Transfer Izusu Dimax

BACK TO CHAPTER INDEX ISUZU KB P190 2007
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TRANSFER CONTROL SYSTEM 7D1-3
General Description
RTW77DLF000501
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
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7D1-4 TRANSFER CONTROL SYSTEM
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.
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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 4u2 - 4u4 sleeve.
PUSH open is achieved with the PUSH open switch when the
shift rod is at the 4u2 position.
u2 - 4u
4u u4 sleeve & Arm
The 4u2 - 4u4 sleeve moves directly in the 4u4 direction with
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the 4u2 - 4u4 shift rod. When moving in 4u2 direction, a spring
standby mechanism is provided between the rod and sleeve so
that the rod is positioned at the 4u2 position, while the sleeve is
at the 4u4 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 4u2 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
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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
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Transfer controller
RHD
RTW77DMF000101
Legend
(1) Transfer Controller
(2) Nut
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LHD
RUW77DMF000101
Legend
(1) Transfer Control Unit
(2) Nut
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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 -54q to 74q to 179q to 215q to 285q to
-29q to 74q 110q to 179q
shaft notch (outline) -29q 110q 215q 285q 300q
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
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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
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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
4H to 4L
On Off Off Closed Open Closed while
driving
During 4H to 4L
Blinking No 0,0,0,1
operation Off Off Off Closed Closed Closed through
(N) neutral
During 4H to 4L
Blinking No
operation Off Off Off 0,1,0,0 Closed Closed Closed through
(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 Closed Open Closed -----
operation
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Actuator
detection
SOF
(limit)
Check actuator
light Axle
LS4
dummy
1 = on
2 = off
4L to 4H
During Blinking No
On Off Off 1,1,0,1 Closed Open Closed while
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 Closed Closed Closed while
driving
4L to 4H
4H Blinking No
Off Off Off 0,0,1,1 Closed Closed Closed while
waiting
No
operation
0,1,1,1
2H to 4H
Off Off Off Closed Open Closed while
driving
1,1,1,0
0,1,1,1
During
Blinking No 0,1,1,0
operation Off Off Off 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 (2HZ) operation waiting
No
operation
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2H to 4H retrial
Actuator
detection
SOF
(limit)
Check actuator
light Axle
LS4
dummy
1 = on
2 = off
No
operation
4H
4H start
position
of Off Off Off Off 1,0,1,0 Open Open Open -----
for 0.1
operation
second
1,1,1,0
2H to 4H
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
operation (4HZ) operation 2H
(2H)
2H
indication
No
after Off Off Off Off 1,0,1,0 Open Open Open -----
operation
10second
s
x Completion of transfer case H-L area and axle shift timing may cause some variation in the 2Hz blinking pattern.
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Æ4L)
Operational limits (4HÆ (Vehicle speed, engine speed, and transmission position not specified)
Actuator
detection
SOF
(limit)
Check actuator
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
Æ4H)
Operational limits (4LÆ (Vehicle speed, engine speed, and transmission position not specified)
Actuator
detection
SOF
(limit)
Check actuator
light Axle
LS4
dummy
1 = on
2 = off
No
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
x Under some conditions, a secondary operational indication may be received when the 4Hz operational indication
is present.
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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 Open Open Open operation
operation for 0.1
sensor
second
1,1,1,0
2H to 4H
Start of Blinking Blinking No 0,0,1,0
Off Off Open Open Open while
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 Closed Open Open -----
through
4H)
During
Blinking No 0,0,1,1
operation On Off Off Closed Open Closed -----
(N)
During Switch
Blinking No
operation On Off Off 0,1,0,0 Closed Open Closed operation
(2HZ) operation
(N) sensor
During 4H to 4L
Blinking No
operation On Off Off 0,0,1,1 Closed Open Closed while
(2HZ) operation
(N) driving
During
operation Blinking Blinking No
Off Off 0,0,1,1 Closed Open Open -----
(Axle (2HZ) (2HZ) operation
drive)
Axle Blinking Blinking No
Off Off 0,0,1,1 Closed Open Open -----
waiting (2HZ) (2HZ) operation
4H to 4L
Blinking No
4L waiting On Off Off 1,1,0,1 Closed Closed Closed while
(2HZ) operation
waiting
No
operation
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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
2H start Switch
position
of On On Off Off 1,1,0,1 Closed Open Closed operation
for 0.1
operation sensor
second
4L to 4H
During Blinking Blinking No
Off Off 1,1,0,1 Closed Open Closed while
operation (2HZ) (2HZ) operation
driving
During
operation 4L to 4H
Blinking No
(Passing On Off Off 1,1,0,0 Closed Closed Closed through
(2HZ) operation
through neutral
N)
During
operation 4L to 4H
Blinking No
(Passing Off Off Off 0,1,0,0 Closed Closed Closed through
(2HZ) operation
through neutral
N)
During
4L to 4H
(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 Closed Open Closed while
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
x Completion of transfer case H-L area and axle shift timing may cause some variation in the 2Hz blinking pattern.
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Æ2H)
Skip operation limitations (4LÆ (Vehicle speed, engine speed, and transmission position not
specified)
Actuator
detection
SOF
(limit)
Check actuator
light Axle
LS4
dummy
1 = on
2 = off
4L Off On Off Off Open 1,1,0,1 Closed Open Closed -----
2H
Off On Off Off 1,1,0,1 Closed Open Closed -----
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 Closed Open Closed -----
seconds
Æ4L)
Skip operation limitations (2HÆ (Vehicle speed, engine speed, and transmission position not
specified)
Actuator
detection
SOF
(limit)
Check actuator
light Axle
LS4
dummy
1 = on
2 = off
2HL Off Off Off Off Open 1,0,1,0 Open Open Open -----
2H
Off Off Off Off 1,0,1,0 Open Open Open -----
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 Open Open Open -----
seconds
y Under some conditions, a secondary operational indication may be received when the 4Hz operational
indication is present.
TO MODEL INDEX

