ISUZU TF SERIES 2004 Workshop Manual

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)


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)




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.
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).














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.


226R300004






Note the direction of the dumper ring installation as
figure.

226R300025

Legend

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

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.








6. Use a press and an appropriate special tool to force
the ball bearings 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 gea
r
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.

7D-26 TRANSFER CASE

226R300003












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.




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
(3) Synchronizer Key and Key Spring
(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 assembl
y
insertion holes (transfer case) with transfer oil.
18.
Install the main shaft together with the H-L shif
t
assembly and the 2-4 shift assembly to the shif
t
drum.

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
(3) Shift Shaft
(2) 2-4 Sleeve ASM with Main Shaft and Shift ASM
(4) Shift Drum

NOTE: Be careful in the direction of an assembly.
P1010041/020124

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.

TRANSFER CASE 7D-29

24.
Align the sprocket thrust washer with the main shaft
groove and install it.

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

226R300008








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).








29.
Install the oil pump wire snap ring to the rear cover.

7D-30 TRANSFER CASE

226R300005



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.







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)



226R300010










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.


Legend

(1) Oil Pump ASM
(2) Wire Snapring
(3) Retaining Ring
(4) Ball Bearing
(5) Speedometer Gear Drive Gear
(6) Rear Cover
Legend

(1) Wire Snapring

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.

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.

226R300022

44.
Use the installer (5-8840-2786-0) to install the rea
r
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)


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 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 Nm (2.2 kgm/16 lbft)
50.
Install the breather hose between the transfe
r
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)