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2011MY UC SERIES
TRANSFER CASE
SECTION 7D
E-Solutions &
Service Marketing Dept.
TRANSFER CASE 7D-1
SECTION 7D
TRANSFER CASE
TABLE OF CONTENTS
PAGE
Service Precaution ......................................................................................................... 7D – 2
General Description ........................................................................................................ 7D – 3
On-Vehicle Service ......................................................................................................... 7D – 4
Transfer Case Oil Level ............................................................................................... 7D – 4
Transfer Case Oil Change ........................................................................................... 7D – 5
Transfer Case Front Oil Seal ...................................................................................... 7D – 6
Transfer Case Rear Oil Seal ........................................................................................ 7D – 9
Transfer Case Assembly ................................................................................................ 7D – 11
Transfer Case Assembly and Associated Parts ........................................................ 7D – 11
Removal ........................................................................................................................ 7D – 12
Installation .................................................................................................................... 7D – 12
Transfer Control Unit ...................................................................................................... 7D – 15
Removal ........................................................................................................................ 7D – 15
Installation .................................................................................................................... 7D – 15
Transfer Disassembly .................................................................................................... 7D – 16
Removal ........................................................................................................................ 7D – 16
Inspection and Repair ................................................................................................. 7D – 25
Inspection and Repair (Transfer Case Assembly) .................................................... 7D – 25
Reassembly .................................................................................................................. 7D – 29
Main Data and Specifications ........................................................................................ 7D – 39
Special Tools ................................................................................................................ 7D – 42
7D-2 TRANSFER CASE
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL CAUTION: Always use the correct fastener in the
RESTRAINT SYSTEM (SRS). REFER TO THE SRS proper location. When you replace a fastener, use
COMPONENT AND WIRING LOCATION VIEW IN ONLY the exact part number for that application.
ORDER TO DETERMINE WHETHER YOU ARE ISUZU will call out those fasteners that require a
PERFORMING SERVICE ON OR NEAR THE SRS replacement after removal. ISUZU will also call out
COMPONENTS OR THE SRS WIRING. WHEN YOU the fasteners that require thread lockers or thread
ARE PERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED, do not
COMPONENTS OR THE SRS WIRING, REFER TO use supplemental coatings (Paints, greases, or
THE SRS SERVICE INFORMATION. FAILURE TO other corrosion inhibitors) on threaded fasteners or
FOLLOW WARNINGS COULD RESULT IN POSSIBLE fastener joint interfaces. Generally, such coatings
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR adversely affect the fastener torque and the joint
OTHERWISE UNNECESSARY SRS SYSTEM clamping force, and may damage the fastener. When
REPAIRS. you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
TRANSFER CASE 7D-3
General Description
RTW57ALF000301
On-Vehicle Service
Transfer Case Oil Level
RTW67DMF000101
Legend
(1) Transfer Case
(2) Filler Plug and O-ring
Removal Installation
1. Disconnect the battery ground cable. 1. Replace the filler plug and O-ring tighten it to the
2. Rise and support the vehicle with suitable stands. specified torque.
3. Remove the filler plug and O-ring. Filler plug torque: 39 N⋅⋅m (4.0 kgf⋅⋅m/29 lb⋅⋅ft)
4. Check the oil level reaches the filler hole. 2. Lower the vehicle to the ground.
5. If the oil level is low, fill the transfer oil (5W-30) or 3. Connect the battery ground cable.
equivalent to the transfer through the filler hole.
TRANSFER CASE 7D-5
RTW67DMF000201
Legend
(1) Transfer Case
(2) Filler Plug and O-ring
(3) Drain Plug and O-ring
Removal Installation
1. Disconnect the battery ground cable. 1. Replace the drain plug and O-ring to the transfer case
2. Rise and support the vehicle with suitable stands. and tighten it to the specified torque.
3. Place a suitable sized drain tray under the transfer Drain plug torque: 39 N⋅⋅m (4.0 kgf⋅⋅m/29 lb⋅⋅ft)
case. 2. Fill the specified volume of the transfer oil (5W-30) or
4. Remove the drain plug and O-ring drain the transfer equivalent to the transfer case through the filler hole.
case oil. Transfer oil volume: 1.3 lit. (1.37 US qt/0.29 Imp gal)
5. Remove the filler plug and gasket. 3. Replace the filler plug and O-ring tighten it to the
specified torque.
Filler plug torque: 39 N⋅⋅m (4.0 kgf⋅⋅m/29 lb⋅⋅ft)
4. Lower the vehicle to the ground.
5. Connect the battery ground cable.
7D-6 TRANSFER CASE
RTW67DMF000301
Removal 8. Remove the front oil seal from the front cover.
1. Disconnect the battery ground cable.
2. Raise and support the vehicle with suitable stands.
3. Place a suitable sized drain tray under the transfer
case.
4. Remove the drain plug and drain the transfer case oil.
5. Remove the filler plug.
6. Remove the front propeller shaft.
7. Use a flange holder (5-8840-0133-0) to remove the
end nut from the front output shaft then remove the
O-ring and the output flange.
