Isuzu D Max 2011 Transfer Case Service Manual

WORKSHOP MANUAL
2011MY UC SERIES
TRANSFER CASE
SECTION 7D
Isuzu Motors Limited
E-Solutions &
Service Marketing Dept.
TRANSFER CASE 7D-1
SECTION 7D
TRANSFER CASE
TABLE OF CONTENTS
PAGE
Service
Precaution ........................................................................
................................. 7D – 2
General
Description .......................................................................
................................. 7D – 3
On-Vehicle
Service ...........................................................................
.............................. 7D – 4
Transfer Case Oil
Level .............................................................................
.................. 7D – 4
Transfer Case Oil
Change ............................................................................
............... 7D – 5
Transfer Case Front Oil
Seal ..............................................................................
........ 7D – 6
Transfer Case Rear Oil
Seal ..............................................................................
.......... 7D – 9
Transfer Case
Assembly ..........................................................................
...................... 7D – 11
Transfer Case Assembly and Associated
Parts ........................................................ 7D – 11
Removal ...........................................................................
............................................. 7D – 12
Installation ......................................................................
.............................................. 7D – 12
Transfer Control
Unit ..............................................................................
........................ 7D – 15
Removal ...........................................................................
............................................. 7D – 15
Installation ......................................................................
.............................................. 7D – 15
Transfer
Disassembly .......................................................................
............................. 7D – 16
Removal ...........................................................................
............................................. 7D – 16
Inspection and
Repair ............................................................................
..................... 7D – 25
Inspection and Repair (Transfer Case
Assembly) .................................................... 7D – 25
Reassembly ........................................................................
.......................................... 7D – 29
Main Data and
Specifications ....................................................................
.................... 7D – 39
Special
Tools .............................................................................
................................... 7D – 42
7D-2 TRANSFER CASE
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL CAUTION: Always use the correct
fastener in the
RESTRAINT SYSTEM (SRS). REFER TO THE SRS proper location. When you replace a
fastener, use
COMPONENT AND WIRING LOCATION VIEW IN ONLY the exact part number for that
application.
ORDER TO DETERMINE WHETHER YOU ARE ISUZU will call out those fasteners
that require a
PERFORMING SERVICE ON OR NEAR THE SRS replacement after removal. ISUZU will
also call out
COMPONENTS OR THE SRS WIRING. WHEN YOU the fasteners that require thread
lockers or thread
ARE PERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED, do
not
COMPONENTS OR THE SRS WIRING, REFER TO use supplemental coatings (Paints,
greases, or
THE SRS SERVICE INFORMATION. FAILURE TO other corrosion inhibitors) on threaded
fasteners or
FOLLOW WARNINGS COULD RESULT IN POSSIBLE fastener joint interfaces. Generally,
such coatings
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR adversely affect the fastener torque
and the joint
OTHERWISE UNNECESSARY SRS SYSTEM clamping force, and may damage the
fastener. When
REPAIRS. you install fasteners, use the correct
tightening
sequence and specifications. Following
these
instructions can help you avoid damage
to parts and
systems.
TRANSFER CASE 7D-3
General Description
RTW57ALF000301
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
On-Vehicle Service
Transfer Case Oil Level
RTW67DMF000101
Legend
(1) Transfer Case
(2) Filler Plug and O-ring
Removal Installation
1. Disconnect the battery ground cable. 1. Replace the
filler plug and O-ring tighten it to the
2. Rise and support the vehicle with suitable stands. specified
torque.
3. Remove the filler plug and O-ring. Filler plug
torque: 39 N⋅⋅m (4.0 kgf⋅⋅m/29 lb⋅⋅ft)
4. Check the oil level reaches the filler hole. 2. Lower the
vehicle to the ground.
5. If the oil level is low, fill the transfer oil (5W-30) or 3. Connect the
battery ground cable.
equivalent to the transfer through the filler hole.
TRANSFER CASE 7D-5
Transfer Case Oil Change
RTW67DMF000201
Legend
(1) Transfer Case
(2) Filler Plug and O-ring
(3) Drain Plug and O-ring
1. Disconnect the battery ground cable. 1. Replace the drain plug
and O-ring to the transfer case
2. Rise and support the vehicle with suitable stands. and tighten it to the
specified torque.
3. Place a suitable sized drain tray under the transfer Drain plug torque: 39
N⋅⋅m (4.0 kgf⋅⋅m/29 lb⋅⋅ft)
case. 2. Fill the specified
volume of the transfer oil (5W-30) or
4. Remove the drain plug and O-ring drain the transfer equivalent to the
transfer case through the filler hole.
case oil. Transfer oil volume:
1.3 lit. (1.37 US qt/0.29 Imp gal)
5. Remove the filler plug and gasket. 3. Replace the filler
plug and O-ring tighten it to the
specified torque.
Filler plug torque: 39
N⋅⋅m (4.0 kgf⋅⋅m/29 lb⋅⋅ft)
4. Lower the vehicle to
the ground.
5. Connect the battery
ground cable.
7D-6 TRANSFER CASE
Transfer Case Front Oil Seal

Transfer Front Oil Seal and Associated Parts
RTW67DMF000301
Legend (3) O-ring

(1) Front Propeller Shaft (4) Output Flange
(2) End Nut (5) Front Oil Seal
Removal 8. Remove the front oil

seal from the front cover.
1. Disconnect the battery ground cable.
2. Raise and support the vehicle with suitable stands.
3. Place a suitable sized drain tray under the transfer
case.
4. Remove the drain plug and drain the transfer case oil.
5. Remove the filler plug.
6. Remove the front propeller shaft.
7. Use a flange holder (5-8840-0133-0) to remove the
end nut from the front output shaft then remove the
O-ring and the output flange.
RTW77DSH000201
TRANSFER CASE 7D-7
Installation 8. Use a punch (5-

8840-2293-0) to caulk the end nut.
1. Thoroughly clean around the oil seal bore in the case
and ensure there are no burrs.
2. Apply the engine oil to the new oil seal outer surfaces
and apply the recommended grease (BESCO L2) or
equivalent to the oil seal lip.
3. Tap the oil seal in to place, use an oil seal installer
5-8840-2785-0 and a soft hammer.
226R300012
RTW77DSH000301
4. Install the output flange to the front output shaft.

5. Apply the engine oil to the new O-ring and install it to
the front output shaft.
6. Secure the output flange with a flange holder
(5-8840-0133-0).
7. Install the new end nut and tighten them to specified
torque.
Front coupling driver fixing nut torque:
137 N⋅⋅m (14.0 kgf⋅⋅m/101 lb⋅⋅ft)
RUW34DSH000301
Legend
(1) MAX 26mm
(1.02in)
(2) MIN 4mm
(0.16in)
7D-8 TRANSFER CASE
9. Install the drain plug to the transfer case and tighten it

to the specified torque.
Drain plug torque: 39 N⋅⋅m (4.0 kgf⋅⋅m/29 lb⋅⋅ft)
Transfer oil volume: 1.3 lit. (1.37 US qt/0.29 Imp gal)
10. Install the filler plug and tighten it to the specified
torque:
Filler plug torque: 39 N⋅⋅m (4.0 kgf⋅⋅m/29 lb⋅⋅ft)
11. Install the front propeller shaft.
Propeller shaft bolts torque:
59 N⋅⋅m (6.0 kgf⋅⋅m/43 lb⋅⋅ft)
12. Lower the vehicle to the ground.
13. Connect the battery ground cable.
TRANSFER CASE 7D-9
Transfer Case Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts
220R300018
Legend
(1) Rear Propeller Shaft
(2) Rear Oil Seal
1. Disconnect the battery ground cable. 1. Thoroughly clean
around the oil seal bore in the
2. Raise and support the vehicle with suitable stands. transfer case and
ensure there are no burrs.
3. Remove the rear propeller shaft. 2. Apply the engine oil
to the new oil seal outer surfaces
4. Remove the oil seal from the transfer case. and apply the
recommended grease (BESCO L2) or
equivalent to the oil
seal lip.
7D-10 TRANSFER CASE
3. Tap the oil seal in to place, use an oil seal installer

(5-8840-2786-0) and a soft hammer.
RTW77DSH000401
220R300021
4. Install the rear propeller shaft.

Propeller shaft bolts torque:
59 N⋅⋅m (6.0 kgf⋅⋅m/43 lb⋅⋅ft)
5. Lower the vehicle to the ground.
6. Connect the battery ground cable.
TRANSFER CASE 7D-11
Transfer Case Assembly

Transfer Case Assembly and Associated Parts
RTW57ALF000201
Legend
(1) Rear Propeller Shaft
(2) Front Propeller Shaft
(3) Transfer Case Assembly
7D-12 TRANSFER CASE
NOTE: Before removing transmission and transfer 1. Apply a thin coat of
molybdenum disulfide grease to
assembly from vehicle, change the transfer mode to the input shaft
spline as shown in the figure.
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 rear propeller shaft and front propeller shaft.
NOTE: Apply alignment marks on the flange at both front
and rear sides.
4. 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).
5. Remove transfer case assembly from the vehicle.
260R300001
TRANSFER CASE 7D-13
2. Install transfer case assembly to the transmission.

