ignition ISUZU TF SERIES 2004 Workshop Manual

3B-54 POWER-ASSISTED STEERING SYSTEM

10. Push the born pad area 1-4.
Tighten the born pad fixing screw to the specifed
torque (without SRS air bag)
Torque: 2 - 4 N




m (0.2 – 0.4 kg




m/17 - 35 lb ft)
NOTE: A horn pad is not struck at the time o
f
attachment.



RTW43BSH000401
11. Align the each snap stud of driver air bag to the hole
of steering wheel. (with SRS air bag)
060R300030

060R300020
12. Push the SRS air bag area1 and area2. At that time
confirm the audible noise of each stud. (with SRS ai
r
bag)
060R300036
13. Enable the SRS (Refer to "Enabling the SRS" in this
section). (with SRS air bag)
14. Install driver knee bolster (reinforcement).
15. Install instrument panel lower cover, then install the
engine hood opening lever.
16. Connect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)
17. Connect the battery "-" terminal cable. (with SRS ai
r
bag)

System Inspection (with SRS air bag)
Turn the ignition switch to "ON" while watching warning
light.
The light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.

POWER-ASSISTED STEERING SYSTEM 3B-55

Steering Column
Steering Column and Associated Parts



This illustration is based on the RHD model.
RTW43BLF000201
Legend
(1) Inflator Module or Horn Pad
(2) Steering Wheel
(3) Steering Column Cover
(4) Combination Switch and SRS Coil Assembly
(5) Steering Column Assembly
(6) Second Steering Shaft
(7) Lower Second Steering Shaft
(8) Instrument Panel Lower Cover
(9) Driver Knee Bolster (reinforcement)



Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to "LOCK".

3. Disconnect the battery "-" terminal cable, and wait at
least 5 minutes. (with SRS air bag)
4. Disconnect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)

POWER-ASSISTED STEERING SYSTEM 3B-61

System Inspection (with SRS air bag)
Turn the ignition switch to "ON" while watching warning
light.
The light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.

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

TRANSFER CONTROL SYSTEM 7D1-31
CONNECTOR LIST
No. Connector face No. Connector face
B-24
Green
Meter-B C-57
(4JH1-
TC)
ECM
B-54
White
J/B I2 C-67
BlackEHCU
B-62
White
Ignition switch (IGSUB : G1) C-94
(4JH1-
TC)
Gray TCM
B-63
White
Ignition switch (IGSUB : G2) C-95
(6VE1)
WhiteTCM
B-64
Silver
Weld splice 1(Illumination) C-107
WhiteJ/B E2
B-65
Silver
Weld splice 2 (Ground) C-108
WhiteJ/B E1
B-66
White
4WD switch C-109
SilverBody-LH ; ground
C-2
Silver
Engine room-RH ; Ground C-118
(4JH1-
TC)
WhiteA/C Resister & Neutral switch
C-36
Silver
Engine room-LH ; Ground C-119
(6VE1)
BlackAuto cruise actuator
C-56
(4JH1-
TC)
Gray
ECM R-15
BlackTransfer controller

TRANSFER CONTROL SYSTEM 7D1-35
3.
Shifting from 4H to 4L
3-1 When the 4L indicator flashes at 2Hz
When shifting from 4H to 4L, the 4L indicator continues flashing at 2Hz until shifting in the transfer case is
completed. The phases of the engaged splines may sometimes deviated preventing completion of shifting.
By correcting the deviation of phases, shifting is completed.

Step 3-1:
(In case of AT): Set the select bar of the transmission to the D position.
(In case of MT): Set the lever of the transmission to a position allowing running and engage the clutch
gently.
At this time, some rotating force acts on the engaged splines, phase is corrected and the engagement is
completed.

3-2 When the 4L indicator flashes at 2Hz for 10 seconds and then keeps ON again (AT vehicle)
This condition occurs when torsional torque has been generated between the transmission and road surface
and the transfer standby mechanism cannot absorb it completely.

Step 3-2:
Set the select lever of the transmission to the N position. (Stepping on the brake pedal is effective at
this time.)