RTW77DSH000201
TRANSFER CASE 7D-7
226R300012
RTW77DSH000301
Legend
(1) MAX 26mm (1.02in)
(2) MIN 4mm (0.16in)
7D-8 TRANSFER CASE
220R300018
Legend
(1) Rear Propeller Shaft
(2) Rear Oil Seal
Removal Installation
1. Disconnect the battery ground cable. 1. Thoroughly clean around the oil seal bore in the
2. Raise and support the vehicle with suitable stands. transfer case and ensure there are no burrs.
3. Remove the rear propeller shaft. 2. Apply the engine oil to the new oil seal outer surfaces
4. Remove the oil seal from the transfer case. and apply the recommended grease (BESCO L2) or
equivalent to the oil seal lip.
7D-10 TRANSFER CASE
RTW77DSH000401
220R300021
RTW57ALF000201
Legend
(1) Rear Propeller Shaft
(2) Front Propeller Shaft
(3) Transfer Case Assembly
7D-12 TRANSFER CASE
Removal Installation
NOTE: Before removing transmission and transfer 1. Apply a thin coat of molybdenum disulfide grease to
assembly from vehicle, change the transfer mode to the input shaft spline as shown in the figure.
2WD using the 4WD push button switch on dash panel.
1. Disconnect battery ground cable.
2. Raise and support vehicle with suitable stands. Drain
transfer case fluid.
3. Remove rear propeller shaft and front propeller shaft.
NOTE: Apply alignment marks on the flange at both front
and rear sides.
4. Disconnect harness connectors and clip.
Connector: transfer switch, 2WD-4WD actuator,
speed sensor.
NOTE: Avoid turning the vehicle ignition switch to the ON
position when the 2WD-4WD connector is removed
(battery connected).
If the ignition switch must be turned to the ON position,
the controller must first be removed (memory must be
cleared because the CHECK 4WD INDICATOR will
light).
5. Remove transfer case assembly from the vehicle.
260R300001
TRANSFER CASE 7D-13
For M/T
N⋅⋅m (kgf⋅⋅m/lb⋅⋅ft)
mm (in)
RTW77DLF000201
7D-14 TRANSFER CASE
For A/T
N⋅⋅m (kgf⋅⋅m/lb⋅⋅ft)
mm (in)
RTW77DLF000301
RUW77DMF000101
Legend
(1) Transfer Control Unit
(2) Nut
Removal Installation
1. Disconnect the battery ground cable. 1. Install the Transfer control unit.
2. Disconnect the harness connector from the Transfer Transfer control unit torque:
control unit. 7 N⋅⋅m (0.7 kgf⋅⋅m/61 lb⋅⋅in)
3. Remove the Transfer control unit. 2. Connect the harness connector to the Transfer
control unit.
3. Connect the battery ground cable.
7D-16 TRANSFER CASE
Transfer Disassembly
RTW57DLF000101
Legend
(1) Transfer Case (6) Switch Bracket
(2) Companion Flange, O-ring and Nut (7) Neutral Switch ASM
(3) Stoneguard (8) Speedometer Bushing, Plate and Driven Gear
(4) Detent Plug, Spring and Detent Ball (9) Transfer Actuator
(5) 2-4 Switch ASM (10) Breather Hose
• 2-4 switch assembly (Gray harness cover) 6. Strike the area around the front output shaft head and
• Neutral switch assembly (Black harness cover) the rear cover bolt holes with a plastic hammer to
• Detent plugs, detent springs, and detent balls (2 remove the rear cover.
parts each)
4. Use a flange holder (5-8840-0133-0) to remove the
end nut from the front companion flange.
RTW77DSH000201
220R300022
7D-18 TRANSFER CASE
7. Remove the parts listed below from the rear cover. Legend
• H-L sleeve (1) Sun Gear Needle Bearing
• H-L shift assembly (2) H-L Sleeve
• 2-4 sleeve, synchronizer key, and front (3) 2-4sleeve, synchronizer key, and front
synchronizer spring (do not remove the rear synchronizer spring
spring) (4) 2-4 Shift ASM
(5) Shift Shaft
• 2-4 shift assembly
(6) H-L Shift ASM
• Shift drum and shift shaft
(7) Shift Drum
• Sun gear needle bearing
226R30001
260R300001
TRANSFER CASE 7D-19
10. Remove the transfer chain and the front output shaft
from the main shaft.
11. Remove the main shaft snap ring.
12. Remove the speedometer drive gear, the ball
bearings, the retaining ring, and the oil pump
assembly.
13. Remove the sprocket snap ring.
14. Remove the thrust washer, the drive sprocket, the
inside ring, the outside ring, the block ring, and the
rear synchronizer spring.
RTW37DMF000101
2260R300021
Legend
(1) Outer Retaining Ring
(2) Carrier and Gear ASM
(3) Thrust needle Bearing
17. Spread the edges of the retaining ring (1) while lightly (4) Sungear Input Shaft
tapping on the sun gear input shaft end. Remove the (5) Planetary DogTeeth
carrier and gear assembly from the transfer case. (6) Dog Teeth Snap Ring
226R300020
18. Remove the dog teeth snap ring from the carrier and
gear assembly.
19. Remove the planetary dog teeth and the sun gear
input shaft together with the thrust needle bearing. 22. Use a sliding hammer (5-8840-0084-0) and a needle
bearing replacer (5-8840-0027-0) to remove the
needle bearing from the center of the carrier and gear
assembly.
