ISUZU TF SERIES 2004 Workshop Manual

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
(4)
Center Exhaust Pipe (6VE1 only)
(2) Front Propeller Shaft

(3) Transfer Case Assembly

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 propelle
r
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 propelle
r
shaft (2)(3).
Torque: 63 N




m (6.4 kg




m/46 lb ft)

7D-10 TRANSFER CASE

Transfer Control Unit

RTW37DLF000401
Legend


(1) Transfer Control Unit

(3) Bolt
(2) Protector


Removal
1.
Disconnect the battery ground cable.
Remove the driver’s 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 Transfe
r
control unit.
4. Remove the Transfer control unit.
Installation
1.
Install the Transfer control unit.
2.
Connect the harness connector to the Transfe
r
control unit.
3.
Connect the battery ground cable.

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

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.







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 hamme
r
to remove the rear cover.

220R300022