TRANSMISSION & DRIVELINE

SECTION DLN DRIVELINE

B

DLN

E
CONTENTS
TRANSFER: TY21B 4WD SYSTEM : Fail-safe ........................................19 F
4WD SYSTEM : Protection Function .......................21
PRECAUTION ............................................... 5
DIAGNOSIS SYSTEM (4WD CONTROL
G
PRECAUTIONS ................................................... 5 MODULE) .......................................................... 22
Precaution for Supplemental Restraint System CONSULT-III Function ............................................22
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 5 ECU DIAGNOSIS INFORMATION .............. 26 H
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect ..................................... 5 4WD CONTROL MODULE ............................... 26
Service Notice or Precautions for Transfer ............... 6 Reference Value ......................................................26
I
Fail-safe ...................................................................30
PREPARATION ............................................ 7 Protection Function ..................................................32
DTC Inspection Priority Chart ..................................33
PREPARATION ................................................... 7 DTC Index ...............................................................33 J
Special Service Tools ................................................ 7
Commercial Service Tools ........................................ 8 WIRING DIAGRAM ...................................... 35
K
SYSTEM DESCRIPTION ............................. 10 4WD SYSTEM ................................................... 35
Wiring Diagram ........................................................35
COMPONENT PARTS .......................................10
Component Parts Location ...................................... 10 BASIC INSPECTION ................................... 36 L
Component Description ........................................... 11
4WD Control Module ............................................... 12 DIAGNOSIS AND REPAIR WORK FLOW ....... 36
4WD Solenoid ......................................................... 12 Work Flow ................................................................36
M
Electric Controlled Coupling .................................... 12 Diagnostic Work Sheet ............................................37
Electric Controlled Coupling Temperature Sensor.... 12 WRITING UNIT PARAMETER .......................... 39
4WD Mode Switch ................................................... 12
Description ...............................................................39 N
4WD Warning Lamp ................................................ 13
Work Procedure .......................................................39
4WD Mode Indicator Lamp ..................................... 13
Torque Distribution Indicator ................................... 13 DTC/CIRCUIT DIAGNOSIS ......................... 40
O
STRUCTURE AND OPERATION .......................15 P1804, P1809 4WD CONTROL MODULE ........ 40
Sectional View ......................................................... 15 DTC Logic ................................................................40
Operation Principle .................................................. 15 Diagnosis Procedure ...............................................40 P
SYSTEM .............................................................17 P1808 WHEEL SPEED SENSOR ..................... 41
DTC Logic ................................................................41
4WD SYSTEM ........................................................... 17
Diagnosis Procedure ...............................................41
4WD SYSTEM : System Diagram ........................... 17
4WD SYSTEM : System Description ...................... 18 P1811 POWER SUPPLY CIRCUIT FOR 4WD
4WD SYSTEM : Torque Split Control ..................... 18 CONTROL MODULE ........................................ 42