2HoNeutralo2H
Actuator
detectio
n (limit) SOF
Transfer Transfer
switch switch
light LS3. and Axle
LS4 dummy
1 = on
2 = off
No
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
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
(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 Closed -----
(2HZ) operation
through
4H)
During
operation 4H to 4L
Blinking No 0,0,0,1
(Passing Off Off Off Closed Open Closed while
through driving
4H)
During 4H to 4L
Blinking No 0,0,0,1
operation Off Off Off Closed Closed Closed through
(N) neutral
During Switch
Blinking No
operation Off Off Off 0,1,0,0 Closed Closed Closed operation
(2HZ) operation
(N) sensor
No
Neutral Off Off On Off 0,1,0,0 Closed Closed Open -----
operation
2H
2H start Switch
position
of Off Off On Off 0,1,0,0 Closed Open Closed operation
for 10
operation sensor
seconds
During
operation 4L to 4H
Blinking No
(Passing Off Off Off 0,1,0,0 Closed Closed Closed through
(2HZ) operation
through neutral
N)
4L to 4H
Off Off Off Closed Closed Closed while
driving
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Actuator
detectio
n (limit) SOF
Transfer Transfer
switch switch
light LS3. and Axle
LS4 dummy
1 = on
2 = off
During
4L to 4H
(4H (2HZ) operation
waiting
waiting)
0,1,1,1
During 2H to 4H
Blinking No 0,1,1,0
operation Off Off Off Closed Open Closed while
(Axle) driving
1,1,1,0
0,1,1,1
During
Blinking No 0,1,1,0 Axle
operation Off Off Off Open Open Closed
(2HZ) operation 0,0,1,0 driving
(Axle)
1,1,1,0
Axle Blinking No
No
operation
x Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer shifts
in both directions (HmoNeutralmoL).
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ÆNeutralÆ
4HÆ Æ4H
Actuator
detection
SOF
(limit)
Check actuator
light Axle
LS4
dummy
1 = on
2 = off
No
operation
Neutral
Neutral
position
start of On On Off Off 1,1,0,1 Closed Open Closed -----
for 10
operation
seconds
4L to N
Start of Blinking No
Off Off Off 1,1,0,0 Closed Open Closed while
driving
During 4L to N
Blinking No
operation Off Off Off 1,1,0,0 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
operation Off Off Off Open Open Closed
(2HZ) operation 0,0,1,0 driving
(Axle)
1,1,1,0
Axle Blinking No
No
operation
2H
4H start Switch
position
of Off Off Off Off 0,1,0,0 Open Open Open operation
for 10
operation sensor
seconds
During 4L to 4H
Blinking No
operation Off Off Off 1,1,0,0 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
operation Off Off Off 0,0,1,1 Closed Open Open
(2HZ) operation driving
(Axle)
Axle Blinking No
Off Off Off 0,0,1,1 Closed Open Open -----
No
operation
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ÆNeutralÆ
4LÆ Æ4L
Actuator
detection
SOF
(limit)
Check actuator
light Axle
LS4
dummy
1 = on
2 = off
No
operation
Neutral
Neutral
position
start of On On Off Off 1,1,0,1 Closed Open Closed -----
for 10
operation
seconds
4L to N
Start of Blinking No
Off Off Off 1,1,0,0 Closed Open Closed while
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
operation Off Off Off 0,1,0,0 Closed Closed Closed
(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 Open Open Open operation
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 (2HZ) operation waiting
During
Blinking No Axle
operation Off Off Off 1,1,0,1 Closed Open Open
(Axle)
Axle Blinking No
Off Off Off 1,1,0,1 Closed Open Open -----
No
4H On On Off Off 1,1,0,1 Closed Open Closed -----
operation
TO MODEL INDEX
Parts Location
RHD
RTW78AXF040501
TO MODEL INDEX
LHD
RTW78AXF040601
TO MODEL INDEX
RHD
RTW78AXF046701
TO MODEL INDEX
LHD
RTW78AXF046801
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C24SE
C56
E70
E60
To E6, E7, E8, E9
E72
H34
To E64, E75
To E18
E84
To E66
To E85
E59
E69
E65
E2
TO MODEL INDEX
4JJ1-TC / 4JK1-TC
RTW78AXF048601
TO MODEL INDEX
4JH1-TC
RTW78AXF049401
TO MODEL INDEX
RTW78AXF035901
TO MODEL INDEX
RTW78AXF036001
TO MODEL INDEX
CIRCUIT DIAGRAM
C24SE
RTW680XF014201
TO MODEL INDEX
HFV6 (RHD)
RTW78AXF023801
TO MODEL INDEX
4JJ1-TC / 4JK1-TC Sheet 1/2
RTW78AXF025801
TO MODEL INDEX
4JJ1-TC / 4JK1-TC Sheet 2/2
RTW78AXF022501
TO MODEL INDEX
4JA1-T Sheet 1/2
RTW78AXF008901
TO MODEL INDEX
4JA1-T Sheet 2/2
RTW78AXF009001
TO MODEL INDEX
HFV6 (LHD)
RTW78AXF012701
TO MODEL INDEX
4JH1-TC
RTW78AXF006901
TO MODEL INDEX
CONNECTOR LIST
No. Connector face No. Connector face
B13 B85
White Fan switch Weld splice 7 (Ground)

