Transfer Luv Dmax

WORKSHOP MANUAL

TF SERIES

TRANSFER

SECTION 7D

TRANSFER CASE 7D-1

SECTION 7D

TRANSFER CASE

TABLE OF CONTENTS

PAGE

Service Precaution .......................................................................................................... 7D – 2

General Description ........................................................................................................ 7D – 3

Transfer Rear Oil Seal .................................................................................................... 7D – 4

Transfer Rear Oil Seal and Associated Parts ............................................................ 7D – 4

Removal ........................................................................................................................ 7D – 4

Installation .................................................................................................................... 7D – 4

Transfer Case Assembly ................................................................................................ 7D – 6

Transfer Case Assembly and Associated Parts ........................................................ 7D – 6

Removal ........................................................................................................................ 7D – 7

Installation .................................................................................................................... 7D – 7

Transfer Control Unit ...................................................................................................... 7D – 10

Removal ........................................................................................................................ 7D – 10

Installation .................................................................................................................... 7D – 10

Transfer Disassembly ..................................................................................................... 7D – 11

Removal ........................................................................................................................ 7D – 11

Inspection and Repair .................................................................................................. 7D – 20

Inspection and Repair (Transfer Case Assembly) ..................................................... 7D – 20

Reassembly .................................................................................................................. 7D – 24

Main Data and Specifications ........................................................................................ 7D – 33

Special Tools ................................................................................................................ 7D – 36

7D-2 TRANSFER CASE

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 UNNEEDED 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 CASE 7D-3

General Description

RUW34DLF000701

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

Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts

220R300018

Legend

(1)Rear Propeller Shaft

(2)Oil Seal

Removal

1. Disconnect the rear propeller shaft (1) from the

transfer case side.

2. Remove the oil seal from the transfer case.

Installation

1. Install oil seal and apply engine oil to the oil seal

outer surfaces.

2. Apply the recommended grease (BESCO L2) or

equivalent to the oil seal lip.

3. Use the oil seal installer 5-8840-2786-0 to install the

rear seal (2) to the transfer rear case.

TRANSFER CASE 7D-5

220R300021

4. Connect the rear propeller shaft.

7D-6 TRANSFER CASE

Transfer Case Assembly

Transfer Case Assembly and Associated Parts

RTW47DLF000501

Legend

(1)Rear Propeller Shaft

(4)Center Exhaust Pipe (6VE1 only)

(2)Front Propeller Shaft

(3)Transfer Case Assembly

TRANSFER CASE 7D-7

Removal NOTE: Before removing transmission and transfer

assembly from vehicle, change the transfer mode to

2WD using the 4WD push button switch on dash panel.

1. Disconnect battery ground cable.

2. Raise and support vehicle with suitable stands. Drain

transfer case fluid.

3. Remove the center exhaust pipe(5). (6VE1 only)

4. Remove rear propeller shaft (1) and front propeller

shaft (2)(3).

NOTE: Apply alignment marks on the flange at both

front and rear sides.

5. Disconnect harness connectors and clip.

Connector: transfer switch, 2WD-4WD actuator,

speed sensor.

NOTE: Avoid turning the vehicle ignition switch to the

ON position when the 2WD-4WD connector is removed

(battery connected).

If the ignition switch must be turned to the ON position,

the controller must first be removed (memory must be

cleared because the CHECK 4WD INDICATOR will

light).

6. Remove transfer case (4) from the vehicle.

Installation

1. Apply a thin coat of molybdenum disulfide grease to

the input shaft spline as shown in the figure.

260R300001

7D-8 TRANSFER CASE

2. Install transfer case (4) to the transmission. Tighten

transfer bolts as shown in the figure.

For M/T

261R300001

TRANSFER CASE 7D-9

For A/T

261R300002

3. Connect harness connectors and clip.

Connector: transfer switch, 2WD-4WD actuator,

speed sensor.

4. Install center exhaust pipe(5). (6VE1 only)

5. Install rear propeller shaft (1) and front propeller

shaft (2)(3).

Torque: 63 N��m (6.4 kg��m/46 lb ft)

7D-10 TRANSFER CASE

Transfer Control Unit

RTW37DLF000401

Legend

(1)Transfer Control Unit (3) Bolt

(2)Protector

Removal

1. Disconnect the battery ground cable.

Remove the driver’s seat.

2. Peel back the floor carpet on the driver's side of the

vehicle to expose the transfer control unit.

3. Disconnect the harness connector from the Transfer

control unit.

4. Remove the Transfer control unit.

Installation

1. Install the Transfer control unit.

2. Connect the harness connector to the Transfer

control unit.

3. Connect the battery ground cable.

TRANSFER CASE 7D-11

Transfer Disassembly

RTW47DLF000101

Legend

(7) Neutral Switch ASM

(1) Transfer Case

(8) Speedometer Bush, Plate and Driven Gear

(2) Companion Flange, O-ring and Nut (9) Transfer Actuator

(3) Stoneguard (10) Breather Hose

(4) Detent Plug, Spring and Detent Ball (11) Heat Protector (Except Diesel Engine)

(5) 2-4 Switch ASM

(6) Switch Bracket

Removal

1. Remove the stoneguard.

2. Remove the drain plug from the transfer case to

drain the oil.