DLN-1
 DTC Logic ............................................................... 42 P183A COUPLING TEMPERATURE SEN-
Diagnosis Procedure .............................................. 42 SOR RIGHT ....................................................... 65
DTC Logic ............................................................... 65
P1813 4WD MODE SWITCH ............................. 44 Diagnosis Procedure ............................................... 65
DTC Logic ............................................................... 44
Component Inspection ............................................ 66
Diagnosis Procedure .............................................. 44
Component Inspection ............................................ 45 P183B SOLENOID POWER SUPPLY .............. 67
DTC Logic ............................................................... 67
P181B INCOMPLETE SELFSHUT .................... 47 Diagnosis Procedure ............................................... 67
DTC Logic ............................................................... 47
Diagnosis Procedure .............................................. 47 P183C DECEL G SENSOR ............................... 69
DTC Logic ............................................................... 69
P181D ENGINE TORQUE SIGNAL ................... 49 Diagnosis Procedure ............................................... 69
DTC Logic ............................................................... 49
Diagnosis Procedure .............................................. 49 P183D SIDE G SENSOR ................................... 70
DTC Logic ............................................................... 70
P181E STEERING ANGLE SENSOR ............... 50 Diagnosis Procedure ............................................... 70
DTC Logic ............................................................... 50
Diagnosis Procedure .............................................. 50 P183E YAW RATE SENSOR ............................ 71
DTC Logic ............................................................... 71
P181F INCOMPLETE CALIBRATION .............. 51 Diagnosis Procedure ............................................... 71
DTC Logic ............................................................... 51
Diagnosis Procedure .............................................. 51 P183F GEAR POSITION SIGNAL .................... 72
DTC Logic ............................................................... 72
P1820 ENGINE SPEED SIGNAL ...................... 52 Diagnosis Procedure ............................................... 72
DTC Logic ............................................................... 52
Diagnosis Procedure .............................................. 52 P1840 OUTPUT SPEED SIGNAL ..................... 73
DTC Logic ............................................................... 73
P1829 ACCELERATOR PEDAL POSITION Diagnosis Procedure ............................................... 73
SENSOR ............................................................ 53
DTC Logic ............................................................... 53 P1864 INPUT SPEED SIGNAL ......................... 74
Diagnosis Procedure .............................................. 53 DTC Logic ............................................................... 74
Diagnosis Procedure ............................................... 74
P182D 4WD SOLENOID LEFT .......................... 54
DTC Logic ............................................................... 54 P1865 GEAR RATIO SIGNAL ........................... 75
Diagnosis Procedure .............................................. 54 DTC Logic ............................................................... 75
Component Inspection ............................................ 55 Diagnosis Procedure ............................................... 75
P182E 4WD SOLENOID RIGHT ........................ 57 U1000 CAN COMM CIRCUIT ............................ 76
DTC Logic ............................................................... 57 Description .............................................................. 76
Diagnosis Procedure .............................................. 57 DTC Logic ............................................................... 76
Component Inspection ............................................ 58 Diagnosis Procedure ............................................... 76
P182F COUPLING TEMPERATURE SEN- U1010 CONTROL UNIT (CAN) ......................... 77
SOR LEFT .......................................................... 60 Description .............................................................. 77
DTC Logic ............................................................... 60 DTC Logic ............................................................... 77
Diagnosis Procedure .............................................. 60 Diagnosis Procedure ............................................... 77
Component Inspection ............................................ 61
POWER SUPPLY AND GROUND CIRCUIT ..... 78
P1830 ABS OPERATION SIGNAL ................... 62 Diagnosis Procedure ............................................... 78
DTC Logic ............................................................... 62
Diagnosis Procedure .............................................. 62 4WD WARNING LAMP ..................................... 80
Component Function Check ................................... 80
P1831 VDC OPERATION SIGNAL ................... 63 Diagnosis Procedure ............................................... 80
DTC Logic ............................................................... 63
Diagnosis Procedure .............................................. 63 4WD MODE INDICATOR LAMP (4WD-V) ........ 81
Component Function Check ................................... 81
P1832 TCS OPERATION SIGNAL .................... 64 Diagnosis Procedure ............................................... 81
DTC Logic ............................................................... 64
Diagnosis Procedure .............................................. 64 4WD MODE INDICATOR LAMP (4WD) ............ 82
Component Function Check ................................... 82
Diagnosis Procedure ............................................... 82