B23 B95
White Meter-A White Keyless entry control unit

B24 B96
White Meter-B Gray PIM1

B54 B97
White J/B I2 White PIM2

B56 C2
White J/B I4 Silver Engine room-RH ground

B62 C4
White Ignition switch (IGSUB: G1) Sky blue Front wiper motor
B63 C5
~ NOT USED
White Ignition switch (IGSUB: G2) C14

B64 C36
Weld splice 1 (Illumination) Silver Engine room-LH; ground

B65 C56
(C24SE)
Weld splice 2 (Ground) ECM

B66 C56
(4JH1-TC)
White 4u4 switch Black ECM-A

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C56 C107
(HFV6)
Black ECM-A White J/B E2

C57 C108
Black ECM-B White J/B E1

C58 C109
Black ECM J2 Silver Body-CTR; ground

C67 C111
Black EHCU Black Transfer case control module

C77 C112
White Clutch switch Black Transfer case control module

C94 C118
White TCM-A (AW30-40LE) A/C Resister & Neutral switch

C94 C134
Gray TCM-A (JR405E) Gray Sof actuator

C95 E6
White TCM-B (AW30-40LE) Injector pump

C95 E10
White TCM-B (JR405E) Silver Engine ground

C106 E11
NOT USED
Natural
green Neutral switch
TO MODEL INDEX

E12 E78
~ NOT USED
Natural
green Neutral switch E80
E35 E96
Black Motor actuator Black Reverse switch

E36 E110
TACHO sensor Brown Backup light switch

E42 E111
Natural
green Backup light switch Brown Neutral switch
E43 E116
Natural
green Backup light switch Backup light switch
E44 F5
Black Vehicle speed sensor Gray Rear combination light-RH

E45 F6
Gray 2WD-4WD switch Black Rear combination light-LH

E46 H3
(HFV6
4JH1-TC)
Brown H-L neutral switch Gray Battery (+) ~ Engine room

G
E51 H4
(HFV6)
(C24SE)
Gray Inhibiter switch (AW30-40LE) White Engine room ~ Mission

