ISUZU TF SERIES 2004 Workshop Manual

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 rea
r
spring)


2-4 shift assembly


Shift drum and shift shaft


Sun gear needle bearing

260R300001












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

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

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
(9) Sprocket Snap Ring
(2) Block Ring
(10) Oil Pump ASM
(3) Outside Ring
(11) Oil Pump Retaining Ring
(4) Inside Ring
(12) Retaining Ring
(5) Drive Sprocket
(13) Ball Bearing
(6) Transfer Chain
(14) Speedometer Drive Gear
(7) Front Output shaft
(15) Main Shaft Snap Ring
(8) Thrust Washer

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.








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.

226R300020

18
Remove the dog teeth snap ring from the carrier and
gear assembly.
19.
Remove the planetary dog teeth and the sun gea
r
input shaft together with the thrust needle bearing.



2260R300021










20.
Remove the carrier snap ring.
21.
Use a press to remove the ball bearings.







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.
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

7D-16 TRANSFER CASE




23.
Remove the retaining ring (spiral type) together with
the internal gear and the damper ring.

226R300004






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 rea
r
cover.

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.


P1010023
Legend

(1) Dumper Ring
(2) Internal Gear
(3) Retaining Ring

TRANSFER CASE 7D-17

Internal Component Disassembly and Reassembly

226R300017


















H-L Shift Disassembly

1.
Remove the guide roller.
2.
Use a vise to compress the H-L shift spirng (inside
the assembly.







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.
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

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 colla
r
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.

226R300014






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.
2-4 shift ASM


226R300016











2-4 shift disassembly
1.
Remove the guide roller.
2.
Compress the spring and remove the snap ring.
3.
Remove the shift arm.
4.
Remove the spring.
5.
Remove the spring pin.
6.
Remove the shift block assembly.
7.
Remove the shift rod.

Legend

(1) 25.62

(2) 14.1mm Legend

(1) ROD; SHIFT
(2) ARM; SHIFT
(3) SPRING
(4) BLOCK ARM;SHIFT
(5) PIN ARM; SPRING
(6) ROLLER; GUIDE
(7) RING; SNAP

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.

226R300015
3.
Install the spring.
4.
Install the shift arm.
5.
Compress the spring and install the snap ring.
6.
Install the guide roller.

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.
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

Legend
(1) OIL PUMP ASM
(2) CLAMP
(3) HOSE
(4) SCREEN ASM

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.

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.

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

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.

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)

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.




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)


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.

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)

226RS037

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)





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.
Clutch hub and insert clearance
Standard : 0.01-0.19 mm (0.0004-0.0075 in)
Limit : 0.3 mm (0.012 in)


226RS038

Detent Springs
1.
Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.