3. Remove the parts listed below.

� Speedometer bush, plate, and speedometer

driven gear

� Breather hose (Between the transfer case and

the transfer actuator assembly)

� Transfer actuator assembly

� Switch bracket

7D-12 TRANSFER CASE

� 2-4 switch assembly (Gray harness cover)

� Neutral switch assembly (Black harness cover)

� Detent plugs, detent springs, and detent balls (2

parts each)

4. Use the companion flange holder (5-8840-0133-0) to

remove the end nut from the front companion flange.

5. Remove the bolts attaching the rear cover to the

transfer case.

6. Strike the area around the front output shaft head

and the rear cover bolt holes with a plastic hammer

to remove the rear cover.

220R300022

TRANSFER CASE 7D-13

7. Remove the parts listed below from the rear cover.

� H-L sleeve

� H-L shift assembly

� 2-4 sleeve, synchronizer key, and front

synchronizer spring (do not remove the rear

spring)

� 2-4 shift assembly

� Shift drum and shift shaft

� Sun gear needle bearing

260R300001

8. Remove the oil pump strainer fixing bolts from the

rear cover.

9. Compress the retaining ring at the rear of the chain.

Strike the rear end of the main shaft with a plastic

hammer to remove the main shaft, transfer chain,

and front output shaft assembly from the rear cover.

Be careful not to damage the oil pump strainer.

226R30001

Legend

(1)Sun Gear Needle Bearing

(2)H-L Sleeve

(3)2-4sleeve, synchronizer key, and front

synchronizer spring

(4)2-4 Shift ASM

(5)Shift Shaft

(6)H-L Shift ASM

(7)Shift Drum

7D-14 TRANSFER CASE

10. Remove the transfer chain and the front output shaft

from the main shaft.

11. Remove the main shaft snap ring.

12. Remove the speedometer drive gear, the ball

bearings, the retaining ring, and the oil pump

assembly.

13. Remove the sprocket snap ring.

14. Remove the thrust washer, the drive sprocket, the

inside ring, the outside ring, the block ring, and the

rear synchronizer spring.

RTW37DMF000101

Legend

(1)Rear synchronizer spring

(9)Sprocket Snap Ring

(2)Block Ring

(10)Oil Pump ASM

(3)Outside Ring

(11)Oil Pump Retaining Ring

(4)Inside Ring

(12)Retaining Ring

(5)Drive Sprocket

(13)Ball Bearing

(6)Transfer Chain

(14)Speedometer Drive Gear

(7)Front Output shaft

(15)Main Shaft Snap Ring

(8)Thrust Washer

TRANSFER CASE 7D-15

15. Remove the snap ring from the main shaft.

16 Use a press to remove the 2-4 hub from the main

shaft.

17. Spread the edges of the retaining ring while lightly

tapping on the sun gear input shaft end. Remove the

carrier and gear assembly from the transfer case.

226R300020

18 Remove the dog teeth snap ring from the carrier and

gear assembly.

19. Remove the planetary dog teeth and the sun gear

input shaft together with the thrust needle bearing.

2260R300021

20. Remove the carrier snap ring.

21. Use a press to remove the ball bearings.

22. Use the sliding hammer (5-8840-0084-0) and the

needle bearing replacer (5-8840-0027-0) to remove

the needle bearing from the center of the carrier and

gear assembly.

Legend

(1)Outer Retaining Ring

(2)Carrier and Gear ASM

(3)Thrust needle Bearing

(4)Sungear Input Shaft

(5)Planetary DogTeeth

(6)Dog Teeth Snap Ring

7D-16 TRANSFER CASE

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

the internal gear and the damper ring.

226R300004

24. Remove the snap ring.

25. Use a press to remove the front output shaft ball

bearings.

26. Remove the oil pump wire snap ring from the rear

cover.

27. Use a sliding hammer (5-8840-0084-0) and a needle

bearing replacer (5-8840-2788-0) to remove the

needle bearing from the front output shaft.

P1010023

Legend

(1)Dumper Ring

(2)Internal Gear

(3)Retaining Ring

TRANSFER CASE 7D-17

Internal Component Disassembly and Reassembly

226R300017

H-L Shift Disassembly

1. Remove the guide roller.

2. Use a vise to compress the H-L shift spirng (inside

the assembly.

3. Remove the uter snap ring.

4. Remove the shift block assembly from the shift rod.

5. Use a socket and a vise to compress the shift block

spring (inside the assembly.

6. Remove the inner retaining ring.

7. Remove the collar (rear.

8. Remove the shift block spring.

9. Remove the collar (rear.

10. Removethe shift block assembly

11. Remove the uter snap ring.

12. Remove the shift arm.

13. Remove the front and rear companion flange.

Legend

(1)ARM; SHIFT

(2)BLOCK ASM; SHIFT

(3)RING; RETAINING, INNER

(4)COLLER (FRONT)

(5)SPRING

(6)COLLER (REAR)

(7)ROD; SHIFT

(8)RING; SNAP, OUTER

(9)ROLLER; GUIDE

(10)PIN ASM; SPRING

7D-18 TRANSFER CASE

H-L shift reassembly

1. Install the shift arm to the shift rod.

2. Install the spring pin. The top of the pin must be

flush with the surrounding surface (no projection).