E51 H4
(4JH1-TC)
Black Inhibitor switch (JR405E) White Engine ~ Engine room

TO MODEL INDEX

H4 H23
(4JJ1-TC) (4JA1-L)
White Engine ~ Engine room White Engine room B ~ T/misson

H5 H27
(HFV6
4JH1-TC) NOT USED
White Engine room ~ Mission

H5 H29
(4JJ1-TC (C24SE)
4JA1-L)
White Engine ~ Engine room Battery (+) ~ Engine room

H6 H32
(C24SE)
White Engine room ~ INST Engine room ~ Rear body

H7 H48
White Engine room ~ INST White Engine room ~ INST

H7 H50
(4JJ1-TC)
White Engine room ~ INST Engine & Mission ~

H15 M26
(HFV6 (C24SE)
4JH1-TC)
Black Engine room ~ Chassis Brown 2WD-4WD switch

H15 M27
(4JJ1-TC, (C24SE)
4JA1-L)
Black Engine room ~ Chassis Brown Head leveling neutral switch

H18 P1
White Engine room ~ INST Silver Battery (+)

H23 P2
White Engine ~ Engine room B Silver Relay & Fuse box

TO MODEL INDEX

P5
Silver Battery (-)

P6
Silver Body earth (Ground)

P7
Battery (ALT)
P10
Silver Engine ground

P11
Silver Fuse & relay box

P13
Gray Shift on the fly actuator

R14
Black 2WD-4WD control unit

R15
Black 2WD-4WD control unit

X12
Black ECM main relay

TO MODEL INDEX
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
x Extremely low temperature (the oil viscosity of the front differential increases requiring a large load for
synchronization).
x 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.

TO MODEL INDEX
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 (Except 4JA1-T)

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 (V6: 2000rpm) 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.
TO MODEL INDEX
Restriction on operation (4JA1-T)

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, and TM position).
Requirement to restrict the speed: Vehicle should be in stop.
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:
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.
Note: Don’t’ accelerate engine speed a the time of this operation.
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.
TO MODEL INDEX
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.
TO MODEL INDEX
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.
TO MODEL INDEX
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 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.
TO MODEL INDEX
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 20 cm(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.
TO MODEL INDEX
Transfer Controller Pin Assignment
RTW77DSF000101
TO MODEL INDEX
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.
TO MODEL INDEX
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
beginning.
2 Does the transfer-related Failed operation switch. Or, Indicator lamp burnt out.
indicators (4WD, 4Lo, Check Failed controller. Disconnected harness wire.
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
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 repairing, trace this chart
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 chart from the beginning.
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.
from the beginning.
*Before determining a trouble (Non-trouble mode)
TO MODEL INDEX
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 After repairing, trace this chart
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? After repairing, trace this chart
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.
TO MODEL INDEX
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.
Is the sound of relay heard from Replace the controller and trace
the transfer controller? this chart from the beginning.
3 Is the sound of running motor Failed control system of the Failed actuator motor.
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.
TO MODEL INDEX
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
1 Is the ignition switch ON? Go to step 2. Failed indicator and harness
(When lighting).
from the beginning.
2 Does the transfer-related Go to step 3. All indicators are burnt out
indicators (4WD, 4Lo, Check (Check for GND short circuit
4WD, neutral) light up for 2 between the indicator and
seconds when the ignition switch transfer controller).
is turned ON? Disconnected harness wire.
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).
TO MODEL INDEX
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
this chart from the beginning.
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? After repairing, trace this chart
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? After repairing, trace this chart
from the beginning.
Note:
Vehicle 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.
TO MODEL INDEX
Though the indicator responds when shifting from 4H to 2H(or other position), it returns
to 4H.
Step Action Yes No
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.
Is the sound of relay heard from Replace the controller and trace
the transfer controller? this chart from the beginning.
5 Is the sound of a running motor Failed control system of the Failed actuator motor.
heart? transfer mechanism. Check and Disconnection of controller motor
repair and trace this chart from drive output circuit or GND short.
the beginning. After repairing, trace this chart
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).
TO MODEL INDEX
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 chart from the beginning.
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
chart from the beginning.
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? After repairing, trace this chart
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 Refer to the paragraph about
met? operation without failure.
TO MODEL INDEX
From 4L to 4H: After the correction step 4-3(*), 4Lo indicator blinks at 4H.
Step Action Yes No
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 chart from the beginning.
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.
Refer to the paragraph about
Check4WD.
4 Set to N position in case of AT Failed T/M position switch and Press the operation switch of 4L
and set to the neutral position in harness (failure of TM1 and TM2 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.
Does the speedometer run at (for the meter).
this time? After repairing, trace this chart
from the beginning.
sensor. sensor.
Is any trouble detected? detection unit, if required.)
7 Run the vehicle for several Failed transfer controller. You did not wait for enough time.
after the requirements were Refer to the paragraph about
met? operation without failure.
TO MODEL INDEX
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
check the valve. Do not start the indicator when it does not react
engine. when shifted from 2H to 4H (7D1-
Has the valve check for 2 37).
seconds been completed After taking the remedy, trace this
normally? chart from the beginning.
3 Can be shifted to 2H and then to Go to step 4. Refer to the paragraph about
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.
Refer to the paragraph about
Check4WD.
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 lamp harness and their related
blinks at 4Hz after operation. switches shown in the figure).
Incorrect wiring.
Does the speedometer run at this (for the meter).
time? After repairing, trace this chart
from the beginning.
sensor. sensor.
Is any trouble noticed? detection unit, if required.)
7 Run the vehicle for several Failed controller. You did not wait for enough time.
after the requirements were met? Refer to the paragraph about
operation without failure.
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.