Tighten transfer bolts as shown in the figure.
For M/T
N⋅⋅m (kgf⋅⋅m/lb⋅⋅ft)
mm (in)
RTW77DLF000201
7D-14 TRANSFER CASE
For A/T
N⋅⋅m (kgf⋅⋅m/lb⋅⋅ft)
mm (in)
RTW77DLF000301
3. Connect harness connectors and clip.

Connector: transfer switch, 2WD-4WD actuator,
speed sensor.
4. Install rear propeller shaft and front propeller shaft.
Propeller shaft torque: 59 N⋅⋅m (6.0 kgf⋅⋅m/43 lb⋅⋅ft)
TRANSFER CASE 7D-15
Transfer Control Unit
RUW77DMF000101
Legend
(1) Transfer Control Unit
(2) Nut
1. Disconnect the battery ground cable. 1. Install the Transfer
control unit.
2. Disconnect the harness connector from the Transfer Transfer control unit
torque:
control unit. 7 N⋅⋅m (0.7 kgf⋅⋅m/61
lb⋅⋅in)
3. Remove the Transfer control unit. 2. Connect the harness
connector to the Transfer
control unit.
3. Connect the battery
ground cable.
7D-16 TRANSFER CASE
Transfer Disassembly
RTW57DLF000101
Legend
(1) Transfer Case (6) Switch Bracket
(2) Companion Flange, O-ring and Nut (7) Neutral Switch
ASM
(3) Stoneguard (8) Speedometer
Bushing, Plate and Driven Gear
(4) Detent Plug, Spring and Detent Ball (9) Transfer Actuator
(5) 2-4 Switch ASM (10) Breather Hose
Removal • Speedometer bushing,

plate, and speedometer
1. Remove the stoneguard. driven gear
2. Remove the drain plug from the transfer case to drain • Breather hose (Between
the transfer case and the
the oil. transfer actuator
assembly)
3. Remove the parts listed below. • Transfer actuator
assembly
• Switch bracket
TRANSFER CASE 7D-17
• 2-4 switch assembly (Gray harness cover) 6. Strike the area

around the front output shaft head and
• Neutral switch assembly (Black harness cover) the rear cover bolt
holes with a plastic hammer to
• Detent plugs, detent springs, and detent balls (2 remove the rear
cover.
parts each)
4. Use a flange holder (5-8840-0133-0) to remove the
end nut from the front companion flange.
RTW77DSH000201
5. Remove the bolts attaching the rear cover to the

transfer case.
220R300022
7D-18 TRANSFER CASE
7. Remove the parts listed below from the rear cover. Legend
• H-L sleeve (1) Sun Gear Needle
Bearing
• H-L shift assembly (2) H-L Sleeve
• 2-4 sleeve, synchronizer key, and front (3) 2-4sleeve,
synchronizer key, and front
synchronizer spring (do not remove the rear synchronizer
spring
spring) (4) 2-4 Shift ASM
(5) Shift Shaft
• 2-4 shift assembly
(6) H-L Shift ASM
• Shift drum and shift shaft
(7) Shift Drum
• Sun gear needle bearing
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
260R300001
TRANSFER CASE 7D-19
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 (8) Thrust Washer

(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
7D-20 TRANSFER CASE
15. Remove the snap ring from the main shaft.

16. Use a press to remove the 2-4 hub from the main
shaft.
2260R300021
Legend
(1) Outer
Retaining Ring
(2) Carrier and
Gear ASM
(3) Thrust
needle Bearing
17. Spread the edges of the retaining ring (1) while lightly (4) Sungear
Input Shaft
tapping on the sun gear input shaft end. Remove the (5) Planetary
DogTeeth
carrier and gear assembly from the transfer case. (6) Dog Teeth
Snap Ring
20. Remove the

carrier snap ring.
21. Use a press to
remove the ball bearings.
226R300020
18. Remove the dog teeth snap ring from the carrier and
gear assembly.
19. Remove the planetary dog teeth and the sun gear
input shaft together with the thrust needle bearing. 22. Use a sliding
hammer (5-8840-0084-0) and a needle
bearing
replacer (5-8840-0027-0) to remove the
needle bearing
from the center of the carrier and gear
assembly.
TRANSFER CASE 7D-21
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.
23. Remove the retaining ring (spiral type) together with

the internal gear and the damper ring.
P1010023
226R300004
Legend
(1) Dumper Ring
(2) Internal Gear
(3) Retaining Ring
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 rear
cover.
7D-22 TRANSFER CASE
Internal Component Disassembly and Reassembly H-L Shift Disassembly

1. Remove the guide roller.
2. Use a vise to compress the
H-L shift spring (inside the
assembly)
226R300017
Legend
(1) Shift Arm
(2) Shift Block Assembly
(3) Inner Retaining Ring 3. Remove the outer snap ring.
(4) Collar (Front) 4. Remove the shift block
assembly from the shift rod.
(5) Shift Block Spring
(6) Collar (Rear)
(7) Shift Rod
(8) Outer Snap Ring
(9) Guide Roller
(10) Spring Pin
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 (front)
10. Remove the shift block
assembly
11. Remove the spring pin.
12. Remove the shift arm.
TRANSFER CASE 7D-23
H-L shift reassembly 2-4 shift ASM

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 collar 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.
226R300016
Legend
(1) Shift
Rod
(2) Shift
Arm
(3) Spring
(4) Shift
Block Assembly
(5) Spring
Pin
(6) Guide
Roller
226R300014
(7) Snap
Ring
Legend 2-4 shift

disassembly
(1) 25.62° 1. Remove the
guide roller.
(2) 14.1mm (0.555 in) 2. Compress
the spring and remove the snap ring.
3. Remove the
shift arm.
4. Remove the
spring.
6. Install the shift lock assembly to the shift rod. 5. Remove the
spring pin.
7. Use a socket and a vise to compress the H-L shift 6. Remove the
shift block assembly.
spring. 7. Remove the
shift rod.
8. Install the outer snap ring.
9. Install the guide roller.
7D-24 TRANSFER CASE
2-4 shift reassembly Oil pump reassembly

1. Install the shift block assembly to the shift rod. 1. Tighten the
clamps to secure the hose.
2. Install the spring pin. The head of the pin must not 2. Tighten the
clamps to secure the screen.
project beyond the surface (1) of the shift block. NOTE: Be careful
in the direction of clamps.
226R300015
RTW37DSH000101
3. Install the spring. Legend

4. Install the shift arm. (1) Oil Pump
Assembly
5. Compress the spring and install the snap ring. (2) Clamp
6. Install the guide roller. (3) Hose
(4) Screen
Assembly
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 protect oil pump function, the
pump is constructed so that it cannot be disassembled.
Under no conditions attempt to disassemble the pump.
TRANSFER CASE 7D-25
Inspection and Repair 2-4 and Neutral

Switch
1. Make the necessary repair or parts replacement if • Check the
continuity of 2-4 and Neutral switch.
wear, damage or any other abnormal conditions are If defects are
observed, replace the 4H and 4L switch.
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.
221R300001
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
261R300003
sprocket inside sliding surface, replace the part.

Switch
2-4 Switch Neutral Switch
Gear Stroke
Signal Signal
• Check whether the gear tooth surface is excessively
Terminal Terminal
worn or damaged, and there is evidence of burrs,
1 to 2 1 to 2
chipping, wear, or damage on the gear spline. 1
Open Close
• Remove minor flaws or scratches with oil stone. If 2
Close Open
excessive wear or damage is observed, replace the
part.
7D-26 TRANSFER CASE
Oil Pump Ball Bearing Play

• Remove foreign materials from the strainer. If the 1. Use a dial
indicator to measure the ball bearing play.
strainer is damaged, replace it. 2. If the measured
value exceeds the specified limit, the
If the area into which the shaft is inserted is excessively ball bearing must
be replaced.
worn or damaged, replace the oil pump assembly.
Limit: 0.2 mm
(0.008 in)
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)
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,
226RS042 replace if these
conditions are present.
Bearings • If scuffed, nicked
or burred conditions cannot be
1. Inspect the condition of all the needles and ball corrected with a
soft stone or crocus cloth, replace the
bearings. Wash bearings thoroughly in a cleaning component.
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.
TRANSFER CASE 7D-27
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: 2.46-2.74 mm (0.097-0.108 in)
Limit: 3.0 mm (0.118 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
226RS037
Standard: 0.01-0.19
mm (0.0004-0.0075 in)
2WD-4WD Synchronizer (3-Cone) Limit: 0.3 mm
(0.012 in)
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)
226RS038
Detent Springs
1. Inspect the springs
for distortion, cracks or wear.
Replace if these
7D-28 TRANSFER CASE
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)
220RS013
Shift Arm
1. Inspect the shift
arms for wear, distortion or scoring.
Replace if these
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
220RW035
Standard: 7.6-7.85
mm (0.299-0.309 in)
Detent Spring Tension Limit: 7.0 mm
(0.276 in)
1. Use a spring tester to measure the detent spring 2-4 Shift arm
thickness
tension. Standard: 9.6-9.85
mm (0.378-0.388 in)
2. If the measured value is less than the specified limit,
Limit: 9.0 mm
(0.354 in)
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 kgf/ 15.4-19.8 lb)
TRANSFER CASE 7D-29
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 an 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).
226R300004
Legend
(1) Dumper Ring
(2) Internal
Gear
(3) Retaining
Ring
Note the direction

of the dumper ring installation as
figure.
226R300025
RTW77DSH000301
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.
7D-30 TRANSFER CASE
4. Use a press and an installer (5-8840-2784-0) to hold

the internal gear against the damper ring. Install the
retaining ring (spiral type).
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 gear
5. Use a press and an installer (5-8840-2782-0) to force assembly in that
order.
the needle bearing fully into the carrier and gear 9. Install the outer
retaining ring to the transfer case
assembly. 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.
6. Use a press and an appropriate special tool to force

the ball bearings fully into the carrier and gear
assembly.
TRANSFER
CASE 7D-31
11. Use a press to install the 2-4 hub.
12. Install the hub snap ring.