TRANSFER CASE 7D-21
P1010023
226R300004
Legend
(1) Dumper Ring
(2) Internal Gear
(3) Retaining Ring
226R300017
Legend
(1) Shift Arm
(2) Shift Block Assembly
(3) Inner Retaining Ring 3. Remove the outer snap ring.
(4) Collar (Front) 4. Remove the shift block assembly from the shift rod.
(5) Shift Block Spring
(6) Collar (Rear)
(7) Shift Rod
(8) Outer Snap Ring
(9) Guide Roller
(10) Spring Pin
226R300016
Legend
(1) Shift Rod
(2) Shift Arm
(3) Spring
(4) Shift Block Assembly
(5) Spring Pin
(6) Guide Roller
226R300014
(7) Snap Ring
226R300015
RTW37DSH000101
Sprocket
• Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
• If excessive wear or damage is observed on the 261R300003
226R3043
Synchronizers
The synchronizer hubs and sliding sleeves are a selected
assembly and should be kept together as originally
assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:
• Teeth for wear, scuffs, nicks, burrs or breaks.
• Keys and springs for wear, cracks or distortion,
226RS042 replace if these conditions are present.
Bearings • If scuffed, nicked or burred conditions cannot be
1. Inspect the condition of all the needles and ball corrected with a soft stone or crocus cloth, replace the
bearings. Wash bearings thoroughly in a cleaning component.
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.
TRANSFER CASE 7D-27
226R300019
226RS038
Detent Springs
1. Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.
7D-28 TRANSFER CASE
220RS013
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring.
Replace if these conditions are present.
Reassembly
Transfer Reassembly
The rear cover oil seals and the rear output shaft ball
bearings cannot be reused. They must be replaced with
new ones when the transfer is reassembled.
1. Use an oil seal installer (5-8840-2785-0) to press the
new input shaft and/or front output shaft oil seals into
place (If replacement is required).
226R300004
Legend
(1) Dumper Ring
(2) Internal Gear
(3) Retaining Ring
226R300025
RTW77DSH000301
226R300003
Legend
(1) Retaining Ring
(2) Carrier and Gear ASM
(3) Thrust Needle Bearing
(4) Sungear Input Shaft
(5) Planetary Dog Teeth
(6) Dog Teeth Snap Ring
7D-32 TRANSFER CASE
226R300023
Legend
(1) H-L Sleeve (3) Synchronizer Key and Key Spring
(2) 2-4 Sleeve
19. Align the shift shaft splines with the shift drum and
install the shafts to the drum.
RTW320MF000201
Legend
(1) H-L Sleeve and Shift ASM (3) Shift Shaft
(2) 2-4 Sleeve ASM with Main Shaft and Shift ASM (4) Shift Drum
NOTE: Be careful in the direction of an assembly. 20. Coat the main shaft with oil.
21. Align the block ring, the outside ring, and the inside
ring with the 2-4 hub assembly and install them.
22. Assemble the sprocket, transfer chain, and front
output shaft.
23. Install the sprocket, transfer chain, and front output
shaft to the main shaft and the transfer case.
P1010041/020124
7D-34 TRANSFER CASE
24. Align the sprocket thrust washer with the main shaft
groove and install it. Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) Sprocket
(5) Transfer Chain
(6) Front Output Shaft
(7) Thrust Washer
(8) Snap Ring
29. Install the oil pump wire snap ring to the rear cover.
226R300008
TRANSFER CASE 7D-35
226R300005
Legend
(1) Wire Snap Ring
226R300011 226R300012
36. Install the rear cover to the transfer case and tighten
the bolts to the specified torque.
Rear cover and transfer case bolt torque:
22 N·m (2.2 kgf·m/16 lb·ft)
37. Apply engine oil to the companion flange O-ring.
38. Install the O-ring to the front output shaft.
39. Secure the front companion flange with a flange
holder (5-8840-0133-0).
40. Install the end nuts and tighten them to the specified
torque.
RUW34DSH000301
Legend
(1) MAX 26mm (1.02 in)
(2) MIN 4mm (0.16 in)
RTW77DSH000201
220R300021
45. Install the detent balls, the detent springs, and the
detent plugs (2 parts each) to the transfer case.
Tighten the plugs to the specified torque.
226R300022
Detent plug torque: 19 N·m (1.9 kgf·m/14 lb·ft)
46. Install the neutral switch (black harness cover) to the
44. Use an installer (5-8840-2786-0) to install the rear transfer case and tighten the bolts to the specified
output oil seal to the rear case. torque.
Neutral switch bolt torque:
39 N·m (4.0 kgf·m/29 lb·ft)
47. Install the 2-4 switch (gray harness cover) to the
transfer case and tighten the bolts to the specified
torque.
2-4 switch bolt torque: 39 N·m (4.0 kgf·m/29 lb·ft)
48. Install the switch bracket to the transfer case and
tighten the bolts to the specified torque.
Switch bracket bolt torque:
15 N·m (1.5 kgf·m/11 lb·ft)
49. Install the transfer actuator assembly to the transfer
case and tighten the bolts to the specified torque. The
actuator must be installed in the same direction as the
shaft.
RTW77DSH000401 Transfer actuator assembly bolt torque:
22 N·m (2.2 kgf·m/16 lb·ft)
50. Install the breather hose between the transfer
actuator and the transfer case.
