Neutral switch ISUZU KB P190 2007 Workshop Repair Manual

7D-18 TRANSFER CASE
Transfer Disassembly



RTW 67DLF000101
Legend

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

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

Removal

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

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ISUZU KB P190 2007

TRANSFER CASE 7D-19
• Breather hose (Between the transfer case and the
transfer actuator assembly)
• Transfer actuator assembly
• Switch bracket
• 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 a flange holder (5-8840-0133-0) to remove the
end nut from the front companion flange.



RTW 77DSH000201

5. Remove the bolts attaching the rear cover to the
transfer case.

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.

220R300022


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TRANSFER CASE 7D-27
Inspection and Repair
1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. W ash 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. Appl
y
compressed air to each oil feed port and channel in
each case half to remove any obstructions or cleaning
solvent residue.

Inspection and Repair (Transfer Case
Assembly)
W hen wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired
or replaced. W ash 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.

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.

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. I
f
excessive wear or damage is observed, replace the
part.

2-4 and Neutral Switch

• Check the continuity of 2-4 and Neutral switch.
If defects are observed, replace the 4H and 4L switch.




221R300001
261R300003
Switch
Stroke 2-4 Switch
Signal Neutral Switch

Signal
Terminal
1 to 2 Terminal
1 to2
1 Open Close
2 Close Open



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TRANSFER CASE 7D-39
43. Use an installer (5-8840-2787-0) to install the main
shaft end snap ring to the rear output shaft (from the
back end of the shaft). Be absolutely sure that the
snap ring is seated in the groove.

226R300022

44. Use an installer (5-8840-2786-0) to install the rear
output oil seal to the rear case.


RTW 77DSH000401


220R300021
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 N ·m (1.9 kgf ·m/14 lb ·ft)
46. Install the neutral switch (black harness cover) to the
transfer case and tighten the bolts to the specified
torque.
Neutral switch bolt torque:
39 N ·m (4.0 kgf ·m/29 lb ·ft)
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 N ·m (4.0 kgf ·m/29 lb ·ft)
48. Install the switch bracket to the transfer case and
tighten the bolts to the specified torque.
Switch bracket bolt torque:
15 N ·m (1.5 kgf ·m/11 lb ·ft)
49. Install the transfer actuator assembly to the transfe
r
case and tighten the bolts to the specified torque. The
actuator must be installed in the same direction as the
shaft.
Transfer actuator assembly bolt torque:
22 N ·m (2.2 kgf ·m/16 lb ·ft)
50. Install the breather hose between the transfe
r
actuator and the transfer case.
51. Install the speedometer driven gear, the speedomete
r
bushing, and the speedometer stay to the transfe
r
case. Tighten the bolts to the specified torque. (M/T:
MUA, MUX, A/T: JR405E, AW 30-40LE)
Speedometer bolt torque:
15 N ·m (1.5 kgf ·m/11 lb ·ft)

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TRANSFER CONTROL SYSTEM 7D1-3
General Description







RTW 77DLF000501

Transfer Position and Drive Mode
Three drive modes can be selected through operation of 4W D switch.

Transfer Position 4WD SWITCH Mode Drive mode
2H RW D Rear wheel drive
HIGH
4H 4W D (HIGH) High-speed mechanical
lock-up four wheel drive
LOW 4L 4W D (LOW ) Low-speed mechanical
lock-up four wheel drive
NEUTRAL 2H & 4L (10 Sec) NEUTRAL Towed by other vehicle


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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
operates 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 and 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 the indicator on the instrument panel.
6. Transmission of the position signal to other controllers.


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7D1-6 TRANSFER CONTROL SYSTEM
the 4×2 - 4 ×4 shift rod. W hen moving in 4 ×2 direction, a spring
standby mechanism is provided between the rod and sleeve so
that the rod is positioned at the 4 ×2 position, while the sleeve is
at the 4 ×4 position.
This mechanism is provided to protect the shift mechanism
from the force and to prevent movement of the sleeve
(torsional torque etc. of the drive system). By releasing the
preventive force, the sleeve can move to the 4 ×2 state by the
spring force.

Neutral switch
The neutral switch detects the movement of the shift rod
driving the high-low sleeve.
PUSH close is achieved with the PUSH close switch when the
shift rod is positioned between the High and the Low, at the
neutral state.

High-Low Sleeve & Arm
The spring standby mechanism is provided for the high-low
sleeve in both directions of the high-low shift rod. Therefore,
the rod position and the actual sleeve position may be offset in
some cases.
This system is provided to protect the shift mechanism from a
collision due to coincidence of the high and low phases of the
engaged splines. By giving rotational force to the preventing
phase coincidence, the splines are moved to the proper
engagement position by the spring force.

Shift actuator
The output shaft is rotated by the built-in motor and the transfer
position is switched.
Detection (limit) switches to detect the rotating angle of the
output shaft that is provided to the actuator at 4 positions.
These are connected to the transfer controller through the
vehicle harness to constantly transmit the actuator operating
angle and changes in its transfer status.

7B4-PDF2
4WD indicator (in meter panel)
This lamp indicates the following items:
Valve check
Drive condition (2W D-4W D)
Operating condition (2Hz: Actuator in operation, mechanism
standby)
Restrictions on operation (4Hz, including indication of
interrupted operation due
to excessive load)

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TRANSFER CONTROL SYSTEM 7D1-7
7B4-PDF3
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)






















RTW 77DSH000601
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-PDF5
Check 4WD warning light (in meter panel)
This light indicates following items:
Valve check
Faulty actuator limit SW , and circuit related faults with the limit
switch



RTW 77DSH000501
4WD switch
Switch to transmit a switching command to the 2H, 4H,
Neutral, or 4L position.
It comprises 3 PUSH momentary switches. By pushing the 2H
and 4L switches for 10 seconds,
operation is changed to the neutral position.
To shift from the neutral to another position, push another
switch for 10 seconds.



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

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

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TRANSFER CONTROL SYSTEM 7D1-13
Item 4WD
lamp 4L lamp Neutral
lamp Check
4WD
warning light 4WD
switch Actu ato r
detection (limit)
switches
LS1, LS2, LS3. and LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral switch SOF
actuator switch Or
Axl e
dummy Remarks
During
operation On Blinking
(2HZ) Off Off No
operation 1,1,0,1 Closed Open Closed 4L to 4H
while
driving
During
operation (N) Off
Blinking
(2HZ) Off Off No
operation 1,1,0,0 Closed Closed Closed 4L to 4H
through neutral
During
operation Off Blinking
(2HZ) Off Off No
operation 0,1,0,1
0,0,0,1 Closed Closed Closed 4L to 4H
while
driving
4H
waiting Off Blinking
(2HZ) Off Off No
operation 0,0,1,1 Closed Closed Closed
4L to 4H
while
waiting
4H On Off Off Off No
operation 0,0,1,1 Closed Open Closed -----
2H start of
operation On Off Off Off 2H position
for 0.1
second 0,0,1,1 Closed Open Closed Switch
operation sensor
Start of
operation Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed
2H to 4H
while
driving
During
operation (Axle) Blinking
(2HZ) Off Off Off No
operation 0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Open Open Closed Axle drive
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation 1,0,1,0 Open Open Closed Axle
waiting
2H Off Off Off Off No
operation 1,0,1,0 Open Open Open -----


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