13. Install the synchronizer key
springs, 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.
226R300003
Legend
(1) Retaining Ring
(2) Carrier and Gear ASM
(3) Thrust Needle Bearing
(4) Sungear Input Shaft
(5) Planetary Dog Teeth
(6) Dog Teeth Snap Ring
7D-32 TRANSFER CASE
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 assembly
insertion holes (transfer case) with transfer oil.
18. Install the main shaft together with the H-L shift
assembly and the 2-4 shift assembly to the shift drum.
TRANSFER CASE 7D-33
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. 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.
P1010041/020124
7D-34 TRANSFER CASE
24. Align the sprocket thrust washer with the main shaft
groove and install it. Legend
(1) Block Ring
(2) Outside
Ring
(3) Inside
Ring
(4) Sprocket
(5) Transfer
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
(2.09 ± 0.02 in)
27. Position the
rear cover so that its mating surfaces are
226R300009
facing up.
28. Use a press
and an installer (5-8840-2783-0) to install
the front
output shaft needle bearing. The installer
25. Select a snap ring that will allow minimum axial play.
must be
aligned with the bearing manufacturer's
Insert it to the main shaft installation groove.
mm (in) name (stamped
into the bearing).
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
29. Install the

oil pump wire snap ring to the rear cover.
226R300008
TRANSFER CASE 7D-35
226R300005
Legend
(1) Wire Snap Ring
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 an installer (9-8522-1268-0) to install
the rear output shaft ball bearings. Do not drive the
226R300010
ball bearings into place with a hammer.
Legend
(1) Oil Pump
Assembly
(2) Wire Snap
Ring
(3) Retaining
Ring
(4) Ball Bearing
(5) Speedometer
Gear Drive Gear
(6) Rear Cover
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.
32. Install the rear output shaft retaining ring.

33. Place the oil pump in its specified position.
34. Secure the oil pump strainer to the rear cover and
tighten the bolts to the specified torque.
Oil pump and rear cover bolt torque:
15 N·m (1.5 kgf·m/11 lb·ft)
7D-36 TRANSFER CASE
226R300011
226R300012
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 N·m (2.2 kgf·m/16 lb·ft)
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 a 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 N·m (14.0 kgf·m/101 lb·ft)
RUW34DSH000301
Legend
(1) MAX 26mm
(1.02 in)
(2) MIN 4mm
(0.16 in)
42. Apply Loctite

575 to the threaded portion of the
detente plugs.
RTW77DSH000201
41. Use a punch (5-8840-2293-0) to caulk the front

companion flange end nut.
TRANSFER CASE 7D-37
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.
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.
226R300022
Detent plug
torque: 19 N·m (1.9 kgf·m/14 lb·ft)
46. Install the
neutral switch (black harness cover) to the
44. Use an installer (5-8840-2786-0) to install the rear transfer case
and tighten the bolts to the specified
output oil seal to the rear case. 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 transfer
case and
tighten the bolts to the specified torque. The
actuator must
be installed in the same direction as the
shaft.
RTW77DSH000401 Transfer
actuator assembly bolt torque:
22 N·m (2.2
kgf·m/16 lb·ft)
50. Install the
breather hose between the transfer
actuator and
the transfer case.
51. Install the
speedometer driven gear, the speedometer
bushing, and
the speedometer stay to the transfer
case. Tighten
the bolts to the specified torque.
Speedometer
bolt torque:
15 N·m (1.5
kgf·m/11 lb·ft)
7D-38 TRANSFER CASE
52. Install the drain plug to the transfer case and tighten it
to the specified torque.
Drain plug torque: 39 N·m (4.0 kgf·m/29 lb·ft)
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 lit. (1.37 US qt/0.29 Imp gal)
54. Replace the filler plug and tighten it to the specified
torque.
Filler plug torque: 39 N·m (4.0 kgf·m/29 lb·ft)
55. Install the underguard and tighten the bolts to the
specified torque.
Underguard bolt torque:
39 N·m (4.0 kgf·m/29 lb·ft)
TRANSFER
CASE 7D-39
Main Data and Specifications

General Specifications
Type Synchronized type gears shifting between the 2 and 4 wheel
drive mode.
Planetary type gears shifting between “low" and “high".
Control method Remote control with the button switch on the instrument
panel for gears
shifting among “2H", “4H" and “4L".
Gear ratio High; 1.000
Low; 2.482
Oil capacity 1.3 lit. (1.37 US qt/0.29 Imp gal)
Type of lubricant BESCO GEAR OIL TRANSAXLE (5W-30)
Refer to Section 0B
Torque Specifications
N⋅m (kgf⋅m/lb⋅ft)
RTW57DLF000201
7D-40 TRANSFER CASE
RTW57DLF000301
TRANSFER CASE 7D-41
E07R300008
7D-42 TRANSFER CASE
Special Tools
PART NO. PART
NO.
ILLUSTRATION ILLUSTRATION
PART NAME PART
NAME
5-8840-2786-0 5-8840-
2784-0
Transfer case oil seal Ring gear
installer
installer
5-8840-0084-0 5-8840-
0133-0
Sliding hammer Flange
holder
5-8840-0027-0 5-8840-
2782-0
Rear output shaft needle Needle
bearing installer
bearing replacer
5-8840-2293-0 5-8840-
2783-0
Punch; end nut Needle
bearing installer
5-8840-2788-0 9-8522-
1268-0
Front output shaft needle Rear output
shaft ball
bearing replacer bearing
installer
5-8840-2785-0 5-8840-
2787-0
Input shaft and/or front Snap ring
installer
output shaft oil seal installer
TRANSFER CONTROL SYSTEM 7D1-1
SECTION 7D1
TRANSFER CONTROL SYSTEM
TABLE OF CONTENTS
PAGE
Service
Precaution ........................................................................
............................. 7D1 - 2
General
Description .......................................................................
............................ 7D1 - 3
System
Components ........................................................................
.......................... 7D1 - 5
Parts
Location ..........................................................................
............................. 7D1 - 5
Transfer
Controller ........................................................................
........................ 7D1 - 8
Functions of Switch and Indicator
Lamp ................................................................. 7D1 - 11
Transfer-related Indicator Lamp and Switch
Function ............................................ 7D1 - 15
Parts
Location ..........................................................................
.................................. 7D1 - 23
Circuit
Diagram ...........................................................................
................................ 7D1 - 26
Connector
List ..............................................................................
.............................. 7D1 - 27
Diagnosis .........................................................................
........................................... 7D1 - 29
Before Determining A Trouble (Non-trouble
mode) ........................................... 7D1 - 29
Memory Erasing
Procedure .........................................................................
.............. 7D1 - 35
Diagnosis from
Symptom ...........................................................................
............... 7D1 - 37
7D1-2 TRANSFER CONTROL SYSTEM
Service Precaution
WARNING:
THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT
SYSTEM (SRS). REFER TO THE SRS COMPONENT AND
WIRING LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS WIRING.
WHEN YOU ARE PERFORMING SERVICE ON OR NEAR
THE SRS COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW
WARNINGS COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE
UNNECESSARY SRS SYSTEM REPAIRS.
CAUTION:
Always use the correct fastener in the proper
location.
When you replace a fastener, use ONLY the exact
part
number for that application. ISUZU will call out
those
fasteners that require a replacement after removal.
ISUZU
will also call out the fasteners that require
thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or
other
corrosion inhibitors) on threaded fasteners or
fastener
joint interfaces. Generally, such coatings
adversely affect
the fastener torque and the joint clamping force,
and may
damage the fastener. When you install fasteners,
use the
correct tightening sequence and specifications.
Following
these instructions can help you avoid damage to
parts
and systems.
TRANSFER
CONTROL SYSTEM 7D1-3
General Description
RTW87DLF000301
Transfer Position and Drive Mode

Three drive modes can be selected through operation of 4WD switch.
Transfer Position 4WD SWITCH Mode