DLN-2
SYMPTOM DIAGNOSIS .............................. 83 Exploded View ....................................................... 108
Disassembly .......................................................... 109 A
4WD WARNING LAMP DOES NOT TURN ON....83 Assembly ............................................................... 110
Description .............................................................. 83 Adjustment ............................................................. 111
Diagnosis Procedure ............................................... 83 Inspection .............................................................. 111 B
4WD WARNING LAMP DOES NOT TURN TRANSFER CASE .......................................... 113
OFF .....................................................................84 Exploded View ....................................................... 113
Description .............................................................. 84 Disassembly .......................................................... 114 C
Diagnosis Procedure ............................................... 84 Assembly ............................................................... 114
Inspection .............................................................. 116
HEAVY TIGHT-CORNER BRAKING SYMP-
DLN
TOM OCCURS ...................................................85 SERVICE DATA AND SPECIFICATIONS
Description .............................................................. 85 (SDS) .......................................................... 117
Diagnosis Procedure ............................................... 85
SERVICE DATA AND SPECIFICATIONS E
VEHICLE DOES NOT ENTER 4WD MODE .......86 (SDS) ............................................................... 117
Description .............................................................. 86 General Specifications ........................................... 117
Diagnosis Procedure ............................................... 86 Preload Torque ...................................................... 117 F
Backlash ................................................................ 117
4WD WARNING LAMP BLINKS QUICKLY .......87
Companion Flange Runout .................................... 117
Description .............................................................. 87
REAR PROPELLER SHAFT: 3Fφ16-ETJ75 G
4WD WARNING LAMP BLINKS SLOWLY .......88
Description .............................................................. 88 PRECAUTION ............................................ 118
Diagnosis Procedure ............................................... 88 H
PRECAUTIONS ............................................... 118
NOISE, VIBRATION AND HARSHNESS Service Notice or Precautions for Rear Propeller
(NVH) TROUBLESHOOTING ............................89 Shaft ...................................................................... 118
NVH Troubleshooting Chart .................................... 89 I
SYMPTOM DIAGNOSIS ............................ 119
PERIODIC MAINTENANCE ......................... 90 NOISE, VIBRATION AND HARSHNESS
TRANSFER OIL .................................................90 (NVH) TROUBLESHOOTING ......................... 119 J
Inspection ................................................................ 90 NVH Troubleshooting Chart .................................. 119
Draining ................................................................... 90
Refilling ................................................................... 90
PERIODIC MAINTENANCE ...................... 120 K
REAR PROPELLER SHAFT ........................... 120
REMOVAL AND INSTALLATION ............... 91
Inspection .............................................................. 120
4WD CONTROL MODULE .................................91 L
Removal and Installation ......................................... 91
REMOVAL AND INSTALLATION ............. 121

4WD MODE SWITCH .........................................92 REAR PROPELLER SHAFT ........................... 121

Exploded View ....................................................... 121 M
Removal and Installation ......................................... 92
Removal and Installation ....................................... 121
UNIT REMOVAL AND INSTALLATION ...... 93 Inspection .............................................................. 123
N
TRANSFER ASSEMBLY ...................................93 SERVICE DATA AND SPECIFICATIONS
Exploded View ........................................................ 93 (SDS) .......................................................... 125
Removal and Installation ......................................... 93 O
SERVICE DATA AND SPECIFICATIONS
UNIT DISASSEMBLY AND ASSEMBLY ... 95 (SDS) ............................................................... 125
General Specifications ........................................... 125
RING GEAR SHAFT ...........................................95 Propeller Shaft Runout .......................................... 125 P
Exploded View ........................................................ 95 Journal Axial Play .................................................. 125
Disassembly ............................................................ 96 REAR FINAL DRIVE: RTVS
Assembly ................................................................. 97
Adjustment .............................................................. 98 PRECAUTION ............................................ 126
Inspection .............................................................. 107
PRECAUTIONS ............................................... 126
DRIVE PINION .................................................. 108 Service Notice or Precautions for Rear Final Drive.. 126

DLN-3
PREPARATION .......................................... 127 Removal and Installation ....................................... 142

PREPARATION ............................................... 127 UNIT REMOVAL AND INSTALLATION ... 144

Special Service Tools ............................................127
Commercial Service Tools .....................................129 REAR FINAL DRIVE ASSEMBLY ................... 144
Exploded View ...................................................... 144
SYSTEM DESCRIPTION ........................... 130 Removal and Installation ....................................... 144