51. Install the speedometer driven gear, the speedometer
bushing, and the speedometer stay to the transfer
case. Tighten the bolts to the specified torque.
Speedometer bolt torque:
15 N·m (1.5 kgf·m/11 lb·ft)
7D-38 TRANSFER CASE
52. Install the drain plug to the transfer case and tighten it
to the specified torque.
Drain plug torque: 39 N·m (4.0 kgf·m/29 lb·ft)
53. Loosen and remove the filler plug. Add the specified
volume of transfer oil (5W-30) or the equivalent to the
transfer through the filler hole.
Transfer oil volume: 1.3 lit. (1.37 US qt/0.29 Imp gal)
54. Replace the filler plug and tighten it to the specified
torque.
Filler plug torque: 39 N·m (4.0 kgf·m/29 lb·ft)
55. Install the underguard and tighten the bolts to the
specified torque.
Underguard bolt torque:
39 N·m (4.0 kgf·m/29 lb·ft)
TRANSFER CASE 7D-39
Torque Specifications
N⋅m (kgf⋅m/lb⋅ft)
RTW57DLF000201
7D-40 TRANSFER CASE
N⋅m (kgf⋅m/lb⋅ft)
RTW57DLF000301
TRANSFER CASE 7D-41
N⋅m (kgf⋅m/lb⋅ft)
E07R300008
7D-42 TRANSFER CASE
Special Tools
PART NO. PART NO.
ILLUSTRATION ILLUSTRATION
PART NAME PART NAME
5-8840-2786-0 5-8840-2784-0
Transfer case oil seal Ring gear installer
installer
5-8840-0084-0 5-8840-0133-0
Sliding hammer Flange holder
5-8840-0027-0 5-8840-2782-0
Rear output shaft needle Needle bearing installer
bearing replacer
5-8840-2293-0 5-8840-2783-0
Punch; end nut Needle bearing installer
5-8840-2788-0 9-8522-1268-0
Front output shaft needle Rear output shaft ball
bearing replacer bearing installer
5-8840-2785-0 5-8840-2787-0
Input shaft and/or front Snap ring installer
output shaft oil seal installer
TRANSFER CONTROL SYSTEM 7D1-1
SECTION 7D1
TRANSFER CONTROL SYSTEM
TABLE OF CONTENTS
PAGE
Service Precaution ..................................................................................................... 7D1 - 2
General Description ................................................................................................... 7D1 - 3
System Components .................................................................................................. 7D1 - 5
Parts Location ....................................................................................................... 7D1 - 5
Transfer Controller ................................................................................................ 7D1 - 8
Functions of Switch and Indicator Lamp ................................................................. 7D1 - 11
Transfer-related Indicator Lamp and Switch Function ............................................ 7D1 - 15
Parts Location ............................................................................................................ 7D1 - 23
Circuit Diagram ........................................................................................................... 7D1 - 26
Connector List ............................................................................................................ 7D1 - 27
Diagnosis .................................................................................................................... 7D1 - 29
Before Determining A Trouble (Non-trouble mode) ........................................... 7D1 - 29
Memory Erasing Procedure ....................................................................................... 7D1 - 35
Diagnosis from Symptom .......................................................................................... 7D1 - 37
7D1-2 TRANSFER CONTROL SYSTEM
Service Precaution
WARNING:
THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT
SYSTEM (SRS). REFER TO THE SRS COMPONENT AND
WIRING LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS WIRING.
WHEN YOU ARE PERFORMING SERVICE ON OR NEAR
THE SRS COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW
WARNINGS COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE
UNNECESSARY SRS SYSTEM REPAIRS.
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.
TRANSFER CONTROL SYSTEM 7D1-3
General Description
RTW87DLF000301
System Components
Parts Location
RTW57DLF000401
Speed sensor
Revolutions of the rear output shaft are decreased and taken
out by the speed/drive/driven gears installed in the transfer
case. The number of revolutions is detected with a speed
sensor.
About 4/3 pulses per revolution of the shaft are output.
4WD switch
The 4WD switch detects the movement of the shift rod driving
the 4×2 - 4×4 sleeve.
PUSH open is achieved with the PUSH open switch when the
shift rod is at the 4×2 position.
×2 - 4×
4× ×4 sleeve & Arm
The 4×2 - 4×4 sleeve moves directly in the 4×4 direction with
7D1-6 TRANSFER CONTROL SYSTEM
the 4×2 - 4×4 shift rod. When moving in 4×2 direction, a spring
standby mechanism is provided between the rod and sleeve so
that the rod is positioned at the 4×2 position, while the sleeve is
at the 4×4 position.
This mechanism is provided to protect the shift mechanism
from the force and to prevent movement of the sleeve
(torsional torque etc. of the drive system). By releasing the
preventive force, the sleeve can move to the 4×2 state by the
spring force.
Neutral switch
The neutral switch detects the movement of the shift rod
driving the high-low sleeve.
PUSH close is achieved with the PUSH close switch when the
shift rod is positioned between the High and the Low, at the
neutral state.
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.
7B4-PDF2
TRANSFER CONTROL SYSTEM 7D1-7
7B4-PDF3
RTW77DSH000601
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
7D1-8 TRANSFER CONTROL SYSTEM
Transfer controller
RUW77DMF000101
Legend
1. Transfer Controller
2. Nut
TRANSFER CONTROL SYSTEM 7D1-9
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.