3. Install the front collar, the spring, and the rear 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.

226R300014

6. Install the shift lock assembly to the shift rod.

7. Use a socket and a vise to compress the H-L shift

spring.

8. Install the outer snap ring.

9. Install the guide roller.

2-4 shift ASM

226R300016

2-4 shift disassembly

1. Remove the guide roller.

2. Compress the spring and remove the snap ring.

3. Remove the shift arm.

4. Remove the spring.

5. Remove the spring pin.

6. Remove the shift block assembly.

7. Remove the shift rod.

Legend

(1)25.62�

(2)14.1mm

Legend

(1)ROD; SHIFT

(2)ARM; SHIFT

(3)SPRING

(4)BLOCK ARM;SHIFT

(5)PIN ARM; SPRING

(6)ROLLER; GUIDE

(7)RING; SNAP

TRANSFER CASE 7D-19

2-4 shift reassembly

1. Install the shift block assembly to the shift rod.

2. Install the spring pin. The head of the pin must not

project beyond the surface (1) of the shift block.

226R300015

3. Install the spring.

4. Install the shift arm.

5. Compress the spring and install the snap ring.

6. Install the guide roller.

Oil pump disassembly

1. Remove the clamps securing the screen.

2. Remove the screen.

3. Remove the clamps securing the hose.

4. Remove the hose.

NOTE: To maintain and porotect oil pump function, the

pump is constructed so that it cannot be disassembled.

Under no conditions attempt to disassemble the pump.

Oil pump reassembly

1. Tighten the clamps to secure the hose.

2. Tighten the clamps to secure the screen.

NOTE: Be carefull in the direction of clamps.

RTW37DSH000101

Legend

(1) OIL PUMP ASM

(2) CLAMP

(3) HOSE

(4) SCREEN ASM

7D-20 TRANSFER CASE

Inspection and Repair

1. Make the necessary repair or parts replacement if

wear, damage or any other abnormal conditions are

found during inspection.

2. Wash all parts thoroughly in clean solvent. Be sure

all old lubricant, metallic particles, dirt, or foreign

material are removed from the surfaces of every

part. Apply compressed air to each oil feed port and

channel in each case half to remove any

obstructions or cleaning solvent residue.

Inspection and Repair (Transfer Case Assembly) When wear, damage, or any other defects are observed

during the inspection, the part or parts must be repaired

or replaced. Wash all the parts with clean detergent,

and check that old oil, metallic particles, dirt, or foreign

materials are completely removed. Blow the air into oil

holes and grooves to remove foreign materials or

residual detergent.

Chain

� Check whether the face that contacts the sprocket is

free from excessive wear or damage. If defects are

observed, replace the part.

� If the chain interference mark is found on the inside

wall of the transfer cover or the chain is so slack that

a skipped engagement occurs between the chain

and sprocket, replace the chain.

Sprocket

� Check whether the sprocket tooth surface is

excessively worn or damaged, and there is evidence

of burrs, chipping, wear, or damage on the gear

spline. Remove minor flaws or scratches with oil

stone. If excessive wear or damage is observed,

replace the part.

� If excessive wear or damage is observed on the

sprocket inside sliding surface, replace the part.

Gear

� Check whether the gear tooth surface is excessively

worn or damaged, and there is evidence of burrs,

chipping, wear, or damage on the gear spline.

� Remove minor flaws or scratches with oil stone. If

excessive wear or damage is observed, replace the

part.

2-4 and Neutral Switch

� Check the continuity of 2-4 and Neutral switch.

If defects are observed, replace the 4H and 4L

switch.

221R300001

261R300003

Switch

Stroke

2-4 Switch

Signal

Neutral Switch

Signal

Terminal

1 to 2

Terminal

1 to2

1 Open Close

2 Close Open

TRANSFER CASE 7D-21

Oil Pump

� Remove foreign materials from the strainer. If the

strainer is damaged, replace it.

If the area into which the shaft is inserted is excessively

worn or damaged, replace the oil pump assembly.

Clutch Hub Spline Play

� Set a dial indicator to the clutch hub to be measured.

� Move the clutch hub as far as possible to both the

right and the left.

Note the dial indicator reading.

� If the measured value exceeds the specified limit,

the clutch hub must be replaced.

Clutch hub spline play

Standard : 0 – 0.1 mm (0 – 0.004 in)

Limit : 0.2 mm (0.008 in)

226RS042

Bearings

1. Inspect the condition of all the needles and ball

bearings. Wash bearings thoroughly in a cleaning

solvent. Apply compressed air to the bearings.

NOTE: Do not allow the bearings to spin. Turn them

slowly by hand. Spinning bearings may damage the

rollers.

2. Lubricate the bearings with a light oil and check them

for roughness by slowly turning the race by hand.

Ball Bearing Play

1. Use a dial indicator to measure the ball bearing play.

2. If the measured value exceeds the specified limit, the

ball bearing must be replaced.

Limit : 0.2 mm (0.008 in)

226R3043

Synchronizers

The synchronizer hubs and sliding sleeves are a

selected assembly and should be kept together as

originally assembled.