STRUCTURE AND OPERATION .................... 130 UNIT DISASSEMBLY AND ASSEMBLY .. 146
Sectional View .......................................................130
Electric controlled coupling ....................................130 ELECTRIC CONTROLLED COUPLING .......... 146
Exploded View ...................................................... 146
SYMPTOM DIAGNOSIS ............................ 131 Disassembly .......................................................... 147
Assembly .............................................................. 148
NOISE, VIBRATION AND HARSHNESS Inspection .............................................................. 150
(NVH) TROUBLESHOOTING .......................... 131
NVH Troubleshooting Chart ..................................131 CENTER STEM ASSEMBLY ........................... 151
Exploded View ...................................................... 151
PERIODIC MAINTENANCE ....................... 132 Disassembly .......................................................... 152
Assembly .............................................................. 153
REAR DIFFERENTIAL GEAR OIL .................. 132 Adjustment ............................................................ 154
Inspection ..............................................................132 Inspection .............................................................. 157
Draining .................................................................132
Refilling ..................................................................132 DRIVE PINION .................................................. 159
Exploded View ...................................................... 159
REMOVAL AND INSTALLATION .............. 133 Disassembly .......................................................... 160
Assembly .............................................................. 161
FRONT OIL SEAL ........................................... 133 Adjustment ............................................................ 164
Exploded View .......................................................133 Inspection .............................................................. 165
Removal and Installation .......................................133
SERVICE DATA AND SPECIFICATIONS
SIDE OIL SEAL ............................................... 137
Exploded View .......................................................137
(SDS) ......................................................... 167
Removal and Installation .......................................137 SERVICE DATA AND SPECIFICATIONS
ELECTRIC CONTROLLED COUPLING ......... 139 (SDS) ................................................................ 167
Exploded View .......................................................139 General Specification ............................................ 167
Removal and Installation .......................................139 Drive Gear Runout ................................................ 167
Preload Torque ..................................................... 167
ELECTRIC CONTROLLED COUPLING OIL Backlash ............................................................... 167
SEAL ................................................................ 142 Companion Flange Runout ................................... 167
Exploded View .......................................................142

DLN-4
 PRECAUTIONS
< PRECAUTION > [TRANSFER: TY21B]

PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000006600488

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
DLN
The vehicle may be equipped with a passenger air bag deactivation switch. Because no rear seat exists where
a rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a
rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the E
instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is
enabled and could inflate for certain types of collision. When the switch is turned to the OFF position, the pas-
senger air bag is disabled and will not inflate. A passenger air bag OFF indicator on the instrument panel lights
up when the passenger air bag is switched OFF. The driver air bag always remains enabled and is not affected F
by the passenger air bag deactivation switch.

WARNING: G
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. H
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SRS AIR BAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this I
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
• The vehicle may be equipped with a passenger air bag deactivation switch which can be operated by J
the customer. When the passenger air bag is switched OFF, the passenger air bag is disabled and
will not inflate. When the passenger air bag is switched ON, the passenger air bag is enabled and
could inflate for certain types of collision. After SRS maintenance or repair, make sure the passenger
air bag deactivation switch is in the same position (ON or OFF) as when the vehicle arrived for ser- K
vice.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
L
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly M
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service. N
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect
INFOID:0000000006600489

O
NOTE:
• Before removing and installing any control units, first turn the ignition switch to the LOCK position, then dis-
connect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both P
battery cables.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.

DLN-5
 PRECAUTIONS
< PRECAUTION > [TRANSFER: TY21B]
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT-III.
Service Notice or Precautions for Transfer INFOID:0000000006359885

• After overhaul refill the transfer with new transfer oil.

• Check the oil level or replace the oil only with the vehicle parked on level surface.
• During removal or installation, keep inside of transfer clear of dust or dirt.
• Replace all tires at the same time. Always use tires of the proper size and the same brand and pattern. Fit-
ting improper size and unusual wear tires applies excessive force to vehicle mechanism and can cause lon-
gitudinal vibration.
• Disassembly should be done in a clean work area.
• Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal
parts from becoming contaminated by dirt or other foreign matter.
• Check for the correct installation status prior to removal or disassembly. If matching marks are required, be
certain they do not interfere with the function of the parts when applied.
• All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new one if necessary.
• Gaskets, seals, O-rings and lock nuts should be replaced any time when the transfer is disassembled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tight-
ening sequence is specified, use it.
• Observe the specified torque when assembling.
• Clean and flush the parts sufficiently and blow-dry them.
• Never damage sliding surfaces and mating surfaces.
• Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
with the operation of the transfer.