7B4-PDF6
7D1-10 TRANSFER CONTROL SYSTEM
C-112 C-111
Vehicle harness connector pin No. (connector of mating parts of the harness is shown in this figure)
Actuator
detection
SOF
(limit)
Check actuator
switches Transfer Transfer
4WD Neutral 4WD 4WD switch
Item 4L lamp LS1, LS2, 4WD neutral Remarks
lamp lamp warning switch Or
LS3. and switch switch
light Axle
LS4
dummy
1 = on
2 = off
No
2H Off Off Off Off 1,0,1,0 Open Open Open -----
operation
4H start 4H position Switch
of Off Off Off Off for 0.1 1,0,1,0 Open Open Open operation
operation second sensor
1,1,1,0
2H to 4H
Start of Blinking No 0,0,1,0
Off Off Off Open Open Open while
operation (2HZ) operation 0,1,1,0
driving
0,1,1,1
2H to 4H
1,1,1,0
During using
Blinking No 0,0,1,0
operation Off Off Off Open Open Open synchro
(2HZ) operation 0,1,1,0
(Synchro) and
0,1,1,1
retrial
During
operation Blinking No
Off Off Off 0,0,1,1 Closed Open Open Axle drive
(Axle (2HZ) operation
drive)
Axle Blinking No
Off Off Off 0,0,1,1 Closed Open Open Axle drive
waiting (2HZ) operation
No
4H On Off Off Off 0,0,1,1 Closed Open Closed -----
operation
4L start 4L position Switch
of On Off Off Off for 0.1 0,0,1,1 Closed Open Closed operation
operation second sensor
4H to 4L
Start of Blinking No 0,0,0,1
On Off Off Closed Open Closed while
operation (2HZ) operation 0,1,0,1
driving
During 4H to 4L
Blinking No 0,0,0,1
operation Off Off Off Closed Closed Closed through
(2HZ) operation 0,1,0,1
(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
operation Off Off Off 1,1,0,0 Closed Closed Closed through
(2HZ) operation
(N) neutral
4H to 4L
4L Blinking No
On Off Off 1,1,0,1 Closed Closed Closed while
waiting (2HZ) operation
waiting
No
4L On On Off Off 1,1,0,1 Closed Open Closed -----
operation
4H start 4H position Switch
of On Off Off Off for 0.1 1,1,0,1 Closed Open Closed operation
operation second sensor
7D1-12 TRANSFER CONTROL SYSTEM
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
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
operation Off Off Off 1,1,0,0 Closed Closed Closed through
(2HZ) operation
(N) neutral
4L to 4H
During Blinking No 0,1,0,1
Off Off Off Closed Closed Closed while
operation (2HZ) operation 0,0,0,1
driving
4L to 4H
4H Blinking No
Off Off Off 0,0,1,1 Closed Closed Closed while
waiting (2HZ) operation
waiting
No
4H On Off Off Off 0,0,1,1 Closed Open Closed -----
operation
2H start 2H position Switch
of On Off Off Off for 0.1 0,0,1,1 Closed Open Closed operation
operation second sensor
0,1,1,1
2H to 4H
Start of Blinking No 0,1,1,0
Off Off Off Closed Open Closed while
operation (2HZ) operation 0,0,1,0
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
(2HZ) operation 0,0,1,0
(Axle)
1,1,1,0
Axle Blinking No Axle
Off Off Off 1,0,1,0 Open Open Closed
waiting (2HZ) operation waiting
No
2H Off Off Off Off 1,0,1,0 Open Open Open -----
operation
TRANSFER CONTROL SYSTEM 7D1-13
2H to 4H retrial
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
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
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
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
• Completion of transfer case H-L area and axle shift timing may cause some variation in the 2Hz blinking pattern.
7D1-14 TRANSFER CONTROL SYSTEM
Operational limits (4H 4L) (Vehicle speed, engine speed, and transmission position not specified)
Actuator
detection
SOF
(limit)
Check actuator
switches Transfer Transfer
4WD Neutral 4WD 4WD switch
Item 4L lamp LS1, LS2, 4WD neutral Remarks
lamp lamp warning switch Or
LS3. and switch switch
light Axle
LS4
dummy
1 = on
2 = off
4H On Off Off Off Open 0,0,1,1 Closed Open Closed -----
4L
4H start
position
of On Off Off Off 0,0,1,1 Closed Open Closed -----
for 0.1
operation
second
10
No
second
Blinking operation
display On Off Off Open 0,0,1,1 Closed Open Closed
(4HZ) during
during
limitation
limitation
Go to 4H
after 10 On Off Off Off Open 0,0,1,1 Closed Open Closed -----
seconds
Operational limits (4L 4H) (Vehicle speed, engine speed, and transmission position not specified)
Actuator
detection
SOF
(limit)
Check actuator
switches Transfer Transfer
4WD Neutral 4WD 4WD switch
Item 4L lamp LS1, LS2, 4WD neutral Remarks
lamp lamp warning switch Or
LS3. and switch switch
light Axle
LS4
dummy
1 = on
2 = off
No
4L On On Off Off 1,1,0,1 Closed Open Closed -----
operation
4H
4L start of position
On On Off Off 1,1,0,1 Closed Open Closed -----
operation for 0.1
second
10
No
second
Blinking operation
display On Off Off Open 1,1,0,1 Closed Open Closed
(4HZ) during
during
limitation
limitation
Go to 4L
No
after 10 On On Off Off 1,1,0,1 Closed Open Closed -----
operation
seconds
• Under some conditions, a secondary operational indication may be received when the 4Hz operational indication
is present.