Clean synchronizer components with clean solvent and

air dry.

Inspect the components for the following:

� Teeth for wear, scuffs, nicks, burrs or breaks.

� Keys and springs for wear, cracks or distortion,

replace if these conditions are present.

� If scuffed, nicked or burred conditions cannot be

corrected with a soft stone or crocus cloth, replace

the component.

7D-22 TRANSFER CASE

Block Ring and Insert Clearance

1. Use a vernier caliper to measure the clearance

between the block ring and the insert.

2. If the measured value exceeds the specified limit,

the block ring and the insert must be replaced.

Block ring and insert clearance

Standard : 3.86 – 4.14 mm (0.152 – 0.163 in)

Limit : 4.9 mm (0.193 in)

226RS037

2WD-4WD Synchronizer (3-Cone)

1. Use a thickness gauge to measure the clearance

between the block ring and the dog teeth.

2. If the measured value exceeds the specified limit,

the 2WD-4WD synchronizer assembly must be

replaced.

Block ring and dog teeth clearance

Standard : 1.5 mm (0.059 in)

Limit : 0.8 mm (0.031 in)

226R300019

Clutch Hub and Insert Clearance

1. Clutch Hub and Insert Clearance

2. Use a thickness gauge to measure the clearance

between the clutch hub and the insert.

3. If the measured value exceeds the specified limit, the

clutch hub and the insert must be replaced.

Clutch hub and insert clearance

Standard : 0.01-0.19 mm (0.0004-0.0075 in)

Limit : 0.3 mm (0.012 in)

226RS038

Detent Springs

1. Inspect the springs for distortion, cracks or wear.

Replace if these conditions are present.

TRANSFER CASE 7D-23

Detent Spring Free Length

1. Use a vernier caliper to measure the detent spring

free length.

2. If the measured value is less than the specified limit,

the detent spring must be replaced.

Detent spring free length

Detent ball

Standard :23.4 mm (0.92 in)

Limit :22.8 mm (0.90 in)

220RW035

Detent Spring Tension

1. Use a spring tester to measure the detent spring

tension.


the detent spring must be replaced.

Detent ball

Compressed height : 18.7 mm (0.736 in)

Standard : 68.6 ~ 88.2 N (7.0 ~ 9.0 kg/ 15.4 ~ 19.8

lb)

220RS013

Shift Arm

1. Inspect the shift arms for wear, distortion or scoring.

Replace if these conditions are present.

Shift Arm Thickness

1. Use a micrometer to measure the shift arm

thickness.


the shift arm must be replaced.

H-L Shift arm thickness

Standard : 7.6-7.85 mm (0.299-0.309 in)

Limit : 7.0 mm (0.276 in)

2-4 Shift arm thickness

Standard : 9.6-9.85 mm (0.378-0.388 in)

Limit : 9.0 mm (0.354 in)

7D-24 TRANSFER CASE

Reassembly

Transfer Reassembly

The rear cover oil seals and the rear output shaft ball

bearings cannot be reused. They must be replaced with

new ones when the transfer is reassembled.

1. Use the oil seal installer (5-8840-2785-0) to press

the new input shaft and/or front output shaft oil seals

into place (If replacement is required).

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

output shaft. Be sure that the bearings are fully

inserted and then install the snap ring.

3. Install the damper ring and the internal gear to the

transfer case. Be sure that the damper ring is

between the internal gear and the case.

226R300004

Note the direction of the dumper ring installation as

figure.

226R300025

Legend

(1)Dumper Ring

(2)Internal Gear

(3)Retaining Ring

TRANSFER CASE 7D-25

4. Use a press and the special tool (5-8840-2784-0) to

hold the internal gear against the damper ring. Install

the retaining ring (spiral type).

5. Use a press and the installer (5-8840-2782-0) to

force the needle bearing fully into the carrier and

gear assembly.

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

the ball bearings fully into the carrier and gear

assembly.

7. Install the carrier snap ring.

8. Install the thrust needle bearing, the sun gear input

shaft, the needle bearing, the planetary dog teeth,

and the dog teeth snap ring to the carrier and gear

assembly in that order.

9. Install the outer retaining ring to the tansfer case

10. Use a pair of snap ring pliers to install the carrier and

gear assembly.

NOTE: Be sure that the outer retaining ring fits snugly in

its groove.

7D-26 TRANSFER CASE

226R300003

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

12. Install the hub snap ring.

13. Install the synchronizer key springs (2), the

synchronizer key, and the 2-4 sleeve to the 2-4 hub.

The key and the open end of the springs must be

facing in the opposite direction.

Legend

(1)Retaining Ring

(2)Carrier and Gear ASM

(3)Thrust Needle Bearing

(4)Sungear Input Shaft

(5)Planetary Dog Teeth

(6)Dog Teeth Snapring

TRANSFER CASE 7D-27

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

226R300023

Legend

(1)H-L Sleeve

(3)Synchronizer Key and Key Spring

(2)2-4 Sleeve

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

16. Install the sleeve to the 2-4 shift assembly.

17. Coat the area around each of the shift 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.

7D-28 TRANSFER CASE

19. Align the shift shaft splines with the shift drum and

install the shafts to the drum.

