SECTION 7D - TRANSFER CASE

Service Precaution

General Description

Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts

Removal

Installation

Transfer Case Assembly

Transfer Case Assembly and Associated Parts

Removal

Installation

Transfer Control Unit

Removal

Installation

Transfer Disassembly

Removal

Internal Component Disassembly and Reassembly

Oil Pump Disassembly

Oil Pump Reassembly

Inspection and Repair

Inspection and Repair (Transfer Case Assembly)

Reassembly

Main Data and Specifica tions

General Specifications

Torque Specifications

Special Tools

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.

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 is n when 4WD is

selected.

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.

pply the recommended grease (BESCO L2) o

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.

220R300021

4. Connect the rear propeller shaft.

Transfer Case Assembly

Transfer Case Assembly and Associated Parts

RTW37DLF000201

Legend

(1)Rear Propeller Shaft (4)Transfer Case Assembly

(2)Front Propeller Shaft (4JH1-TC) (5)Center Exhaust Pipe (6VE1 only )

(3)Front Propeller Shaft (6VE1)

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 vehic le with suitable stands. Drain

transfer case fluid.

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

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

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

pply a thin coat of molybdenum disulfide grease to

the input shaft spline as shown in the figure.

260R300001

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

transfer bolts as shown in the figure.

For M/T

261R300001

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 propelle

shaft (2)(3).

Torque: 63 N⋅

⋅⋅⋅m (6.4 kg⋅

⋅⋅⋅m/46 lb ft)

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. Dis connect the harness connector f rom the T ransfe

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 Disassembly

RTW37DLF000101

Legend (7) Neutral Switch ASM

(1)Transfer Case (8) Speedometer Bush, Plate and Driven Gear

(2)Companion Flange, O-ring and Nut (4JH1-TC) (9) Transfer Actuator

(3)Stoneguard (10) Breather Hose

(4)Detent Plug, Spring and Detent Ball (11) Companion Flange, O-ring and Nut (6VE1)

(5)2-4 Switch ASM (12) Heat Protector

(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

• 2-4 switch assembly (Gray harness cover)

• Neut ral switch assembly (Black harness cover)

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

parts each)

4. Use the com panion 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

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

• H-L sleeve

• H-L shift asse mbly

• 2-4 sleeve, synchroniser key, and front

synchroniser 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. Com press 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 s haft assem bly f rom 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, synchroniser key, and front

synchroniser spring

(4)2-4 Shift ASM

(5)Shift Shaft

(6)H-L Shift ASM

(7)Shift Drum

10. Remove the transfer c hain and the front output shaf t

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 synchroniser spring.

RTW37DMF000101

Legend

(1)Rear synchroniser 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

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 lightl

tapping on the sun gear input shaf t end. Rem ove the

carrier and gear assembly from the transfer case.

226R300020

18 Remove the dogteeth snap r ing from the carr ier and

gear assembly.

19. Remove the planetary dogteeth 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 f rom the center of the car rier and

gear assembly.

Legend

(1)Outer Retaining Ring

(2)Carrier and Gear ASM

(3)Thrust needle Bearing

(4)Sun gear Input Shaft

(5)Planetary dogteeth

(6)Dog Teeth Snap Ring

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 ham m er (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

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 com press 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. Remove the shift block assembly

11. Remove the outer 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 (RE AR)

(7)ROD; SHIFT

(8)RING; SNAP, OUTER

(9)ROLLER; GUIDE

(10)PIN ASM; SPRING

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 com press 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

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 protect 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 careful in the alignment of the clamps.

RTW37DSH000101

Legend

(1) OIL PUMP ASM

(2) CLAMP

(3) HOSE

(4) SCREEN ASM

Inspection and Repair

1. Make the necessary repair or parts replacement i

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 ever

part. Apply compressed air to each oil feed port and

channel in each case half to remove an

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 sprock et 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 transf er c over or the c hain is so s lack that

a skipped engagement occurs between the chain

and sprocket, replace the chain.

Sprocket

• Check whether the sprocket tooth surface is

exces sively worn or dam aged, 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 excessivel

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. I

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 switch.