TRANSFER CONTROL SYSTEM 7D1-15
Actuator
detectio
n (limit) SOF
switches actuator
Check Transfer Transfer
4WD Neutral 4WD LS1, switch
Item 4L lamp 4WD 4WD neutral Remarks
lamp lamp switch LS2, Or
lamp switch switch
LS3. and Axle
LS4 dummy
1 = on
2 = off
2H
Switch
2H start of position
On On Off Off 1,1,0,1 Closed Open Closed operation
operation for 0.1
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
operation Blinking No
Off Off Off 0,0,1,1 Closed Closed Closed while
(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 -----
waiting (2HZ) operation
No
2H Off Off Off Off 1,0,1,0 Open Open Open -----
operation
• Completion of transfer case H-L area and axle shift timing may cause some variation in the 2Hz blinking pattern.
TRANSFER CONTROL SYSTEM 7D1-17
Skip operation limitations (4L 2H) (Vehicle speed, engine speed, and transmission position not
specified)
Actuator
detection
SOF
(limit)
Check actuator
switches Transfer Transfer
4WD Neutral 4WD 4WD switch
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
4L Off On Off Off Open 1,1,0,1 Closed Open Closed -----
2H
4L start of position
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
Skip operation limitations (2H 4L) (Vehicle speed, engine speed, and transmission position not
specified)
Actuator
detection
SOF
(limit)
Check actuator
switches Transfer Transfer
4WD Neutral 4WD 4WD switch
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
2HL Off Off Off Off Open 1,0,1,0 Open Open Open -----
2H
4L start of position
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
Under some conditions, a secondary operational indication may be received when the 4Hz operational
indication is present.
7D1-18 TRANSFER CONTROL SYSTEM
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
During
4L to 4H
operation Blinking No
Off Off Off 0,0,1,1 Closed Closed Closed while
(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
(2HZ) operation 0,0,1,0
(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
Off Off Off 1,0,1,0 Open Open Closed -----
waiting (2HZ) operation
No
2H Off Off Off Off 1,0,1,0 Open Open Open -----
operation
• Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer shifts
in both directions (H←→Neutral←→L).
7D1-20 TRANSFER CONTROL SYSTEM
4H Neutral 4H
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
4H On Off Off Off 0,0,1,1 Closed Open Closed -----
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
operation (2HZ) operation
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
operation Off Off Off 0,1,0,0 Closed Closed Closed with axle
(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
Off Off Off 1,0,1,0 Open Open Closed -----
waiting (2HZ) operation
No
Neutral Off Off On Off 0,1,0,0 Closed Closed Open -----
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
operation Off Off Off 0,1,0,0 Closed Closed Open through
(2HZ) operation
(N) neutral
4L to 4H
During Blinking No 0,1,0,1
Off Off Off Closed Closed Open while
operation (2HZ) operation 0,0,0,1
driving
4L to 4H
4H Blinking No
Off) Off Off 0,0,1,1 Closed Closed Open while
waiting (2HZ) operation
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 -----
waiting (2HZ) operation
No
4H On Off Off Off 0,0,1,1 Closed Open Closed -----
operation
TRANSFER CONTROL SYSTEM 7D1-21
• Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer shifts
in both directions (H←→Neutral←→L).
7D1-22 TRANSFER CONTROL SYSTEM
4L Neutral 4L
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
4L On On Off Off 1,1,0,1 Closed Open Closed -----
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
operation (2HZ) operation
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
operation Off Off Off 0,1,0,0 Closed Closed Closed with axle
(2HZ) operation
(N) removed
During
Blinking No Axle
operation Off Off Off 0,1,0,0 Closed Closed Closed
(2HZ) operation driving
(Axle)
Axle Blinking No
Off Off Off 0,1,0,0 Closed Closed Closed -----
waiting (2HZ) operation
No
Neutral Off Off On Off 0,1,0,0 Closed Closed Open -----
operation
4L
Switch
4L start of position
Off Off On Off 0,1,0,0 Open Open Open operation
operation for 10
sensor
seconds
During 4H to 4L
Blinking No
operation Off Off Off 1,1,0,0 Closed Closed Open through
(2HZ) operation
(N) neutral
During 4H to 4L
Blinking No
operation Off Off Off 1,1,0,0 Closed Closed Open through
(2HZ) operation
(N) neutral
During 4H to 4L
Blinking No
operation Off Off Off 1,1,0,0 Closed Closed Open through
(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
(2HZ) operation driving
(Axle)
Axle Blinking No
Off Off Off 1,1,0,1 Closed Open Open -----
waiting (2HZ) operation
No
4H On On Off Off 1,1,0,1 Closed Open Closed -----
operation
• Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer shifts
in both directions (H←→Neutral←→L).