3-3 When the 4L indicator flashes at a frequency of 4Hz
Shifting from 4H to 4L is restricted.
When the vehicle is running, the transmission lever is at the running range and the engine speed is high (L4:
3000rpm or more V6: 2000rpm), the transfer cannot be shifted from 4H to 4L (restriction on operation).

Restriction on operation (Except 4JA1-LT)
The 4H, neutral and 4L shifting mechanism has no synchronization function. Therefore, if relative rotations in the
mechanism become excessive, shifting exerts adverse influence on the internal mechanism of the transfer. To
avoid such a trouble, vehicle condition is detected to restrict the operation (vehicle speed, engine speed and TM
position).
Requirement to restrict the speed: Vehicle should be in stop.
For the reason of the detection logic, time to wait for start of operation may be required.
A/T: If the vehicle is in stop for a long time at the TM running range (D, 1, 2) before operating the AT, waiting
time becomes longer (from 1 second to 3 minutes at the maximum).
M/T: If the vehicle is at stop with the clutch stepped on at the T/M running position (1 – R), the time to wait
becomes longer.
Waiting time means the time commencing from when other requirements (engine speed and T/M position) are
met to permission of the speed restriction. Operation during the waiting time is not permissible.
The waiting time is 1 second at the minimum and increases up to 5 seconds if the above condition continues 3
minutes. After that, the waiting time increases up to 3 minutes in 2 minutes.
When it is clear that the above condition has continued and reduction of waiting time is desirable, turn on or off
the ignition or start and stop the vehicle several meters.
Requirements for permission of restriction on engine speed: Engine speed should be decreased.
The engine speed of 3000rpm (V6: 2000rpm) or below is advisable.
Requirements for permission of restriction on T/M position restriction:
(AT) N range is recommendable
(MT) should be at the neutral.

These requirements for permission should be all met before the switch is operated. If the requirements are met
after operation, operation is not automatically effected but re-operation is required after permission is given.

TRANSFER CONTROL SYSTEM 7D1-39
Trouble diagnosis based on the operation switch, transfer indicator lamp and operating
sound “Check 4WD” indicator ON (operation guard based on the transfer actuator
position detection error)
This condition indicates a faulty circuit related with the detection (limit) switches of the system actuator.
Detection (limit) switches detect the actuator operating angle based on their combinations.
The controller monitors transition of the actuator based on the combination of the detection (limit) switch output.
If the transition based on the combinations indicates some trouble, it is memorized, shifting operation is stopped
when the trouble is counted 5 times, and the “Check 4WD” indicator lights up. At this time, the system permits
operation to 2H only.
When such a condition results, inspection of the transfer shift actuator, check of harness related with the
detection (limit) switch, and erasure of the memory of the controller are required.
(Refer to the memory erasure procedure for the erasure of the memory.)
At this time, the position indicator may flash at 4Hz. It means that a detection (limit) switch trouble wad
detected in the operation process shown by that position indicator (example: 4WD indicator when shifting from
2H to 4H).

Caution:
In the course of trouble diagnosis and correction, do not turn ON the ignition with the harness connector of
the transfer actuator disconnected. (Do not disconnect the harness connector of the transfer actuator
when the ignition is ON.)
If the controller is connected at this condition, a limit SW trouble is judged and the above-described
“Check 4WD” condition is brought about.
This can be reset by clearing the memory.
When it is required to disconnect the harness connector of the actuator and turning the ignition ON,
remove the controller at the same time or remove the IG power fuse of the transfer controller.

7D1-40 TRANSFER CONTROL SYSTEM

Memory erasing procedure
1. Prepare two pieces of short harness with the end sharped
like a needle (bout 20cm(7.9 in) long).
2. Turn OFF the ignition.
3. Remove the front left seat ASM.


4. Make the controller under the front left seat ASM (spread
the cut of the floor carpet).





5. Keeping the connector of the transfer controller connected,
set the short harness from the back of the connector as
illustrated.
6. Turn ON the ignition, wait for 2 seconds, and turn OFF the
ignition after confirming the relay sound.
7. Disconnect the short harness, turn ON the ignition again,
and confirm the “Check 4WD” lamp in the meter panel is
OFF.
8. Before erasing the memory, check that the circuit of the T/F
actuator position detection harness, etc. for it are normal.