RTW320MF000201

Legend

(1)H-L Sleeve and Shift ASM

(3)Shift Shaft

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

(4)Shift Drum

NOTE: Be careful in the direction of an assembly.

P1010041/020124

20. Coat the main shaft with oil.

21. Align the block ring, the outside ring, and the inside

ring with the 2-4 hub assembly and install them.

22. Assemble the sprocket, transfer chain, and front

output shaft.

23. Install the sprocket, transfer chain, and front output

shaft to the main shaft and the transfer case.

TRANSFER CASE 7D-29

24. Align the sprocket thrust washer with the main shaft

groove and install it.

226R300009

25. Select a snap ring that will allow minimum axial play.

Insert it to the main shaft installation groove.

mm (in)

Snap ring thickness Identification color

2.15 (0.085) Red

2.10 (0.083) Not colored

2.05 (0.081) Blue

2.00 (0.079) White

226R300008

Legend

(1)Block Ring

(2)Outside Ring

(3)Inside Ring

(4)Sprocket

(5)Chain

(6)Front Output Shaft

(7)Thrust Washer

(8)Snap Ring

26. Measure the snap ring external diameter. If the

measured diameter is outside the specified range, a

larger or smaller snap ring must be used.

Snap ring outside diameter (Standard):

53.0 �� 0.5 mm

27. Position the rear cover so that its mating surfaces

are facing up.


install the front output shaft needle bearing. The

installer must be aligned with the bearing

manufacturer's name (stamped into the bearing).

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

7D-30 TRANSFER CASE

226R300005

30. Temporarily install the speedometer drive gear to the

inside of the rear cover. Pay close attention to

installation direction.


install the rear output shaft ball bearings. Do not

drive the ball bearings into place with a hammer.

32. Install the rear output shaft retaining ring.

33. Place the oil pump in its specified position.

34. Secure the pump strainer to the rear cover and

tighten the bolts to the specified torque.

Rear cover and transfer case bolt torque:

15 Nm (1.5 kgm/11 lb ft)

226R300010

35. Apply Loctite FMD 127 to the mating surfaces of the

rear cover and the transfer case. Be sure that the

Loctite is evenly applied to the inside surfaces of the

bolt holes with no gaps.

Legend

(1)Oil Pump ASM

(2)Wire Snapring

(3)Retaining Ring

(4)Ball Bearing

(5)Speedometer Gear Drive Gear

(6)Rear Cover

Legend

(1)Wire Snapring

TRANSFER CASE 7D-31

226R300011

36. Install the rear cover to the transfer case and tighten

the bolts to the specified torque.

Rear cover and transfer case bolt torque:

22 Nm (2.2 kgm/16 lbft)

37. Apply engine oil to the companion flange O-ring.

38. Install the O-ring to the front output shaft.

39. Secure the front companion flange with the

companion flange holder (5-8840-0133-0).

40. Install the end nuts and tighten them to the specified

torque.

Front companion flange end nut torque:

137 Nm (14 kgm/101 lbft)

41. Use a cold chisel to caulk the front companion

flange end nuts.

226R300012

RUW34DSH000301

Legend

(1) MAX 26mm (1.02 in)

(2) MIN 4mm (0.16 in)

42. Apply Loctite 575 to the threaded portion of the

detenteplugs.

7D-32 TRANSFER CASE

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

shaft end snap ring to the rear output shaft (from the

back end of the shaft). Be absolutely sure that the

snap ring is seated in the groove.

226R300022

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

output oil seal to the rear case.

45. Install the detent balls, the detent springs, and the

detent plugs (2 parts each) to the transfer case.

Tighten the plugs to the specified torque.

Detent plug torque: 19 Nm (1.9 kgm/14 lbft)

46. Install the neutral switch (black harness cover) to the

transfer case and tighten the bolts to the specified

torque.

Neutral start switch bolt torque:

39 Nm (4 kgm/29 lbft)

47. Install the 2-4 switch (gray harness cover) to the

transfer case and tighten the bolts to the specified

torque.

2-4 switch bolt torque: 39 Nm (4 kgm/29 lbft)

48. Install the switch bracket to the transfer case and

tighten the bolts to the specified torque.

Switch bracket bolt torque:

15 Nm (1.5 kgm/11 lbft)

49. Install the transfer actuator assembly to the transfer

case and tighten the bolts to the specified torque.

The actuator must be installed in the same direction

as the shaft.

Transfer actuator assembly bolt torque:

22 Nm (2.2 kgm/16 lbft)

50. Install the breather hose between the transfer

actuator and the transfer case.

51. Install the speedometer driven gear, the

speedometer bush, and the speedometer stay to the

transfer case. Tighten the bolts to the specified

torque.

Speedometer bolt torque:

15 Nm (1.5 kgm/11 lbft)

52. Install the drain plug to the transfer case and tighten

it to the specified torque.

Drain plug torque: 39 Nm (4 kgm/29 lbft)

53. Loosen and remove the filler plug. Add the specified

volume of transfer oil (5W-30) or the equivalent to

the transfer through the filler hole.