TRANSFER CONTROL SYSTEM 7D1-23
Parts Location
RUW780XF019501
7D1-24 TRANSFER CONTROL SYSTEM
RUW780XF019601
TRANSFER CONTROL SYSTEM 7D1-25
RTW780XF006301
7D1-26 TRANSFER CONTROL SYSTEM
CIRCUIT DIAGRAM
RUW780XF012901
TRANSFER CONTROL SYSTEM 7D1-27
CONNECTOR LIST
No. Connector face No. Connector face
B23 C95
White White
Meter-A TCM B
B24 C107
White White
J/B I4 J/B E1
B62 C109
White Silver
Ignition switch (IGSUB : G1) Body-LH ; ground
B63 C111
White Black
Ignition switch (IGSUB : G2) Transfer case control module
B64 C112
Silver Black
Weld splice 1 (Illumination) Transfer case control module
B65 C134
Silver Gray
Weld splice 2 (Ground) Motor actuator
B66 E10
White Silver
4WD switch Engine ground
C36 E35
Silver Black
Engine room - LH ; Ground Motor actuator (Transfer)
C67 E44
Black Black
EHCU Vehicle speed sensor
7D1-28 TRANSFER CONTROL SYSTEM
Gray Silver
2WD-4WD switch Battery (-)
E46 P6
Brown Silver
H-L neutral switch Body ground
E51 P10
Black Silver
Inhibiter switch Engine ground
H4 C58
(A/T)
White
Engine ~ Engine room
H5
White
Engine room ~ INST
H41
Gray
INST ~ Engine room
H23
Silver
Battery (+)
P2
Silver
Relay & Fuse box
TRANSFER CONTROL SYSTEM 7D1-29
Diagnosis
Before determining a trouble (Non-trouble mode)
1. When shifting from 2H to 4H:
1-1-1 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Shift on the fly)
If the load is too large to shift the gears synchronously, the operation is repeated up to 3 times. If the shifting
is not effected after being repeated 3 times, the indicator frequency is changed from 2Hz to 4Hz. At the same
time, the actuator condition is changed to 2H, indicator flashes at 4Hz for 10 seconds, and then goes out.
Cause of excessive synchronous shifting load
• Extremely low temperature (the oil viscosity of the front differential increases requiring a large load for
synchronization).
• High speed (since the difference of relative revolutions of gears to be shifted synchronously is too large,
required work load per unit time becomes larger).
Step 1-1-1:
Stop the vehicle or decrease the speed and operate as required again.
1-1-2 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Rigid and free wheel
Hub) / Block out of meshing spline in transfer case.
Step 1-1-2:
Run the vehicle forward and backward several meters and operate as required again.
1-2 When the flashing of 4WD indicator at 2Hz continues more than 11.5 seconds (repetition of 3 times of
above No.1 is counted) (Shift on the fly)
If there is difference of revolutions and phases between the front wheel and the axle, connecting the front
wheel and axle is difficult.
Until shifting in the transfer and connection of the front wheel and axle are completed∗, the indicator flashes at
a frequency of 2Hz. In the above case, the indicator continues flashing at a frequency of 2Hz until the
connection of the front axle is completed. (If the shifting in the transfer is not completed, the flashing
frequency is changed to 4Hz (above No.1).)
By correcting the difference of relative revolutions and deviation of phases, the shifting can be completed.
Step 1-2:
While the vehicle is running, check it is safe around the vehicle and then accelerate or decelerate the
vehicle while going straight.
When the vehicle is at a stop, run the vehicle forward and backward several meters.
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.)
Restriction on operation
The 4H, neutral and 4L shifting mechanism has no synchronization function. Therefore, if relative rotations in
the mechanism become excessive, shifting exerts adverse influence on the internal mechanism of the transfer.
To avoid such a trouble, vehicle condition is detected to restrict the operation (vehicle speed, engine speed and
TM position).
Requirement to restrict the speed: Vehicle should be in stop.
Due to the detection logic, time to wait for start of operation may be required.
A/T: If the vehicle is in stop for a long time at the TM running range (D, 1, 2) before operating the AT, waiting
time becomes longer (from 1 second to 3 minutes at the maximum).
M/T: If the vehicle is at stop with the clutch stepped on at the T/M running position (1 – R), the time to wait
becomes longer.
Waiting time means the time commencing from when other requirements (engine speed and T/M position) are
met to permission of the speed restriction. Operation during the waiting time is not permissible.
The waiting time is 1 second at the minimum and increases up to 5 seconds if the above condition continues
for 3 minutes. After that, the waiting time increases up to 3 minutes in 2 minute intervals.
When it is clear that the above condition has continued and reduction of waiting time is required, turn on or off
the ignition or start and stop the vehicle several meters.
Requirements for permission of restriction on engine speed: Engine speed should be decreased.
The engine speed of 3000rpm or below is advisable.
Requirements for permission of restriction on T/M position restriction:
(AT) N range is recommended
(MT) should be at the neutral.
These requirements for permission should all be met before the switch is operated. If the requirements are met
after operation, operation is not automatically effected but re-operation is required after permission is given.
TRANSFER CONTROL SYSTEM 7D1-31
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.
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 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
Step 5-2:
Stop the vehicle.
(In case of AT): Set the transmission select lever to the N (or P) position.
(In case of MT): Set the transmission lever to the neutral position (at this time, stepping on the clutch
is recommended).
Keep pushing the 2H and 4L button for 10 seconds.