DLN-6
 PREPARATION
< PREPARATION > [TRANSFER: TY21B]

PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000006359768
B

Tool number
Description C
Tool name
ST33200000 Removing ring gear bearing inner race (left
Drift side).
a: 60 mm(2.36 in) dia. DLN
b: 44.5 mm (1.752 in) dia.

E
ZZA1002D

KV381054S0 • Removing drive shaft oil seal.

Puller • Removing drive pinion oil seal. F

ZZA0601D
H
ST33230000 • Installing drive shaft oil seal.
Drift • Installing pinion rear bearing outer race.
a: 51 mm (2.01 in) dia.
b: 28.5 mm (1.122 in) dia. I

J
NT084

ST3127S000 Measuring pinion bearing preload and total

Preload gauge preload.
K

ZZA0503D

ST35272000 Installing pinion front bearing inner race. M

Drift
a: 40 mm (1.57 in) dia.
b: 72 mm (2.83 in) dia.
N

ZZA0881D O
ST30720000 • Installing drive pinion oil seal.
Drift • Installing transfer case oil seal (right side).
a: 77 mm (3.03 in) dia. P
b: 55.5 mm (2.185 in) dia.

ZZA0811D

DLN-7
 PREPARATION
< PREPARATION > [TRANSFER: TY21B]
Tool number
Description
Tool name
KV38102510 Installing drive pinion oil seal.
Drift
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.

ZZA0838D

ST17130000 Installing pinion front bearing outer race.

Drift
a: 31.8 mm (1.252 in) dia.
b: 58 mm (2.28 in) dia.

ZZA0836D

ST19820000 Installing transfer case oil seal (right side).

Drift
a: 70 mm (2.76 in) dia.
b: 50 mm (1.97 in) dia.

ZZA0838D

KV40100621 Installing transfer case oil seal (left side).

Drift
a: 76 mm (2.99 in) dia.
b: 69 mm (2.72 in) dia.

NT086

Commercial Service Tools INFOID:0000000006359769

Tool name Description

Replacer • Remove ring gear bearing inner race (left
side).
• Remove ring gear bearing inner race (right
side).
• Remove pinion front bearing inner race.

ZZA0700D

Drift Install ring gear bearing inner race (right side).

a: 57 mm (2.42 in) dia.
b: 51 mm (2.01 in) dia.
c: 85 mm (3.35 in)

ZZA0546D

DLN-8
 PREPARATION
< PREPARATION > [TRANSFER: TY21B]
Tool name Description
A
Drift Install ring gear bearing inner race (left side).
a: 66 mm (2.60 in) dia.
b: 60 mm (2.36 in) dia.
c: 50 mm (1.97 in) B

C
JSDIA1061ZZ

Drift Install ring gear assembly.

a: 61 mm (2.40 in) dia.
b: 51 mm (2.01 in) dia. DLN
c: 85 mm (3.35 in)

ZZA0546D

Drift Install ring gear assembly. F

a: 74 mm (2.91 in) dia.
b: 60 mm (2.36 in) dia.

ZZA0936D
H
Puller • Remove companion flange.
• Remove ring gear bearing inner race (right
side).
I

J
ZZA0119D

DLN-9
 COMPONENT PARTS
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]

SYSTEM DESCRIPTION
COMPONENT PARTS
Component Parts Location INFOID:0000000006359886