Drive mode
2H RWD Rear
wheel drive
HIGH High-
speed mechanical
4H 4WD (HIGH)
lock-
up four wheel drive
Low-
speed mechanical
LOW 4L 4WD (LOW)
lock-
up four wheel drive
NEUTRAL 2H & 4L (10 Sec) NEUTRAL Towed
by other vehicle
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 or
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 or
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.
System Components
Parts Location
RTW57DLF000401
Speed sensor
Revolutions of the rear output shaft are decreased and taken
out by the speed/drive/driven gears installed in the
transfer
case. The number of revolutions is detected with a speed
sensor.
About 4/3 pulses per revolution of the shaft are output.
4WD switch
The 4WD switch detects the movement of the shift rod driving
the 4×2 - 4×4 sleeve.
PUSH open is achieved with the PUSH open switch when the
shift rod is at the 4×2 position.
×2 - 4×
4× ×4 sleeve & Arm
The 4×2 - 4×4 sleeve moves directly in the 4×4 direction
with
the 4×2 - 4×4 shift rod. When 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.
4WD indicator (in meter panel)

This lamp indicates the following items:
Valve check
Drive condition (2WD-4WD)
Operating condition (2Hz: Actuator in
operation, mechanism
standby)
Restrictions on operation (4Hz: including
indication of
interrupted operation due
to excessive load)
7B4-PDF2
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)
7B4-PDF3
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)
RTW77DSH000601
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
7B4-PDF5
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.
RTW77DSH000501
Transfer controller
RUW77DMF000101
Legend
1. Transfer Controller
2. Nut
Transfer Actuator
Method of confirming the
actuator position detection
(limit) switch
The actuator indicates
the continuity condition of combinations,
as shown in the list
below between the 4 detection (limit) switch
pins and the GND pin
along the direction of the notch of the
output shaft spline.
Check that these combinations are as
specified.
The middle condition
between these positions (4 patterns in
the case of 2H-4H) is
either of the combinations shown below,
depending upon
manufacturing variations of the switch plate.
2H 2H-4H 4H
4H-N N N-L 4L
Direction of output -54° to 74° to
179° to 215° to 285° to
-29° to 74°
110° to 179°
shaft notch (outline) -29° 110°
215° 285° 300°
LS1 Close Close Open Open Open Open Open
Open Open Close Close
LS2 Open Close Open Close Close Open Open
Close Close Close Close
LS3 Close Close Close Close Close Close Open
Open Open Open Open
LS4 Open Open Open Open Close Close
Close Close Open Open Close
Continuity between each pin and GND pin. (Continuity also exists between
CLOSE pins.)
Transfer Actuator
Connector
7B4-PDF6
Method of checking the position

detection switch harness
Disconnect the vehicle harness
connector on the transfer
controller side, and the vehicle
harness connector on the
transfer actuator side as shown
in the wiring diagram. Check
the continuity between the
following connector pins, ensure
there is no continuity between
those pins and GND or power
source.
Check that there is continuity
between the GND pin and the
vehicle GND on the transfer
actuator, and there is no continuity
between the GND pin and another
power source.
C-112 C-111
Vehicle harness connector pin No. (connector of mating parts of the harness is
shown in this figure)
Name of pin T/F controller side T/F actuator side

Remarks
LS1 C-112, 17 5
LS2 C-112, 6 4
LS3 C-112, 15 7
LS4 C-112, 14 6
GND C-111, 1, 9 8
Functions of Switch and indicator Lamp

Transfer-related indicator lamp and switch function
Actuator
detection
SOF
(limit)
Check
actuator
switches
Transfer Transfer
4WD Neutral 4WD 4WD
switch
Item 4L lamp LS1, LS2,
4WD neutral Remarks
lamp lamp warning switch
Or
LS3. and
switch switch
light
Axle
LS4
dummy
1 = on
2 = off
No
2H Off Off Off Off 1,0,1,0
Open Open Open -----
operation
4H start 4H position
Switch
of Off Off Off Off for 0.1 1,0,1,0
Open Open Open operation
operation second
sensor
1,1,1,0
2H to 4H
Start of Blinking No 0,0,1,0
Off Off Off
Open Open Open while
operation (2HZ) operation 0,1,1,0
driving
0,1,1,1
2H to 4H
1,1,1,0
During
using
Blinking No 0,0,1,0
operation Off Off Off
Open Open Open synchro
(2HZ) operation 0,1,1,0
(Synchro)
and
0,1,1,1
retrial
During
operation Blinking No
Off Off Off 0,0,1,1
Closed Open Open Axle drive
(Axle (2HZ) operation
drive)
Axle Blinking No
Off Off Off 0,0,1,1
Closed Open Open Axle drive
waiting (2HZ) operation
No
4H On Off Off Off 0,0,1,1
Closed Open Closed -----
operation
4L start 4L position
Switch
of On Off Off Off for 0.1 0,0,1,1
Closed Open Closed operation
operation second
sensor
4H to 4L
On Off Off
Closed Open Closed while
driving
During
4H to 4L
Blinking No 0,0,0,1
Closed Closed Closed through
(N)
neutral
During
4H to 4L
Blinking No
operation Off Off Off 0,1,0,0
(2HZ) operation
(N)
neutral
During
4H to 4L
Blinking No
(2HZ) operation
(N)
neutral
4H to 4L
4L Blinking No
On Off Off 1,1,0,1
Closed Closed Closed while
waiting
No
4L On On Off Off 1,1,0,1
operation
Switch
operation second
sensor
Actuator
detection
SOF
(limit)
Check
actuator
switches
Transfer Transfer
4WD Neutral 4WD 4WD
switch
4WD neutral Remarks
Or
LS3. and
switch switch
light
Axle
LS4
dummy
1 = on
2 = off
4L to 4H
During Blinking No
On Off Off 1,1,0,1
operation (2HZ) operation
driving
During
4L to 4H
Blinking No
(2HZ) operation
(N)
neutral
4L to 4H
During Blinking No 0,1,0,1
Off Off Off
driving
4L to 4H
4H Blinking No
Off Off Off 0,0,1,1
waiting
No
operation
Switch
operation second
sensor
0,1,1,1
2H to 4H
Off Off Off
driving
1,1,1,0
0,1,1,1
During
Blinking No 0,1,1,0
Open Open Closed Axle drive
(Axle)
1,1,1,0
Axle Blinking No
Axle
Off Off Off 1,0,1,0
Open Open Closed
waiting
No
operation
2H to 4H retrial
Actuator
detection
SOF
(limit)
Check
actuator
switches
Transfer Transfer
4WD Neutral 4WD 4WD
switch
4WD neutral Remarks
Or
LS3. and
switch switch
light
Axle
LS4
dummy
1 = on
2 = off
No
operation
4H
4H start
position
of Off Off Off Off 1,0,1,0
for 0.1
operation
second
1,1,1,0
2H to 4H
Off Off Off
driving
0,1,1,1
During
2H to 4H
operation 1,1,1,0
using
(Synchro) Blinking No 0,0,1,0
Off Off Off
Open Open Open synchro
(Go to 4H (2HZ) operation 0,1,1,0
and retrial
if synchro 0,1,1,1
X2
complete)
Abandon
ed Blinking No
Return to
Off Off Off 1,0,1,0
Open Open Open
2H
(2H)
2H
indication
No
after Off Off Off Off 1,0,1,0
operation
10second
s
• Completion of transfer case H-L area and axle shift timing may cause some
variation in the 2Hz blinking pattern.
Operational limits (4H 4L) (Vehicle speed, engine speed, and transmission
position not specified)
Actuator
detection
SOF
(limit)
Check
actuator
switches
Transfer Transfer
4WD Neutral 4WD 4WD
switch
Item 4L lamp LS1, LS2, 4WD
neutral Remarks
Or
LS3. and switch
switch
light
Axle
LS4
dummy
1 = on
2 = off
4H On Off Off Off Open 0,0,1,1 Closed
Open Closed -----
4L
4H start
position
of On Off Off Off 0,0,1,1 Closed
Open Closed -----
for 0.1
operation
second
10
No
second
Blinking
operation
display On Off Off Open 0,0,1,1 Closed
Open Closed
(4HZ)
during
during
limitation
limitation
Go to 4H
after 10 On Off Off Off Open 0,0,1,1 Closed
Open Closed -----
seconds
Operational limits (4L 4H) (Vehicle speed, engine speed, and transmission
position not specified)
Actuator
detection
SOF
(limit)
Check
actuator
switches
Transfer Transfer
4WD Neutral 4WD 4WD
switch
Item 4L lamp LS1, LS2, 4WD
neutral Remarks
Or
LS3. and
switch switch
light
Axle
LS4
dummy
1 = on
2 = off
No
4L On On Off Off 1,1,0,1 Closed
Open Closed -----
operation
4H
4L start of position
On On Off Off 1,1,0,1 Closed
Open Closed -----
operation for 0.1
second
10
No
second
Blinking
operation
display On Off Off Open 1,1,0,1 Closed
Open Closed
(4HZ)
during
during
limitation
limitation
Go to 4L
No
after 10 On On Off Off 1,1,0,1 Closed
Open Closed -----
operation
seconds
• Under some conditions, a secondary operational indication may be received when

the 4Hz operational indication
is present.

