampNeutral
lamp Check
4WD
warning
light 4WD
switch Actuator
detection
(limit)
switches
LS1, LS2,
LS3. and
LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral
switch SOF
actuator
switch
Or
Axle
dummyRemarks
2HL Off Off Off Off Open 1,0,1,0 Open Open Open -----
4L start of
operation Off Off Off Off 2H
position
for 0.1
second 1,0,1,0 Open Open Open -----
10
second
display
during
limitation Blinking
(4HZ) Blinking
(4HZ) Off Off Open 1,0,1,0 Open Open Open No
operation
during
limitation
Go to 2H
after 10
seconds
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.

TRANSFER CONTROL SYSTEM 7D1-19
Item 4WD
lamp 4L lampNeutral
lamp Check
4WD
warning
light 4WD
switch Actuator
detectio
n (limit)
switches
LS1,
LS2,
LS3. and
LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral
switch SOF
actuator
switch
Or
Axle
dummy Remarks
During
operation
(4H
waiting) Off Blinking
(2HZ) Off Off No
operation0,0,1,1 Closed Closed Closed 4L to 4H
while
waiting
During
operation
(Axle) Blinking
(2HZ) Off Off Off No
operation0,1,1,1
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
operation0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Open 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 -----


Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer
shifts in both directions (H
Neutral
L).

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
4L




Neutral




4L

Item 4WD
lamp 4L lampNeutral
lamp Check
4WD
warning
light 4WD
switch Actuator
detection
(limit)
switches
LS1, LS2,
LS3. and
LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral
switch SOF
actuator
switch
Or
Axle
dummyRemarks
4L On On Off Off No
operation1,1,0,1 Closed Open Closed -----
Neutral
start of
operation On On Off Off Neutral
position
for 10
seconds 1,1,0,1 Closed Open Closed -----
Start of
operation Off Off Blinking
(2HZ) Off No
operation1,1,0,0 Closed Open Closed 4L to N
while
driving
During
operation
(N) Off Off Blinking
(2HZ) Off No
operation1,1,0,0 Closed Closed Closed 4L to N
with axle
driving
During
operation
(N) Off Off Blinking
(2HZ) Off No
operation0,1,0,0 Closed Closed Closed 4L to 4N
with axle
removed
During
operation
(Axle) Blinking
(2HZ) Off Off Off No
operation0,1,0,0 Closed Closed Closed Axle
driving
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation0,1,0,0 Closed Closed Closed -----
Neutral Off Off On Off No
operation0,1,0,0 Closed Closed Open -----
4L start of
operation Off Off On Off 4L
position
for 10
seconds 0,1,0,0 Open Open Open Switch
operation
sensor
During
operation
(N) Off Blinking
(2HZ) Off Off No
operation1,1,0,0 Closed Closed Open 4H to 4L
through
neutral
During
operation
(N) Off Blinking
(2HZ) Off Off No
operation1,1,0,0 Closed Closed Open 4H to 4L
through
neutral
During
operation
(N) Off Blinking
(2HZ) Off Off No
operation1,1,0,0 Closed Closed Open 4H to 4L
through
neutral
4H
waiting On Blinking
(2HZ) Off Off No
operation1,1,0,1 Closed Closed Open 4L while
waiting
During
operation
(Axle) Blinking
(2HZ) Off Off Off No
operation1,1,0,1 Closed Open Open Axle
driving
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation1,1,0,1 Closed Open Open -----
4H On On Off Off No
operation1,1,0,1 Closed Open Closed -----

Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer
shifts in both directions (H
Neutral
L).