LHD models

JSDIA2065GB

1. ABS actuator and electric unit (con- 2. ECM 3. Front wheel sensor
trol unit) Refer to EC-25, "ENGINE CON- Refer to BRC-97, "Component Parts
Refer to BRC-97, "Component Parts TROL SYSTEM : Location".
Location". Component Parts Location".
4. TCM 5. Combination meter 6. 4WD warning lamp
Refer to TM-131, "CVT CONTROL Refer to MWI-4, "METER SYSTEM : (In combination meter)
SYSTEM : Component Parts Loca- Component Parts Location".
tion".
7 4WD mode indicator lamp (4WD-V) 8. 4WD mode indicator lamp (4WD) 9. Torque distribution indicator
(In combination meter) (In combination meter) (In combination meter)
10. Steering angle sensor 11. Rear wheel sensor 12. 4WD mode switch
Refer to BRC-97, "Component Parts Refer to BRC-97, "Component Parts
Location". Location".
13. 4WD control module 14. 4WD solenoid 15. Electric controlled coupling
(Inside rear final drive) (Inside rear final drive)
16. Electric controlled coupling tempera-
ture sensor
(Inside rear final drive)

A. Instrument driver lower panel B. Under front (left side) seat C Rear final drive assembly

DLN-10
 COMPONENT PARTS
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
RHD models
A

DLN

I
JSDIA2064GB

1. Steering angle sensor 2. Combination meter 3. 4WD warning lamp

Refer to BRC-97, "Component Parts Refer to MWI-4, "METER SYSTEM : (In combination meter) J
Location". Component Parts Location".
4. 4WD mode indicator lamp (4WD-V) 5. 4WD mode indicator lamp (4WD) 6. Torque distribution indicator
(In combination meter) (In combination meter) (In combination meter) K
7 ECM 8. ABS actuator and electric unit (con- 9. Front wheel sensor
Refer to EC-25, "ENGINE CON- trol unit) Refer to BRC-97, "Component Parts
TROL SYSTEM : Refer to BRC-97, "Component Parts Location".
Component Parts Location". Location". L
10. TCM 11. Rear wheel sensor 12. 4WD mode switch
Refer to TM-131, "CVT CONTROL Refer to BRC-97, "Component Parts
SYSTEM : Component Parts Loca- Location". M
tion".
13. 4WD control module 14. 4WD solenoid 15. Electric controlled coupling
(Inside rear final drive) (Inside rear final drive)
N
16. Electric controlled coupling tempera-
ture sensor
(Inside rear final drive)
O
A. Instrument driver lower panel B. Under front (left side) seat C Rear final drive assembly

Component Description INFOID:0000000006359887

Component parts Reference/Function

4WD control module DLN-12, "4WD Control Module"
4WD solenoid DLN-12, "4WD Solenoid"
Electric controlled coupling DLN-12, "Electric Controlled Coupling"
Electric controlled coupling temperature sensor DLN-12, "Electric Controlled Coupling Temperature Sensor"

DLN-11
 COMPONENT PARTS
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
Component parts Reference/Function
4WD mode switch DLN-12, "4WD Mode Switch"
4WD warning lamp DLN-13, "4WD Warning Lamp"
4WD mode indicator lamp (4WD-V, 4WD) DLN-13, "4WD Mode Indicator Lamp"
Torque distribution indicator DLN-13, "Torque Distribution Indicator"
Transmits/receives the signals for control of 4WD system via CAN communication
ABS actuator and electric unit (control unit)· line to/from 4WD control module. For transmitting/recieving mainly signals, refer to
DLN-17, "4WD SYSTEM : System Diagram".
Wheel sensor BRC-102, "Wheel Sensor and Sensor Rotor"
Yaw rate/side/decel G sensor BRC-104, "Yaw Rate/Side/Decel G Sensor"
Transmits/receives the signals for control of 4WD system via CAN communication
ECM line to/from 4WD control module. For transmitting/recieving mainly signals, refer to
DLN-17, "4WD SYSTEM : System Diagram".
Accelerator pedal position sensor EC-32, "Accelerator Pedal Position Sensor"
Transmits/receives the signals for control of 4WD system via CAN communication
TCM line to/from 4WD control module. For transmitting/recieving mainly signals, refer to
DLN-17, "4WD SYSTEM : System Diagram".
Transmits/receives the signals for control of 4WD system via CAN communication
Combination meter line to/from 4WD control module. For transmitting/recieving mainly signals, refer to
DLN-17, "4WD SYSTEM : System Diagram".
Transmits/receives the signals for control of 4WD system via CAN communication
Steering angle sensor line to/from 4WD control module. For transmitting/recieving mainly signals, refer to
DLN-17, "4WD SYSTEM : System Diagram".