Skip operation
Actuator
detectio
n (limit)
SOF
Check switches
actuator
Transfer Transfer
4WD Neutral 4WD 4WD LS1,
switch
Item 4L lamp
4WD neutral Remarks
lamp lamp warning switch LS2,
Or
switch switch
light LS3. and
Axle
LS4
dummy
1 = on
2 = off
No
operation
4L
Switch
Off Off Off Off 1,0,1,0
operation for 0.1
sensor
second
1,1,1,0
2H to 4H
Start of Blinking Blinking No 0,0,1,0
Off Off
operation (2HZ) (2HZ) operation 0,1,1,0
driving
0,1,1,1
1,1,1,0
2H to 4H
During
Blinking Blinking No 0,0,1,0
using
operation Off Off
Open Open Open
(2HZ) (2HZ) operation 0,1,1,0
synchro
(Synchro)
0,1,1,1
and retrial
During
operation
Blinking No
(Passing Off Off Off 0,0,1,1
Closed Open Open -----
(2HZ) operation
through
4H)
During
operation
Blinking No 0,0,1,1
(Passing Off Off Off
through
4H)
During
Blinking No 0,0,1,1
operation On Off Off
(N)
During
Switch
Blinking No
operation On Off Off 0,1,0,0
(2HZ) operation
(N)
sensor
During
4H to 4L
Blinking No
operation On Off Off 0,0,1,1
(2HZ) operation
(N)
driving
During
operation Blinking Blinking No
Off Off 0,0,1,1
(Axle (2HZ) (2HZ) operation
drive)
Axle Blinking Blinking No
Off Off 0,0,1,1
waiting (2HZ) (2HZ) operation
4H to 4L
Blinking No
4L waiting On Off Off 1,1,0,1
(2HZ) operation
waiting
No
operation
Actuator
detectio
n (limit)
SOF
switches
actuator
Check
Transfer Transfer
4WD Neutral 4WD LS1,
switch
Item 4L lamp 4WD
4WD neutral Remarks
lamp lamp switch LS2,
Or
lamp
switch switch
LS3. and
Axle
LS4
dummy
1 = on
2 = off
2H
Switch
2H start of position
On On Off Off 1,1,0,1
operation for 0.1
sensor
second
4L to 4H
During Blinking Blinking No
Off Off 1,1,0,1
operation (2HZ) (2HZ) operation
driving
During
operation
4L to 4H
Blinking No
(Passing On Off Off 1,1,0,0
(2HZ) operation
through
neutral
N)
During
operation
4L to 4H
Blinking No
(2HZ) operation
through
neutral
N)
During
4L to 4H
Off Off Off 0,0,1,1
(4H (2HZ) operation
waiting
waiting)
Blinking
Off while (2HZ) 0,1,1,1
During
2H to 4H
waiting for while No 0,1,1,0
operation Off Off
start of H waiting for operation 0,0,1,0
(Axle)
driving
shift start of H 1,1,1,0
shift
Blinking 0,1,1,1
During
(2HZ) at Off at end No 0,1,1,0
Axle
operation Off Off
Closed Open Closed
end of H of H shift operation 0,0,1,0
driving
(Axle)
shift 1,1,1,0
Axle Blinking No
Off Off Off 1,0,1,0
Open Open Closed -----
No
operation
• Completion of transfer case H-L area and axle shift timing may cause some
variation in the 2Hz blinking pattern.
Skip operation limitations (4L 2H) (Vehicle speed, engine speed, and
transmission position not
specified)
Actuator
detection
SOF
(limit)
Check
actuator
switches
Transfer Transfer
4WD Neutral 4WD 4WD
switch
4WD neutral Remarks
Or
LS3. and
switch switch
light
Axle
LS4
dummy
1 = on
2 = off
4L Off On Off Off Open 1,1,0,1
2H
Off On Off Off 1,1,0,1
operation for 0.1
second
10
No
second
Blinking
operation
display Off Off Off Open 1,1,0,1
Closed Open Closed
(4HZ)
during
during
limitation
limitation
Go to 4L
after 10 Off ON Off Off Open 1,1,0,1
seconds
Skip operation limitations (2H 4L) (Vehicle speed, engine speed, and
transmission position not
specified)
Actuator
detection
SOF
(limit)
Check
actuator
switches
Transfer Transfer
4WD Neutral 4WD 4WD
switch
4WD neutral Remarks
Or
LS3. and
switch switch
light
Axle
LS4
dummy
1 = on
2 = off
2HL Off Off Off Off Open 1,0,1,0
2H
Off Off Off Off 1,0,1,0
operation for 0.1
second
10
No
second
Blinking Blinking
operation
display Off Off Open 1,0,1,0
Open Open Open
(4HZ) (4HZ)
during
during
limitation
limitation
Go to 2H
after 10 Off Off Off Off Open 1,0,1,0
seconds
Under some conditions, a secondary operational indication may be received when

the 4Hz operational
indication is present.

2H→Neutral→2H
Actuator
detectio
n (limit)
SOF
Check switches
actuator
Transfer Transfer
switch
Item 4L lamp 4WD
neutral Remarks
Or
switch switch
light LS3. and
Axle
LS4
dummy
1 = on
2 = off
No
2H Off Off Off Off 1,0,1,0 Open
Open Open -----
operation
Neutral
Neutral
Switch
position
start of Off Off Off Off 1,0,1,0 Open
Open Open operation
for 10
operation
sensor
seconds
1,1,1,0
2H to 4H
Off Off Off Open
Open Open while
driving
0,1,1,1
1,1,1,0
2H to 4H
During
Blinking No 0,0,1,0
using
operation Off Off Off Open
Open Open
synchro
(Synchro)
0,1,1,1
and retrial
During
operation
Blinking No
(2HZ) operation
through
4H)
During
operation
4H to 4L
Blinking No 0,0,0,1
(Passing Off Off Off
through
driving
4H)
During
4H to 4L
Blinking No 0,0,0,1
(N)
neutral
During
Switch
Blinking No
Closed Closed Closed operation
(2HZ) operation
(N)
sensor
No
Neutral Off Off On Off 0,1,0,0
Closed Closed Open -----
operation
2H
Switch
2H start of position
Off Off On Off 0,1,0,0
operation for 10
sensor
seconds
During
operation
4L to 4H
Blinking No
(2HZ) operation
through
neutral
N)
4L to 4H
Off Off Off
driving
Actuator
detectio
n (limit)
SOF
Check switches
actuator
Transfer Transfer
switch
Item 4L lamp
4WD neutral Remarks
Or
switch switch
light LS3. and
Axle
LS4
dummy
1 = on
2 = off
During
4L to 4H
Off Off Off 0,0,1,1
(4H (2HZ) operation
waiting
waiting)
0,1,1,1
During
2H to 4H
Blinking No 0,1,1,0
(Axle)
driving
1,1,1,0
0,1,1,1
During
Blinking No 0,1,1,0
Axle
Open Open Closed
driving
(Axle)
1,1,1,0
Axle Blinking No
Off Off Off 1,0,1,0
No
operation
• Operational restrictions (vehicle speed, engine speed, and transmission position)

are applicable to transfer shifts
in both directions (H←→Neutral←→L).
4H Neutral 4H
Actuator
detection
SOF
(limit)
Check
actuator
switches
Transfer Transfer
4WD Neutral 4WD 4WD
switch
4WD neutral Remarks
Or
LS3. and
switch switch
light
Axle
LS4
dummy
1 = on
2 = off
No
operation
Neutral
Neutral
position
start of On On Off Off 1,1,0,1
for 10
operation
seconds
4L to N
Start of Blinking No
Off Off Off 1,1,0,0
driving
During
4L to N
Blinking No
Closed Closed Closed with axle
(2HZ) operation
(N)
driving
During
4L to 4N
Blinking No
(2HZ) operation
(N)
removed
0,1,1,1
During
Blinking No 0,1,1,0
Axle
Open Open Closed
driving
(Axle)
1,1,1,0
Axle Blinking No
Off Off Off 1,0,1,0
No
operation
2H
4H start
Switch
position
of Off Off Off Off 0,1,0,0
for 10
operation
sensor
seconds
During
4L to 4H
Blinking No
Closed Closed Open through
(2HZ) operation
(N)
neutral
During
4L to 4H
Blinking No
(2HZ) operation
(N)
neutral
4L to 4H
Off Off Off
Closed Closed Open while
driving
4L to 4H
4H Blinking No
Off) Off Off 0,0,1,1
Closed Closed Open while
waiting
During
Blinking No
Axle
Closed Open Open
(2HZ) operation
driving
(Axle)
Axle Blinking No
Off Off Off 0,0,1,1
No
operation
TRANSFER