Follow the start procedure for confirmation. (Confirmation of drive force is not transferred; same as in
step 5-1)
After the confirmation, set the transmission to the neutral position in the case of MT or to the neutral
position in the case of AT.
TRANSFER CONTROL SYSTEM 7D1-33
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.
7D1-34 TRANSFER CONTROL SYSTEM
Trouble diagnosis based on the operation switch, transfer indicator lamp and operating
sound “Check 4WD” indicator ON (operation guard based on the transfer actuator
position detection error)
This condition indicates a faulty circuit related with the detection (limit) switches of the system actuator.
Detection (limit) switches detect the actuator operating angle based on their combinations.
The controller monitors transition of the actuator based on the combination of the detection (limit) switch output.
If the transition based on the combinations indicates some trouble, it is memorized, and shifting operation is
stopped when the trouble is counted 5 times, and the “Check 4WD” indicator lights up. At this time, the system
permits operation to 2H only.
When such a condition occurs, inspection of the transfer shift actuator, checking of the harness related with the
detection (limit) switch, and erasure of the memory of the controller is required.
(Refer to the memory erasure procedure for the erasure of the memory.)
At this time, the position indicator may flash at 4Hz. It means that a detection (limit) switch trouble wad detected
in the operation process shown by that position indicator (example: 4WD indicator when shifting from 2H to 4H).
Caution:
During trouble diagnosis and correction, do not turn ON the ignition with the harness connector of the
transfer actuator disconnected. (Do not disconnect the harness connector of the transfer actuator when
the ignition is ON.)
If the controller is connected during this condition, a limit SW trouble is judged and the above-described
“Check 4WD” condition is occurs.
This can be reset by clearing the memory.
When disconnecting the harness connector of the actuator and turning the ignition ON is required, remove
the controller at the same time or remove the IG power fuse of the transfer controller.
TRANSFER CONTROL SYSTEM 7D1-35
RTW77DSH000101
RTW77DSF000201
TRANSFER CONTROL SYSTEM 7D1-37
Even after correction step 1-1(*), 4WD indicator blinks at 4Hz and changes to 2H after 10
seconds.
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Turn the ignition switch ON and
trace this chart from the
beginning.
2 Does the transfer-related Go to step 3. 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?
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.
After repairing, trace this chart
from the beginning.
*Before determining a trouble (Non-trouble mode)
TRANSFER CONTROL SYSTEM 7D1-39
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.
*Before determining a trouble (Non-trouble mode)
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.
7D1-40 TRANSFER CONTROL SYSTEM
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.
After repairing, trace this chart
from the beginning.
2 Press the 4H button. Go to step 3. Failed controller.
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.
After repairing, trace this chart
from the beginning.
TRANSFER CONTROL SYSTEM 7D1-41
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.
*Before determining a trouble (Non-trouble mode)
Note:
Vehicles with manual hub and rigid hub don’t have axle actuator.
When the above-mentioned procedure is followed, check the harness between the axle dummy output terminal and
the axle switch input terminal of the transfer controller, instead of axle actuator.
TRANSFER CONTROL SYSTEM 7D1-43
Though the indicator responds when shifting from 4H to 2H(or other position), it returns
to 4H.
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Turn the ignition switch ON and
trace this chart from the
beginning.
2 Does the transfer-related Go to step 3. 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?
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.
After repairing, trace this chart
from the beginning.
4 Press the 2H button. Go to step 5. Failed controller.
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).
7D1-44 TRANSFER CONTROL SYSTEM
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.
*Before determining a trouble (Non-trouble mode)
TRANSFER CONTROL SYSTEM 7D1-45
From 4L to 4H: After the correction step 4-3(*), 4Lo indicator blinks at 4H.
Step Action Yes No
1 Is the ignition switch ON? Turn it OFF once. Go to step 2.
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 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.
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 noticed? detection unit, if required.)
7 Run the vehicle for several Failed transfer 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.
*Before determining a trouble (Non-trouble mode)
7D1-46 TRANSFER CONTROL SYSTEM
To neutral: After the correction step 5-2(*), neutral indicator blinks at 4Hz.
Check the function between H and L according to the chart for 4L to 4H instead of check
for the requirements of neutral.
Step Action Yes No
1 Is the ignition switch ON? Turn it OFF once. Go to step 2.
2 Turn ON the ignition switch and Go to step 3. Refer to the paragraph about the
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.
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 this (for the meter).
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 noticed? detection unit, if required.)
7 Run the vehicle for several Failed controller. You did not wait for enough time.
meters, stop it, meet the Replace the controller and trace Optimum waiting time is 1 second
permission requirements for this chart from the beginning. or maximum 3 minutes
operation limits. depending on the previous
Did you wait for several seconds conditions.
after the requirements were met? Refer to the paragraph about
operation without failure.
*Before determining a trouble (Non-trouble mode)
For shifting to neutral, 2H and 4L switches should be pressed at the same time for 10 seconds.
For shifting from neutral to other position, 2H, 4H or 4L switch should be pressed for 10 seconds.
When shifting from neutral to other position, the lamp blinking at 2Hz indicates active condition.
When the lamp keeps blinking at 2Hz, follow the step for the case when the lamp keeps blinking at 2Hz when
shifting between positions.
UCT150-WE-1101
Issued by
ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Tokyo, Japan