Isuzu Amigo / Axiom / Trooper / Rodeo / VehiCross. Manual - part 147

4D2–2

TRANSFER CASE (TOD)

General Description

A04R200003

The Torque-On-Demand (TOD) is an
electronically-controlled torque-split 4-wheel drive
system with the following features.

Shifting Between High and Low Ranges

The shifting mechanism consists of the cam and shaft rail
assembly, the high/low shift motor and the encoder. The
encoder is built-in to the motor.
The encoder senses high/low range shift motor rotation
position and sends this data to the TOD control unit.
Based on this data, the TOD control unit adjusts motor
rotation speed or stops the motor.
The shifting between the high and low ranges using the
TOD switch only is possible. The vehicle must be stopped
or nearly stopped (vehicle speed less than 2 km/h (1.2
mph) and engine speed less than 1,500 rpm), the
automatic transmission selector level must be in the
neutral (N) position, and the brakes must be applied.

Electronically-controlled Wet-type Multiple
Disc Clutch

The clutch automatically provides the optimum drive
power to the front wheels of the vehicle in response to
varying road surface conditions when the vehicle is
operated in the TOD mode. The delivered power ranges
from 0% to 100% of power train output. Superior
operational stability is maintained over a wide range of
operating conditions.

Front Output Drive

Front output drive is provided by a chain. This reduces the
loud noise associated with 4-wheel drive operation.

Oil Pump Lubrication

An oil pump is used to lubricate the transfer. This ensures
stable multiple-disc clutch operation and maintains the
lubricating oil at a constant temperature.

4D2–3

TRANSFER CASE (TOD)

Removal and Installation of Tfansfer Case Assembly

F07R200001

Legend

(1) Transfer Protector
(2) Front Propeller Shaft Assembly
(3) Speedometer Sensor Harness Connector
(4) Rear Propeller Shaft Assembly

(5) Center Exhaust Pipe
(6) Transfer Case Bolt
(7) Transfer Case Assembly
(8) Transfer Case Harness Connector

4D2–4

TRANSFER CASE (TOD)

Removal

1. Disconnect the battery ground cable.
2. Remove the transfer protector.
3. Disconnect the rear propeller shaft assembly from the

transfer case.

4. Disconnect the front propeller shaft assembly from

the transfer case.

5. Remove the center exhaust pipe.
6. Disconnect the speedometer sensor harness

connector from the speedometer sensor, and remove
the harness clamp from the connector bracket of the
transfer case.

7. Disconnect the engine harness connector from the

transfer harness connector.

8. Support the transfer case with a transmission jack.
9. Remove the transfer bolts.

10. Remove the transfer case assembly.

Installation

1. Apply grease (Besco L2 or its equivalent) to the input

shaft spline.

260RY00011

2. Install the transfer case assembly to the transmission

assembly.

3. Install the transfer bolts to the specified torque (Refer

to 

next page).

Torque: 46 N·m (34 lb ft)

4. Connect the engine harness connector to the transfer

harness connector.

5. Install the breather hose up to bottom of the transfer

case breather and clip them firmly.

6. Securely insert the breather hose into the cutout

portion of the transfer case.

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4D2–5

TRANSFER CASE (TOD)

7. Install the speedometer harness clamp to the

connector bracket of the transfer case, and then
connect the harness connector to the speedometer
sensor.

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8. Install the center exhaust pipe.

Torque: 43 N·m (32 lb ft)

9. Connect the front and rear propeller shaft assembly

to the transfer case.

Torque: 63 N·m (46 lb ft)

10. Install the transfer protector.

Torque: 37 N·m (27 lb ft)

11. Connect the battery ground cable.