Transfer Izusu Dimax

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Transfer Izusu Dimax

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BACK TO CHAPTER INDEX ISUZU KB P190 2007

Transfer Position and Drive Mode

Transfer Position 4WD SWITCH Mode Drive mode

Summary of transfer control system

High-Low Sleeve & Arm

4WD indicator (in meter panel)

4L indicator (in meter panel)

Neutral indicator (in operation switch panel)

Check 4WD warning light (in meter panel)

2H 2H-4H 4H 4H-N N N-L 4L

Transfer Actuator Connector

Method of checking the position detection switch harness

Name of pin T/F controller side T/F actuator side Remarks

Functions of Switch and indicator Lamp

Transfer-related indicator lamp and switch function

Transfer-related indicator lamp and switch function

To E6, E7, E8, E9

4JJ1-TC / 4JK1-TC Sheet 1/2

4JJ1-TC / 4JK1-TC Sheet 2/2

4JA1-T Sheet 1/2

4JA1-T Sheet 2/2

White Fan switch Weld splice 7 (Ground)

White Meter-A White Keyless entry control unit

White Meter-B Gray PIM1

White J/B I2 White PIM2

White J/B I4 Silver Engine room-RH ground

White Ignition switch (IGSUB: G2) C14

Weld splice 1 (Illumination) Silver Engine room-LH; ground

Weld splice 2 (Ground) ECM

White 4u4 switch Black ECM-A

No. Connector face No. Connector face

Black ECM-A White J/B E2

Black ECM-B White J/B E1

Black ECM J2 Silver Body-CTR; ground

Black EHCU Black Transfer case control module

White Clutch switch Black Transfer case control module

White TCM-A (AW30-40LE) A/C Resister & Neutral switch

Gray TCM-A (JR405E) Gray Sof actuator

White TCM-B (AW30-40LE) Injector pump

White TCM-B (JR405E) Silver Engine ground

No. Connector face No. Connector face

Black Motor actuator Black Reverse switch

TACHO sensor Brown Backup light switch

Black Vehicle speed sensor Gray Rear combination light-RH

Gray 2WD-4WD switch Black Rear combination light-LH

Brown H-L neutral switch Gray Battery (+) ~ Engine room

Gray Inhibiter switch (AW30-40LE) White Engine room ~ Mission

Black Inhibitor switch (JR405E) White Engine ~ Engine room

No. Connector face No. Connector face

White Engine ~ Engine room White Engine room B ~ T/misson

White Engine room ~ Mission

White Engine ~ Engine room Battery (+) ~ Engine room

White Engine room ~ INST Engine room ~ Rear body

White Engine room ~ INST White Engine room ~ INST

White Engine room ~ INST Engine & Mission ~

Black Engine room ~ Chassis Brown 2WD-4WD switch

Black Engine room ~ Chassis Brown Head leveling neutral switch

White Engine room ~ INST Silver Battery (+)

White Engine ~ Engine room B Silver Relay & Fuse box

No. Connector face No. Connector face

Silver Battery (-)

Silver Body earth (Ground)

Silver Engine ground