221R300001

261R300003

Switch Position 1: Terminals 1&2 are open circuit

Switch Position 2: Terminals 1&2 have continuity

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

Synchronisers

The synchroniser hubs and sliding sleeves are a

selected assembly and should be kept together as

originally assembled.

Clean synchroniser 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.

Block Ring and Insert Clearance

1. Use a vernier caliper to measure the clearance

between the block ring and the insert.

2. If the measured value exceeds the specified limit,

the block ring and the insert must be replaced.

Block ring and insert clearance

Standard : 2.46-2.74 mm (0.097-0.108 in)

Limit : 3.0 mm (0.118 in)

226RS037

2WD-4WD Synchroniser (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 synchroniser 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 Spri ngs

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

Replace if these conditions are present.

Detent Spring Free Length

1. Use a vernier caliper to measure the detent spring

free length.

2. If the m easured value is less than the s pecified 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 Spri ng Tension

1. Use a spring tester to measure the detent spring

tension.

2. If the m easured value is less than the spec ified limit,

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.

2. If the measured value is less than the specif ied limit,

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)

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 f ront output shaf t oil s eals

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 full

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

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

hold the internal gear against the dam per 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 gea

assembly in that order.

9. Install the outer retaining ring to the tansfer case

10. Use a pair of s nap ring plier s to ins tall the carr ier and

gear assembly.

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

its groove.

226R300003

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

12. Install the hub snap ring.

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

synchroniser 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.

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

Legend

(1)Retaining Ring

(2)Carrier and Gear ASM

(3)Thrust Needle Bearing

(4)Sun gear Input Shaft

(5)Planetary Dog Teeth

(6)Dog Teeth Snap ring

226R300023

Legend

(1)H-L Sleeve (3)Synchroniser 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 assembl

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.

19.

lign 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.

ssemble 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.

24.

lign the sprocket thrust washer with the main shaft

groove and install it.

226R300009

25. Select a snap r ing that will allow minim um axial play.

Insert it to the main shaft installation groove.

Identification colour Snap ring thickness -mm (in)

Red 2.15 (0.085)

No colour 2.10 (0.083)

Blue 2.05 (0.081)

White 2.00 (0.079)

226R300008

Legend

(1)Block Ring (5)Chain

(2)Outside Ring (6)Front Output Shaft

(3)Inside Ring (7)Thrust Washer

(4)Sprocket (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.

28. Use a press and the installer (5-8840-2783-0) to

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.

226R300005

30. Temporarily install the speedometer drive gear to the

inside of the rear cover. Pay close attention to

installation direction.

31. Use a press and the installer (9-8522-1268-0) to

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.

pply Loctite FMD 127 to the m ating surfaces of the

rear cover and the transfer case. Be sure that the

Loctite is evenly applied to the inside surfac es of the

bolt holes with no gaps.

Legend

(1)Oil Pump ASM

(2)Wire Snap ring

(3)Retaining Ring

(4)Ball Bearing

(5)Speedometer Gear Drive Gear

(6)Rear Cover

Legend

(1)Wire Snap ring

226R300011

36. Install the rear cover to the transf er 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 s pecified

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.

pply Loctite 575 to the threaded portion of the

detenteplugs.

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

shaft end s nap ring to the rear output s haft (f rom 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 neutr al s witch (blac k harnes s 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

speedom eter bush, and the speedom eter stay to the

transfer case. Tighten the bolts to the specified

torque.

Speedometer bolt torque:

15 Nm (1.5 kgm/11 lbft)

52. Ins tall the drain plug to the transfer case and tighten

it to the specified torque.

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

53. Loos en and remove the f iller 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)

Main Data and Specifications

General Specifications

Type Synchronised 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; 2.050

Oil capacity 1.3 lit. (1.37 U.S. quart)

Type of lubricant Refer to chart in Section 0B

Torque Specifications N⋅m (kg⋅m/lb ft)

RTW37DLF000501

N⋅m (kg⋅m/lb ft)

RTW37DLF000301

N⋅m (kg⋅m/lb ft)

E07R300008

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

5-8840-2787-0

Snap ring installer