Transfer oil volume: 1.3 liters

54. Replace the filler plug and tighten it to the specified

torque.

Filler plug torque: 39 Nm (4 kgm/29 lbft)

55. Install the underguard and tighten the bolts to the

specified torque.

Underguard bolt torque: 39 Nm (4 kgm/29 lbft)

TRANSFER CASE 7D-33

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 U.S. quart)

Type of lubricant BESCO GEAR OIL TRANSAXLE (5W-30)

Refer to chart in Section 0

Torque Specifications

N�m (kg�m/lb ft)

RTW47DLF000201

7D-34 TRANSFER CASE


RTW47DLF000401

TRANSFER CASE 7D-35


E07R300008

7D-36 TRANSFER CASE

Special Tools

ILLUSTRATION PART NO.

PART NAME

ILLUSTRATION

PART NO.

PART NAME

5-8840-2786

Transfer case oil seal

installer

5-8840-2784-0

Ring gear installer

5-8840-0084-0

Sliding hammer

5-8840-0133-0

Flange holder

5-8840-0027-0

Rear output shaft needle

bearing replacer

5-8840-2782-0

Needle bearing installer

5-8840-2293-0

Punch; end nut

5-8840-2783-0

Needle bearing installer

5-8840-2788-0

Front output shaft needle

bearing replacer

5-8840-0007-0

Driver handle

5-8840-2785-0

Input shaft and/or front

output shaft oil seal

installer

5-8840-1268-0

Rear output shaft ball

bearing installer

TRANSFER CASE 7D-37

ILLUSTRATION PART NO.

PART NAME

5-8840-2787-0

Snapring installer

7D-38 TRANSFER CASE

MEMO

TRANSFER CONTROL SYSTEM 7D1-5

System Components

Parts Location

Speed sensor

Revolutions of the rear output shaft are decreased and taken

out by the speed/drive/driven gears installed in the transfer

case and the number of revolutions is detected with a speed

sensor.

About 4/3 pulses per revolution of the shaft is 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.

4�� 2 - 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, but, when moving in 4�2 direction, a

7D1-6 TRANSFER CONTROL SYSTEM

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 in sometime.

This mechanism is provided to protect the shift mechanism

from the force to prevent the movement of the sleeve

(torsional torque etc. of the drive system). By releasing the

preventive force, the sleeve can move to 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, that is,

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. For this

reason, the rod position and the actual sleeve position may be

offset in some cases.

This system is provided to protect the shift mechanism from

the 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 is provided to the actuator at 4 positions, which

are connected to the transfer controller through the vehicle

harness to constantly transmit the actuator operating angle

and changes in its transfer status.

7B4-PDF2

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)

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

7B4-PDF4

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)

7B4-PDF5

Check 4WD warning light (in meter panel)

This light indicates following items.

Valve check

Faulty actuator limit SW, and fault of circuit related with the

limit switch

825R300018

4WD switch

Switch to transmit a switching command to the 2H, 4H,

Neutral, or 4L position.

It comprises 3 PUSH momentary switches. By keeping to push

the 2H and 4L switches for 10 seconds,

operation is instructed to the neutral position.

To shift from the neutral to other position, other required

switches should be pushed for 10 seconds.


2H to 4H retrial

Item 4WD

lamp 4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

2H Off Off Off Off No

operation1,0,1,0 Open Open Open -----

4H start

of

operation

Off Off Off Off

4H

position

for 0.1

second

1,0,1,0 Open Open Open -----

Start of

operation

Blinking

(2HZ) Off Off Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

while

driving

During

operation

(Synchro)

(Go to 4H

if synchro

complete)

Blinking

(2HZ) Off Off Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

using

synchro

and retrial

X 2

Abandon

ed

operation

(2H)

Blinking

(4HZ) Off Off Off

No

operation1,0,1,0 Open Open Open

Return to

2H

2H

indication

after

10second

s

Off Off Off Off No


� Completion of transfer case H-L area and axle shift timing may cause some variation in 2Hz blinking pattern.


Operational limits (4H��4L) (Vehicle speed, engine speed, and transmission position not specified)

Item 4WD

lamp 4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

4H On Off Off Off Open 0,0,1,1 Closed Open Closed -----

4H start

of

operation

On Off Off Off

4L

position

for 0.1

second

0,0,1,1 Closed Open Closed -----

10

second

display

during

limitation

On Blinking

(4HZ) Off Off Open 0,0,1,1 Closed Open Closed

No

operation

during

limitation

Go to 4H

after 10

seconds

On Off Off Off Open 0,0,1,1 Closed Open Closed -----

Operational limits (4L��4H) (Vehicle speed, engine speed, and transmission position not specified)

Item 4WD

lamp 4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

4L On On Off Off No

operation1,1,0,1 Closed Open Closed -----

4L start of

operation On On Off Off

4H

position

for 0.1

second


10

second

display

during

limitation

On Blinking

(4HZ) Off Off Open 1,1,0,1 Closed Open Closed

No

operation

during

limitation

Go to 4L

after 10

seconds

On On Off Off No


� Under some conditions, a secondary operational indication may be received when the 4Hz operational indication

is present.


