I'm having a very frustrating problem with my otherwise great 1998 Rodeo.
At 100,000 miles, shift lever on transfer case started popping into a neutral position between 4 high and 4 low when the the 4WD button was activated. I have to pull over and shut off before I can reingage. Never has a problem in 4-low.

Transmission shop said it was likely a worn range hub and range fork. I found a used transfer case (80K miles) at salvage yard and replaced. Still same problem. Salvage yard gave me another one, (also about 80K), replaced, still same problem.

There are no Isuzu mechanics in this part of Idaho. Any suggestions on what problem might be?

thanks

 

Seems like the transmission range sensor. You have swapped out transmission though so maybe PCM?


DESCRIPTION AND OPERATION


NOTE: </B>The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected.
The four inputs from the transmission range switch indicate to the Powertrain Control Module (PCM) which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, Exhaust Gas Recirculation (EGR) and Idle Air Control (IAC) valve operation.
----------------------
REMOVAL

1. Place selector lever in neutral.
2. Disconnect battery ground cable.

1. Remove mode switch cover (1).
2. Disconnect selector lever (2) from the mode switch.
3. Remove bracket with cable (3).
4. Disconnect transmission harness from the mode switch connector (4).
5. Remove bracket with mode switch connector from the transmission case.
6. Remove mode switch connector (4) from the bracket (5).
7. Remove two mode switch bolts and nut then remove mode switch (6).

INSTALLATION
To install, follow the removal steps in the reverse order, noting the following points;

1. Torque Mode switch bolt: 13 Nm (113 inch lbs.) Selector lever nut: 23 Nm (17 ft. lbs.)
2. Mode switch setting procedure. Perform either of the following adjustment procedures:

Procedure 1 </B>

1. Place selector lever in neutral.
2. Remove selector lever from the mode switch.
3. Remove the mode switch cover.
4. Loosen the two 10 mm screws.

1. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 inch (2.4 mm) drill bit or punch (1) into the slot.
2. Tighten the screws to 13 Nm (113 inch lbs.) .
3. After completing adjustment, snap the mode switch cover into place.
4. Reinstall the selector lever.

Procedure 2</B>

1. Place selector lever in neutral.
2. Disconnect transmission harness connector from mode switch connector.
3. Remove mode switch connector with bracket from the transmission case.

1. Connect multimeter (resistance mode) to terminals 1 (E) and 4(H) on mode switch connector.
2. Loosen two mounting screws.
3. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact.
4. Position mode switch in middle of contact range.
5. Tighten two mounting screws.
6. Remove multimeter and install mode switch harness connector with bracket to the transmission case.
7. Connect transmission harness connector to mode switch connector.

 

Thanks neuwbea!
Where did you get such great instruction manual. We've been looking for one? I'll get this info to the mechanic and let you all know what happens.

Thanks again,
robby