4L Neutral 4L
Actuator
detection
SOF
(limit)
Check
actuator
switches
Transfer Transfer
4WD Neutral 4WD 4WD
switch
4WD neutral Remarks
Or
LS3. and
switch switch
light
Axle
LS4
dummy
1 = on
2 = off
No
operation
Neutral
Neutral
position
start of On On Off Off 1,1,0,1
for 10
operation
seconds
4L to N
Start of Blinking No
Off Off Off 1,1,0,0
driving
During
4L to N
Blinking No
(2HZ) operation
(N)
driving
During
4L to 4N
Blinking No
(2HZ) operation
(N)
removed
During
Blinking No
Axle
Closed Closed Closed
(2HZ) operation
driving
(Axle)
Axle Blinking No
Off Off Off 0,1,0,0
Closed Closed Closed -----
No
operation
4L
Switch
Off Off On Off 0,1,0,0
operation for 10
sensor
seconds
During
4H to 4L
Blinking No
(2HZ) operation
(N)
neutral
During
4H to 4L
Blinking No
(2HZ) operation
(N)
neutral
During
4H to 4L
Blinking No
(2HZ) operation
(N)
neutral
4H Blinking No
4L while
On Off Off 1,1,0,1
Closed Closed Open
waiting
During
Blinking No
Axle
Closed Open Open
(2HZ) operation
driving
(Axle)
Axle Blinking No
Off Off Off 1,1,0,1
No
4H On On Off Off 1,1,0,1
operation
Parts Location
RUW780XF019501
RUW780XF019601
RTW780XF006301
CIRCUIT DIAGRAM
RUW780XF012901
CONNECTOR LIST
No. Connector face No. Connector face
B23 C95
White White
Meter-A TCM B
B24 C107
White Meter-B White

J/B E2
B56 C108
White White
J/B I4 J/B E1
B62 C109
White Silver
Ignition switch (IGSUB : G1) Body-LH ; ground
B63 C111
White Black
Ignition switch (IGSUB : G2) Transfer case control module
B64 C112
Silver Black
Weld splice 1 (Illumination) Transfer case control module
B65 C134
Silver Gray
Weld splice 2 (Ground) Motor actuator
B66 E10
White Silver
4WD switch Engine ground
C36 E35
Silver Black
Engine room - LH ; Ground Motor actuator (Transfer)
C67 E44
Black Black
EHCU Vehicle speed sensor
No. Connector face No. Connector face

E45 P5
Gray Silver
2WD-4WD switch Battery (-)
E46 P6
Brown Silver
H-L neutral switch Body ground
E51 P10
Black Silver
Inhibiter switch Engine ground
H4 C58
(A/T)
White
Engine ~ Engine room
H5
White Black ECM J1

H7
White
Engine room ~ INST
H41
Gray
INST ~ Engine room
H23
White Engine ~ Engine room B

P1
Silver
Battery (+)
P2
Silver
Relay & Fuse box
TRANSFER
Diagnosis
Before determining a trouble (Non-trouble mode)
1. When shifting from 2H to 4H:
1-1-1 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz
(Shift on the fly)
If the load is too large to shift the gears synchronously, the operation is
repeated up to 3 times. If the shifting
is not effected after being repeated 3 times, the indicator frequency is
changed from 2Hz to 4Hz. At the same
time, the actuator condition is changed to 2H, indicator flashes at 4Hz for 10
seconds, and then goes out.
Cause of excessive synchronous shifting load
• Extremely low temperature (the oil viscosity of the front differential
increases requiring a large load for
synchronization).
• High speed (since the difference of relative revolutions of gears to be
shifted synchronously is too large,
required work load per unit time becomes larger).
Step 1-1-1:
Stop the vehicle or decrease the speed and operate as required again.
1-1-2 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz
(Rigid and free wheel
Hub) / Block out of meshing spline in transfer case.
Step 1-1-2:
Run the vehicle forward and backward several meters and operate as required
again.
1-2 When the flashing of 4WD indicator at 2Hz continues more than 11.5 seconds
(repetition of 3 times of
above No.1 is counted) (Shift on the fly)
If there is difference of revolutions and phases between the front wheel and
the axle, connecting the front
wheel and axle is difficult.
Until shifting in the transfer and connection of the front wheel and axle are
completed∗, the indicator flashes at
a frequency of 2Hz. In the above case, the indicator continues flashing at a
frequency of 2Hz until the
connection of the front axle is completed. (If the shifting in the transfer is
not completed, the flashing
frequency is changed to 4Hz (above No.1).)
By correcting the difference of relative revolutions and deviation of phases,
the shifting can be completed.
Step 1-2:
While the vehicle is running, check it is safe around the vehicle and then
accelerate or decelerate the
vehicle while going straight.
When the vehicle is at a stop, run the vehicle forward and backward several
meters.
2. When shifting from 4H to 2H

2-1 When 4WD indicator continues flashing at 2Hz
When shifting from 4H to 2H, the 4WD indicator continues flashing at 2Hz until
separation in the transfer and
the separation of the front wheel axle are completed∗. When torsional torque is
accumulated in the drive
system, separation in the transfer and separation of the front axle∗ is
difficult. In such a case, they can be
separated by removing the torsional torque of the drive system.
Step 2-1:
While the vehicle is running, check it is safe around the vehicle and then
accelerate or decelerate the
vehicle while going straight.
When the vehicle is in stop, run the vehicle several meters forward and backward.
∗: Shift on the fly only.

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 deviate 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
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.
Due to 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
for 3 minutes. After that, the waiting time increases up to 3 minutes in 2 minute
intervals.
When it is clear that the above condition has continued and reduction of waiting
time is required, 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 or below is advisable.
Requirements for permission of restriction on T/M position restriction:
(AT) N range is recommended
(MT) should be at the neutral.
These requirements for permission should all be 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
Step 3-3:
Stop the vehicle. (Close the accelerator and decrease the engine speed to below
L4: 3000rpm, V6:
2000rpm.)
(In case of AT): Set the transmission select lever to the N position.
(In case of MT): Set the transmission lever to the neutral position. (Stepping on
the clutch is
recommended.) Push the 4L button.
If shifting operation is not completed (the lamp flashes at 2Hz), perform step 3-
1.
4. Shifting from 4L to 4H
4-1 When 4L indicator continues flashing at 2Hz
When shifting from 4L to 4H, the 4L indicator continues flashing at 2Hz until
the shifting in the transfer case is
completed. Phases of engaged splines may deviate and the operation may not be
completed in some cases.
Shifting is completed by correcting the deviation of the splines.
Step 4-1: (same as step 3-1)

(In case of AT): Set the transmission select lever to the D position.
(In case of MT): Shift the transmission lever to a position allowing running
and engage the clutch
gently.
4-2 When the indicator continues flashing at 2Hz for 10 seconds and then keeps on
at 4L again (AT
vehicle)
This condition occurs when torsional torque has been generated between the
transmission and the road
surface (use of the parking position on a slope). Resistance against the
separation of the driving force cannot
be completed by the waiting mechanism of the transfer.
Shifting is also possible by using the brake at the neutral position of the
transmission
Step 4-2: (Same procedure as the step 3-2)

Set the transmission select lever to the N position.
(Leaving the brake lever and stepping on it again is recommended.)
4-3 When the 4L indicator flashes at 4Hz

Shifting from 4L to 4H is restricted.
When the vehicle is running, the transmission lever is at the running range,
and the engine speed is high, the
transfer 4L cannot be shifted to 4H.
Step 4-3: (Same procedure as the step 3-3)

Stop the vehicle (close the accelerator and decrease the engine speed to L4:
3000rpm V6: 2000rpm or
below).
(In case of AT): Set the transmission select lever to the N position.
(In case of MT): Set the transmission lever to the neutral position
(stepping on the clutch lever is
recommended).
Push the 4H button.
If shifting is not complete (indicator flashes at 2Hz), go to step 4-1.
5. When shifting from 4H or 4L to neutral

(Same procedure is required when shifting from 2H but in such a case,
requirements for shifting from
2H to 4H are also applied.)
5-1 Neutral indicator continues flashing at 2Hz
The neutral indicator continues flashing at 2Hz until 4H (4L) is completely
separated in the transfer. If torsional
torque has accumulated between the transmission and road surface, separation
may be difficult.
Step 5-1:
If the operation is not complete, execute step 7 for confirmation.
(In case of AT): Set the transmission select lever to the D position.
After confirming that the gears are at the neutral position,
return the lever to the N
position.
(In case of MT): Set the transmission lever to a vehicle running position and
engage the clutch gently.
After confirming that the gears are at the neutral position,
return the lever to the
neutral position
5-2 When the neutral indicator flashes at 4Hz

As in the case of shifting from 4L to 4H, restriction is imposed to the
operation from 4L or 4H (including 2H). If
the transmission lever is at a running range and engine speed is high (L4:
3000rpm, V6: 2000rpm or more)
while the vehicle is running, operation from the 4L or 4H (including 2H) of the
transfer to the neutral is
impossible (restriction on operation).
Step 5-2:
Stop the vehicle.
(In case of AT): Set the transmission select lever to the N (or P) position.
(In case of MT): Set the transmission lever to the neutral position (at this
time, stepping on the clutch
is recommended).
Keep pushing the 2H and 4L button for 10 seconds.
Follow the start procedure for confirmation. (Confirmation of drive force is not
transferred; same as in
step 5-1)
After the confirmation, set the transmission to the neutral position in the case
of MT or to the neutral
position in the case of AT.
TRANSFER
6. When shifting from neutral to 2H, 4H or 4L