Transfer-related indicator lamp and switch function Skip operation

Item 4WD

lamp 4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detectio

n (limit)

switches

LS1,

LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks



4L start of

operation Off Off Off Off

4L

position

for 0.1

second

1,0,1,0 Open Open Open

Switch

operation

sensor

Start of

operation

Blinking

(2HZ)

Blinking

(2HZ) Off Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

while

driving

During

operation

(Synchro)

Blinking

(2HZ)

Blinking

(2HZ) Off Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

using

synchro

and retrial

During

operation

(Passing

through

4H)

Off Blinking

(2HZ) Off Off

No

operation0,0,1,1 Closed Open Open -----

During

operation

(Passing

through

4H)

Off Blinking

(2HZ) Off Off

No

operation

0,0,1,1

0,1,0,1 Closed Open Open -----

During

operation

(N)

On Blinking

(2HZ) Off Off

No

operation

0,0,1,1


During

operation

(N)

On Blinking

(2HZ) Off Off

No

operation0,1,0,0 Closed Open Closed

Switch

operation

sensor

During

operation

(N)

On Blinking

(2HZ) Off Off

No


4H to 4L

while

driving

During

operation

(Axle

drive)

Blinking

(2HZ)

Blinking

(2HZ) Off Off

No


Axle

waiting

Blinking

(2HZ)

Blinking

(2HZ) Off Off

No


4L waiting On Blinking

(2HZ) Off Off

No

operation1,1,0,1 Closed Closed Closed

4H to 4L

while

waiting

4L On On Off Off No



Item 4WD

lamp 4L lamp

Neutral

lamp

Check

4WD

lamp

4WD

switch

Actuator

detectio

n (limit)

switches

LS1,

LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

2H start of

operation On On Off Off

2H

position

for 0.1

second

1,1,0,1 Closed Open Closed

Switch

operation

sensor

During

operation

Blinking

(2HZ)

Blinking

(2HZ) Off Off

No


4L to 4H

while

driving

During

operation

(Passing

through

N)

On Blinking

(2HZ) Off Off

No


4L to 4H

through

neutral

During

operation

(Passing

through

N)

Off Blinking

(2HZ) Off Off

No


4L to 4H

through

neutral

During

operation

(4H

waiting)

Off Blinking

(2HZ) Off Off

No


4L to 4H

while

waiting

During

operation

(Axle)

Off while

waiting for

start of H

shift

Blinking

(2HZ)

while

waiting for

start of H

shift

Off Off No

operation

0,1,1,1

0,1,1,0

0,0,1,0

1,1,1,0

Closed Open Closed

2H to 4H

while

driving

During

operation

(Axle)

Blinking

(2HZ) at

end of H

shift

Off at end

of H shiftOff Off

No

operation

0,1,1,1

0,1,1,0

0,0,1,0

1,1,1,0

Closed Open Closed Axle

driving

Axle

waiting

Blinking

(2HZ) Off Off Off

No

operation1,0,1,0 Open Open Closed -----



� Completion of transfer case H-L area and axle shift timing may cause some variation in 2Hz blinking pattern.


Skip operation limitations (4L��2H) (Vehicle speed, engine speed, and transmission position not

specified)

Item 4WD

lamp 4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

4L Off On Off Off Open 1,1,0,1 Closed Open Closed -----

4L start of

operation Off On Off Off

2H

position

for 0.1

second


10

second

display

during

limitation

Blinking

(4HZ) Off Off Off Open 1,1,0,1 Closed Open Closed

No

operation

during

limitation

Go to 4L

after 10

seconds

Off ON Off Off Open 1,1,0,1 Closed Open Closed -----

Skip operation limitations (2H��4L) (Vehicle speed, engine speed, and transmission position not

specified)

Item 4WD

lamp 4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

2HL Off Off Off Off Open 1,0,1,0 Open Open Open -----

4L start of

operation Off Off Off Off

2H

position

for 0.1

second

1,0,1,0 Open Open Open -----

10

second

display

during

limitation

Blinking

(4HZ)

Blinking

(4HZ) Off Off Open 1,0,1,0 Open Open Open

No

operation

during

limitation

Go to 2H

after 10

seconds

Off Off Off Off Open 1,0,1,0 Open Open Open -----

�� Under some conditions, a secondary operational indication may be received when the 4Hz operational

indication is present.


Transfer-related indicator lamp and switch function 2H�Neutral�2H

Item 4WD

lamp 4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detectio

n (limit)

switches

LS1,

LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks



Neutral

start of

operation

Off Off Off Off

Neutral

position

for 10

seconds


Switch

operation

sensor

Start of

operation Off Off

Blinking

(2HZ) Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

while

driving

During

operation

(Synchro)

Off Off Blinking

(2HZ) Off

No

operation

1,1,1,0

0,0,1,0

0,1,1,0

0,1,1,1

Open Open Open

2H to 4H

using

synchro

and retrial

During

operation

(Passing

through

4H)

Off Off Blinking

(2HZ) Off

No


During

operation

(Passing

through

4H)

Off Off Blinking

(2HZ) Off

No

operation

0,0,0,1


4H to 4L

while

driving

During

operation

(N)