Transfer Controller Pin Assignment


RTW47DSF000101

TRANSFER CONTROL SYSTEM 7D1-41
Diagnosis from symptom
Check4WD lighting up
Step Action Yes No
1 Check what was done before
the trouble occurred.
Was the harness between the
transfer controller and actuator
disconnected with the ignition
kept ON for the purpose of
servicing the vehicle, etc.?
Or, was the ignition turned ON
(power supplied to the transfer
controller) with the harness of
the actuator removed? If the power is supplied with the
actuator not connected, faulty
position detection switch is
considered.
Clear the memory and trace this
chart from the beginning. Go to step 2.
2 Is the ignition switch ON? Go to step 3. Turn the ignition switch ON and
trace this chart from the
beginning.
3 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON? Go to step 4. Indicator lamp burnt out.
Disconnected harness wire .
After repairing, trace this chart
from the beginning.
4 Isn’t the harness between the
Check4WD indicator and
transfer controller GND shorted? GND (body) short of the indicator
harness.
After repairing, trace this chart
from the beginning. Go to step 5.
5 Check the continuity of harness
between the transfer controller
and transfer actuator. Check
the power short and GND short.
Check the GND harness of the
transfer actuator.
Is a trouble noticed? Repair the harness, clear the
memory and trace this chart from
the beginning. Go to step 6.
6 Check the limit switch of the
actuator.
Is a trouble noticed? Failed actuator. Replace the
actuator, clear the memory and
trace this chart from the
beginning. Clear the memory and trace this
chart from the beginning.
Failed controller.
Replace the controller, clear the
memory and trace this chart from
the beginning.
To check the operation after completing the repair and clearing the memory, shift between 2H and 4L 5 times at
least.
To judge the condition more quickly, ask the customer the situation when the Check4WD lamp lighted up.
When the position indicator blinks at a frequency of 4Hz immediately after occurrence of a trouble, position of
failure which the indicator shows may be limited.
(Since it indicates the situation immediately before detection of failure whether the vehicle is running or standstill so
that possibility of failure around that point is high.)
Status of the transfer when the Check4WD lights up is not always the same. Immediately after occurrence of the
failure, 2H can be operated.

7D1-42 TRANSFER CONTROL SYSTEM
Cannot shift from 2WD to 4H or 4L.

When shifting from 2H to other position, the indicator (4WD, 4Lo, Check4WD, neutral)
does not respond.
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Turn the ignition switch ON and
trace this chart from the
beginning.
2 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON? Failed operation switch. Only 2H
is stuck at ON condition and 4H-
4L position is internally
disconnected. Or,
Failed controller Indicator lamp burnt out.
Disconnected harness wire .
After repairing, trace this chart
from the beginning.


Even after correction step 1-1(*), 4WD indicator blinks at 4Hz and changes to 2H after 10
seconds.
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Turn the ignition switch ON and
trace this chart from the
beginning.
2 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON? Go to step 3. Indicator lamp burnt out.
Disconnected harness wire.
After repairing, trace this chart
from the beginning.
3 After 2 seconds, check that the
Check4WD lamp is ON or OFF.
Is the Check4WD lamp OFF? Go to step 4. Failed actuator position detection
switch (LS1, LS2, LS3, LS4,
GND).
Short or disconnection of harness
of this detection switch.
After repairing, trace this chart
from the beginning.
4 Press the 4H button.
Is sound of relay heard from the
transfer control? Go to step 5. Failed controller.
Replace the controller and trace
this chart from the beginning.
5 Is the sound of running motor
heard? Failed control system of the
transfer mechanism. Check and
repair and trace this chart from
the beginning. Failed actuator motor.
Disconnected controller motor
drive output circuit, GND short
circuit. +B fuse blown out.
Disconnection of that harness.
After repairing, trace this chart
from the beginning.
*Before determining a trouble (Non-trouble mode)