6-1 When the 4L indicator or 4WD indicator flashes at 2Hz
Indicator flashing at 2Hz indicates that the engagement of the splines has not
completed because of deviation
of the spline phases. By eliminating such a deviation, shifting is complete
(same as in step 3-1 and 4-1).
6-2 When the 4L indicator or 4WD indicator flashes at 4Hz
As in the case of shifting from 4L to 4H, restriction is imposed to the
operation to 4L or 4H (including 2H). If
the transmission lever is at a running range and engine speed is high (3000rpm
or more) while the vehicle is
running, operation from neutral of the transfer to the 4L or 4H (including 2H)
is impossible (restriction on
operation).
Step 6-2:
Stop the vehicle.
(In case of AT): Set the transmission select lever to the N (or P) position.
(In case of MT): Set the transmission lever to the neutral position (at this
time, stepping on the clutch
is recommended).
Keep pushing the 4H or 4L or 2H button for 10 seconds.
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, and 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 occurs, inspection of the transfer shift actuator, checking
of the harness related with the
detection (limit) switch, and erasure of the memory of the controller is
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:
During 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 during this condition, a limit SW trouble is judged
and the above-described
“Check 4WD” condition is occurs.
This can be reset by clearing the memory.
When disconnecting the harness connector of the actuator and turning the ignition
ON is required, remove
the controller at the same time or remove the IG power fuse of the transfer
controller.
Memory erasing procedure

1-1 Memory erasing with operation button
1. Turn on the ignition.
2. Shift to the “N” position with the vehicle stopped.
3. Simultaneously push the 3 buttons (2H/4H/4L) for 20
seconds.
4. Confirm the “Check 4WD” indicator on the meter panel is
OFF.
5. Before erasing the memory, check that the circuit of the T/F
actuator position detection harness is normal.
RTW77DSH000101
1-2 Memory erasing with short harness (Other procedure)

1. Prepare two pieces of short harness with the end
sharpened like a needle (about 200 mm (7.9 in) long).
2. Turn OFF the ignition.
3. Keeping the connector of the transfer controller connected,
set the short harness from the back of the connector as
illustrated.
4. Turn ON the ignition, wait for 2 seconds, and then turn OFF
the ignition after confirming the relay sound.
5. Disconnect the short harness, turn ON the ignition again,
and confirm the “Check 4WD” lamp on the meter panel is
OFF.
6. Before erasing the memory, check that the circuit of the T/F
actuator position detection harness is normal.
Transfer Controller Pin Assignment
RTW77DSF000201
TRANSFER
Diagnosis from symptom

Check4WD lighting up
Step Action Yes
No
1 Check what was done before the If the power is supplied with the
Go to step 2.
trouble occurred. actuator not connected, a faulty
Was the harness between the position detection switch is
transfer controller and actuator considered.
disconnected with the ignition Clear the memory and trace this
kept ON for the purpose of chart from the beginning.
servicing the vehicle?
Or, was the ignition turned ON
(power supplied to the transfer
controller) with the harness of
the actuator removed?
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 Go to step 4.
Indicator lamp burnt out.
indicators (4WD, 4Lo, Check
Disconnected harness wire.
4WD, neutral) light up for 2
After repairing, trace this chart
seconds when the ignition switch
from the beginning.
is turned ON?
4 Has the harness between the GND (body) short of the indicator
Go to step 5.
Check4WD indicator and harness.
transfer controller GND shorted? After repairing, trace this chart
from the beginning.
5 Check the continuity of harness Repair the harness, clear the
Go to step 6.
between the transfer controller memory and trace this chart from
and transfer actuator. Check the beginning.
the power short and GND short.
Check the GND harness of the
transfer actuator.
Is a trouble noticed?
6 Check the limit switch of the Failed actuator. Replace the
Clear the memory and trace this
actuator. actuator, clear the memory and
chart from the beginning.
Is a trouble noticed? trace this chart from the
Failed controller.
beginning.
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 at least 5
times.
To judge the condition more quickly, ask the customer what happens when the
Check4WD lamp lights up.
When the position indicator blinks at a frequency of 4Hz immediately after trouble
occurs, the 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 at a
standstill, the possibility of failure around that point is high.)
Status of the transfer when the Check4WD lights up is not always the same.
Immediately after failure occurs, 2H
can be operated.
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 Failed operation switch. Or,
indicators (4WD, 4Lo, Check Failed controller
4WD, neutral) light up for 2 After
repairing, trace this chart
seconds when the ignition switch from
the beginning.
is turned ON?
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.
4WD, neutral) light up for 2 After
seconds when the ignition switch from
the beginning.
is turned ON?
3 After 2 seconds, check that the Go to step 4.
Failed actuator position detection
Check4WD lamp is ON or OFF.
switch (LS1, LS2, LS3, LS4,
Is the Check4WD lamp OFF? GND).
Short
or disconnection of harness
of
this detection switch.
After
from
the beginning.
4 Press the 4H button. Go to step 5.
Failed controller.
Is sound of relay heard from the
Replace the controller and trace
transfer control? this
5 Is the sound of a running motor Failed control system of the
Failed actuator motor.
heard? transfer mechanism. Check and
Disconnected controller motor
repair and trace this chart from drive
output circuit, GND short
the beginning.
circuit. +B fuse blown out.
Disconnection of that harness.

After
from
the beginning.
*Before determining a trouble (Non-trouble mode)
TRANSFER
Even after the correction step 1-2(*), the 4WD indicator still blinks at 2Hz when
shifting
from 2H to 4H.
Step Action Yes
No
1 Check the air pressure and wear After adjusting the air pressure Go
to step 2.
of all the tires. Is any trouble and repairing the worn tires, try
noticed? the correction step 1-2(*).
2 Check the 4WD detection switch 4WD detection switch is open or Go
to step 3.
on the transfer case, neutral the harness failed.
detection switch and each The neutral detection switch is
harness. Is a trouble noticed? closed or the harness GND is
shorted.
Replace or repair and then trace
this chart from the beginning.
3 Is there continuity in the harness Go to step 4.
Body short or disconnection of
between the transfer controller
the harness between the transfer
and front axle actuator? Has a
controller and front axle actuator.
body short or disconnection
been detected?
from the beginning.
4 Is trouble detected in the axle Disconnected harness.
Malfunction of axle actuator.
detection harness between the After repairing trace this chart
Refer to the paragraph of the axle
axle actuator and transfer from the beginning.
disconnect.
controller?
from the beginning.

Note:
Vehicles with manual hub and rigid hub don’t have axle actuator.
When the above-mentioned procedure is followed, check the harness between the axle
dummy output terminal and
the axle switch input terminal of the transfer controller, instead of axle
actuator.
After operation, indicator of target position blinks for 1.5 sec. at 2Hz, return to
2H
condition (4WD indicator going out)
Step Action Yes
No
1 Keep pressing the 4H button Failed actuator motor. Go
to step 2.
(about 10 seconds). Disconnection of controller motor
Does the 4WD indicator blink at drive output circuit, or GND short.
2Hz for 15 seconds and then +B fuse blown out.
blink at 4Hz? Disconnection of that harness.
from the beginning.
Failed controller.
Is the sound of relay heard from
the transfer controller?
3 Is the sound of running motor Failed control system of the
heard? transfer mechanism. Check and
Disconnection or GND short of
repair and trace this chart from
controller motor drive output
the beginning.
circuit.
from the beginning.

TRANSFER
Transfer cannot shift to another position (Except “Check 4WD” failure).

When shifting to another position, indicator (4WD, 4Lo, Check4WD, neutral) does not
respond (Current condition keeping).
Step Action Yes
No
Failed indicator and harness
(When lighting).
from the beginning.

All indicators are burnt out
(Check for GND short circuit
between the indicator and
transfer controller).
is turned ON?
from the beginning.

3 Press the other positions button. Failed controller.
*Failed operation switch. Or
Is the sound of relay heard from After replacing the controller,
harness for the operation switch
under the seat, and the sound of trace this chart from the
has disconnected or shorted.
a running motor heard? beginning.
* The operation switch is an analog type switch which reads the internal composite
resistance value at the time of
operation. If an abnormal value is detected, it is kept at the home position (The
position before operating it).
Even after the correction step 2-1(*), the 4WD indicator still blinks at 2Hz when
shifting
from 4H to 2H.
Step Action Yes
No
1 Check all the tires for air After adjusting the air pressure
Go to step 2.
pressure and wear. Is any and repairing the worn tires, try
trouble detected? the correction step 2-1(*).
2 Check the 4WD detection switch 4WD detection switch is closed
Go to step 3.
on the transfer case and neutral or the GND short of harness.
detection switch and each The neutral detection switch is
harness. Is a trouble detected? closed or the harness GND has
shorted.
Replace or repair and then trace
3 Is there continuity in the harness Go to step 4.
Body short, disconnection or
between the transfer controller
incorrect connection of the
and axle actuator?
harness between the transfer
Has a short or disconnection
controller and actuator.
been detected?
Is the connection incorrect?
from the beginning.
4 Is trouble detected in the axle GND short of harness
Malfunction of axle actuator.
detection harness between the
Refer to the paragraph of axle
axle actuator and transfer
disconnect.
controller?
from the beginning.