Off Off Blinking

(2HZ) Off

No

operation

0,0,0,1

0,1,0,1 Closed Closed Closed

4H to 4L

through

neutral

During

operation

(N)

Off Off Blinking

(2HZ) Off

No


Switch

operation

sensor

Neutral Off Off On Off No

operation0,1,0,0 Closed Closed Open -----

2H start of

operation Off Off On Off

2H

position

for 10

seconds


Switch

operation

sensor

During

operation

(Passing

through

N)

Off Blinking

(2HZ) Off Off

No


4L to 4H

through

neutral

During

operation Off

Blinking

(2HZ) Off Off

No

operation

0,1,0,1

0,0,0,1 Closed Closed Closed

4L to 4H

while

driving


Item 4WD

lamp 4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detectio

n (limit)

switches

LS1,

LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

During

operation

(4H

waiting)

Off Blinking

(2HZ) Off Off

No


4L to 4H

while

waiting

During

operation

(Axle)

Blinking

(2HZ) Off Off Off

No

operation

0,1,1,1

0,1,1,0

0,0,1,0

1,1,1,0

Closed Open Closed

2H to 4H

while

driving

During

operation

(Axle)

Blinking

(2HZ) Off Off Off

No

operation

0,1,1,1

0,1,1,0

0,0,1,0

1,1,1,0

Open Open Closed Axle

driving

Axle

waiting

Blinking

(2HZ) Off Off Off

No




� Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer

shifts in both directions (H��Neutral��L).


4H��Neutral��4H

Item 4WD

lamp 4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

4H On Off Off Off No


Neutral

start of

operation

On On Off Off

Neutral

position

for 10

seconds


Start of

operation Off Off

Blinking

(2HZ) Off

No


4L to N

while

driving

During

operation

(N)

Off Off Blinking

(2HZ) Off

No


4L to N

with axle

driving

During

operation

(N)

Off Off Blinking

(2HZ) Off

No


4L to 4N

with axle

removed

During

operation

(Axle)

Blinking

(2HZ) Off Off Off

No

operation

0,1,1,1

0,1,1,0

0,0,1,0

1,1,1,0

Open Open Closed Axle

driving

Axle

waiting

Blinking

(2HZ) Off Off Off

No




4H start

of

operation

Off Off Off Off

2H

position

for 10

seconds


Switch

operation

sensor

During

operation

(N)

Off Blinking

(2HZ) Off Off

No

operation1,1,0,0 Closed Closed Open

4L to 4H

through

neutral

During

operation

(N)

Off Blinking

(2HZ) Off Off

No


4L to 4H

through

neutral

During

operation Off

Blinking

(2HZ) Off Off

No

operation

0,1,0,1

0,0,0,1 Closed Closed Open

4L to 4H

while

driving

4H

waiting

Blinking

(2HZ) Off) Off Off

No


4L to 4H

while

waiting

During

operation

(Axle)

Blinking

(2HZ) Off Off Off

No

operation0,0,1,1 Closed Open Open

Axle

driving

Axle

waiting

Blinking

(2HZ) Off Off Off

No


4H On Off Off Off No



4L��Neutral��4L

Item 4WD

lamp 4L lamp

Neutral

lamp

Check

4WD

warning

light

4WD

switch

Actuator

detection

(limit)

switches

LS1, LS2,

LS3. and

LS4

1 = on

2 = off

Transfer

4WD

switch

Transfer

neutral

switch

SOF

actuator

switch

Or

Axle

dummy

Remarks

4L On On Off Off No


Neutral

start of

operation

On On Off Off

Neutral

position

for 10

seconds


Start of

operation Off Off

Blinking

(2HZ) Off

No


4L to N

while

driving

During

operation

(N)

Off Off Blinking

(2HZ) Off

No


4L to N

with axle

driving

During

operation

(N)

Off Off Blinking

(2HZ) Off

No


4L to 4N

with axle

removed

During

operation

(Axle)

Blinking

(2HZ) Off Off Off

No


Axle

driving

Axle

waiting

Blinking

(2HZ) Off Off Off

No

operation0,1,0,0 Closed Closed Closed -----



4L start of

operation Off Off On Off

4L

position

for 10

seconds


Switch

operation

sensor

During

operation

(N)

Off Blinking

(2HZ) Off Off

No


4H to 4L

through

neutral

During

operation

(N)

Off Blinking

(2HZ) Off Off

No


4H to 4L

through

neutral

During

operation

(N)

Off Blinking

(2HZ) Off Off

No


4H to 4L

through

neutral

4H

waiting On

Blinking

(2HZ) Off Off

No


4L while

waiting

During

operation

(Axle)

Blinking

(2HZ) Off Off Off

No

operation1,1,0,1 Closed Open Open

Axle

driving

Axle

waiting

Blinking

(2HZ) Off Off Off

No


4H On On Off Off No





Parts Location (RHD)

RTW48AXF021701&RTW48AXF021801


Parts Location (LHD)

RTW48AXF021901&RTW48AXF022001


RTW48AXF021601


PARTS LOCATION

RTW48AXF031701


Circuit Diagram 6VE1 (RHD / LHD)

RTW48AXF007201

Transfer Luv Dmax

Documents

Transcript of Transfer Luv Dmax