Note:
Vehicles with manual hub and rigid hub don’t have axle actuator.
When the above-mentioned procedure is followed, check the harness between the axle
dummy output terminal and
the axle switch input terminal of the transfer controller, instead of axle
actuator.
TRANSFER
Though the indicator responds when shifting from 4H to 2H(or other position), it
returns
to 4H.
Step Action Yes
No
Turn the ignition switch ON and
trace this chart from the
beginning.
from the beginning.
is turned ON?
3 After 2 seconds, check if the Go to step 4.
Failed actuator position detection
Check4WD lamp lights up.
(limit) switch (LS1, LS2, LS3,
Is the Check4WD lamp OFF?
LS4, GND).
Short or disconnection of harness
of this detection switch.
Refer to paragraph of
Check4WD.
from the beginning.

Failed controller.
Is the sound of relay heard from
the transfer controller?
5 Is the sound of a running motor Failed control system of the
heart? transfer mechanism. Check and
Disconnection of controller motor
repair and trace this chart from
drive output circuit or GND short.
the beginning.
from the beginning.

If the motor does not or cannot run at all (stuck transfer mechanism, disconnected
motor, failed drive circuit), the
lamp blinks at 4Hz when the position is shifted to other position by pressing the
button for more 10 seconds (20
seconds in case of neutral position).
From 4H to 4L; Even after the correction step 3-3(*), 4Lo indicator blinks at 4Hz
Step Action Yes
No
1 Is the ignition switch ON? Turn it OFF once. Go
to step 2.
2 Turn ON the ignition switch and Go to step 3.
Refer to the paragraph about the
check the valve. Do not start
indicator when it does not react
the engine.
when shifted from 2H to 4H.
Has the valve check for 2
After taking the remedy, trace this
seconds been completed
normally?
3 Shift to 2H. Go to step 4.
Refer to the paragraph about
Can be shifted to 2H and then to
shifting from 2H to 4H.
4H? In
particular, check if not at the
Check4WD condition, return to
this chart and trace it from the
beginning.
4 Set to N position in case of AT Failed T/M position switch and
Shift back to 4H and go to step 5.
and set to the neutral position in harness (failure of TM1 and TM2
case of MT and check if the harness and their related
lamp blinks at 4Hz after switches shown in the figure).
operation. Incorrect wiring.
Repair as required and trace this
5 Start the engine and use the Go to step 6.
Failure of speed sensor or
vehicle.
disconnection or short of harness
Does the speedometer run at
(for the meter).
this time?
from the beginning.

6 Check the harness between the Failed harness between the Go
to step 7.
transfer controller and speed transfer controller and speed
sensor. sensor.
(Check the engine rotation After repairing, trace this chart
detection harness at the same from the beginning.
time.) (Repair the engine rotation
Is any trouble detected? detection unit, if required.)
7 Run the vehicle for several Failed controller.
You did not wait for enough time.
meters, stop it, meet the Replace the controller and trace
Optimum waiting time is 1 second
permission requirements for this chart from the beginning. or
maximum 3 minutes
operation limits.
depending on the previous
Did you wait for several seconds
conditions.
after the requirements were
met?
operation without failure.
TRANSFER
From 4L to 4H: After the correction step 4-3(*), 4Lo indicator blinks at 4H.
Step Action Yes
No
1 Is the ignition switch ON? Turn it OFF once. Go
to step 2.
check the valve. Do not start
the engine.
when shifted from 2H to 4H.
normally?
3 Can be shifted to 2H and then to Go to step 4. In
case of Check 4WD, shifting to
4L? (Impossible usually.) 2H
is possible.
Failed controller
Returning to 4L is impossible.
Check4WD.
Press the operation switch of 4L
and go to step 5.
case of MT and check if the harness and their related
lamp blinks at 4Hz after switches shown in the figure).
operation. Incorrect wiring.
vehicle.
Does the speedometer run at
(for the meter).
this time?
from the beginning.

to step 7.
sensor. sensor.
Is any trouble noticed? detection unit, if required.)
7 Run the vehicle for several Failed transfer controller.
maximum 3 minutes
operation limits.
conditions.
after the requirements were
met?
To neutral: After the correction step 5-2(*), neutral indicator blinks at 4Hz.
Check the function between H and L according to the chart for 4L to 4H instead of
check
for the requirements of neutral.
Step Action Yes
No
1 Is the ignition switch ON? Turn it OFF once.
Go to step 2.
check the valve. Do not start the
engine.
when shifted from 2H to 4H (7D1-
37).
normally?
3 Can be shifted to 2H and then to Go to step 4.
4L? (Impossible usually.)
shifting from 2H to 4H.
Failed controller In
particular, check if not at the
Check4WD condition, return to
this chart and trace it from the
beginning.
In
case of Check4WD, shifting to
2H
is possible.
Returning to 4H is impossible.
Check4WD.
Shift back to 4H and go to step 5.
case of MT and check if the lamp harness and their related
blinks at 4Hz after operation. switches shown in the figure).
Incorrect wiring.
vehicle.
Does the speedometer run at this
(for the meter).
time?
from the beginning.

to step 7.
sensor. sensor.
Is any trouble noticed? detection unit, if required.)
7 Run the vehicle for several Failed controller.
maximum 3 minutes
operation limits.
conditions.
after the requirements were met?

For shifting to neutral, 2H and 4L switches should be pressed at the same time for
10 seconds.
For shifting from neutral to other position, 2H, 4H or 4L switch should be pressed
for 10 seconds.
When shifting from neutral to other position, the lamp blinking at 2Hz indicates
active condition.
When the lamp keeps blinking at 2Hz, follow the step for the case when the lamp
keeps blinking at 2Hz when
shifting between positions.
UCT150-WE-1101
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all countries

except the USA and Canada.
All rights reserved, This manual may not be

reproduced in whole or in part, without the permission
in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Tokyo, Japan
First edition Aug., 2010 1008-01K

No. UCT150-WE-1101

Isuzu D Max 2011 Transfer Case Service Manual

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Isuzu D Max 2011 Transfer Case Service Manual

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WORKSHOP MANUAL

Isuzu Motors Limited

The transfer case is used to provide a means of

Transfer Case Oil Change

Transfer Case Front Oil Seal

Legend (3) O-ring

Removal 8. Remove the front oil

Installation 8. Use a punch (5-

4. Install the output flange to the front output shaft.

9. Install the drain plug to the transfer case and tighten it

Transfer Case Rear Oil Seal

3. Tap the oil seal in to place, use an oil seal installer

4. Install the rear propeller shaft.

Transfer Case Assembly

2. Install transfer case assembly to the transmission.

3. Connect harness connectors and clip.

Transfer Control Unit

Removal • Speedometer bushing,

• 2-4 switch assembly (Gray harness cover) 6. Strike the area

5. Remove the bolts attaching the rear cover to the

8. Remove the oil pump

Legend (8) Thrust Washer

15. Remove the snap ring from the main shaft.

20. Remove the

27. Use a sliding

23. Remove the retaining ring (spiral type) together with

24. Remove the snap ring.

Internal Component Disassembly and Reassembly H-L Shift Disassembly

5. Use a socket and a vise to

H-L shift reassembly 2-4 shift ASM

Legend 2-4 shift

2-4 shift reassembly Oil pump reassembly

3. Install the spring. Legend

Inspection and Repair 2-4 and Neutral

Inspection and Repair (Transfer Case

sprocket inside sliding surface, replace the part.

Oil Pump Ball Bearing Play

Block Ring and Insert Clearance

Clutch Hub and Insert

Detent Spring Free Length

Shift Arm Thickness

Note the direction

2. Use a press to install the ball bearings to the front

4. Use a press and an installer (5-8840-2784-0) to hold

7. Install the carrier

6. Use a press and an appropriate special tool to force

11. Use a press to install the 2-4 hub.

12. Install the hub snap ring.

14. Insert the H-L sleeve into the main shaft.

15. Install the sleeve to the H-L shift assembly.

NOTE: Be careful in the direction of an assembly. 20. Coat the main

26. Measure the

29. Install the

30. Temporarily install the speedometer drive gear to the

35. Apply Loctite

32. Install the rear output shaft retaining ring.

Front companion flange end nut torque:

42. Apply Loctite

41. Use a punch (5-8840-2293-0) to caulk the front

43. Use an installer (5-8840-2787-0) to install the main

45. Install the

Main Data and Specifications

Transfer Position and Drive Mode