4WD Control Module INFOID:0000000006359888

• 4WD control module controls driving force distribution by signals from each sensor from front wheel driving
mode (100:0) to 4-wheel driving mode (50:50).
• Driving torque between both rear wheels is automatically controlled between 100:0 and 0:100 during accel-
eration and cornering.
• Front wheel driving conditions is available by fail-safe function if malfunction is detected in 4WD system.
• 4WD actuator relay is integrated with 4WD control module, and supplies 4WD solenoid with voltage.
• Self-diagnosis can be done with CONSULT-III.
4WD Solenoid INFOID:0000000006359889

4WD solenoid is integrated with each electric controlled coupling, and controls electric controlled couplings by
command current from 4WD control module.
Electric Controlled Coupling INFOID:0000000006359890

Electric controlled couplings are integrated with rear final drive and transmits driving force to rear drive shaft.
For operation, refer to DLN-15, "Operation Principle".
Electric Controlled Coupling Temperature Sensor INFOID:0000000006484786

• Electric controlled coupling temperature sensor is integrated with each electric controlled coupling.
• Electric controlled coupling temperature sensor detects the electric controlled coupling temperature and
transmits a signal to 4WD control module.
4WD Mode Switch INFOID:0000000006359891

• 4WD mode is selectable among 2WD, 4WD-V, and 4WD by operating the 4WD mode switch while the igni-
tion switch is ON or the engine is running.
• Tilting the switch to the 2WD/4WD side allows mode selection between 2WD and 4WD. To switch mode to
4WD-V, simply position the switch in 4WD-V (neutral position).

DLN-12
 COMPONENT PARTS
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
4WD Warning Lamp INFOID:0000000006542955

A
• After the 4WD system is activated, the 4WD warning lamp turns OFF during front and rear wheels driving
torque distribution.
• After the 4WD system is deactivated by fail-safe function and torque distribution of front and rear wheels is B
stopped, the 4WD warning lamp turns ON to indicate that the state is in 2WD.
NOTE:
The 4WD warning lamp does not turn ON when only torque distribution of both rear wheels is stopped by the
fail-safe function. C
• The 4WD warning lamp blinks to indicate that the state is in 2WD when the 4WD system is temporarily
stopped by the protection function.
• Also turns ON when ignition switch is turned ON, for the purpose of lamp check. Turns OFF after the engine DLN
starts if system is normal.

Condition 4WD warning lamp

E
Turns ON when ignition switch is turned ON.
Lamp check
(Turns OFF approx. 1 second after the engine start.)

4WD system is malfunction* ON

F
Protection function is activated due to heavy load to electric controlled
Quick blinking: 2 times/second
coupling. (4WD system is not malfunctioning and 4WD system chang-
(Blinking in approx. 1 minute and then turning OFF)
es to front wheel drive.)
G
Slow blinking: 1 time/2 seconds
Large difference in diameter of front/rear tires
(Continuing to blink until turning ignition switch OFF)
Other than above (System is normal) OFF
H
*: The 4WD warning lamp does not turn ON when only torque distribution of both rear wheels is stopped.
NOTE:
4WD warning lamp also turns ON due to data reception error, CAN communication error etc.
I
4WD Mode Indicator Lamp INFOID:0000000006542956

The following is the indications of 4WD mode indicator lamp. J

4WD mode indicator lamp

Condition
4WD-V 4WD K
Turns ON when ignition switch is turned ON in aprrox.
Lamp check —
1 second and then turns OFF.
4WD mode: 2WD OFF OFF L
4WD mode: 4WD-V ON OFF
4WD mode: 4WD OFF ON
M
Torque Distribution Indicator INFOID:0000000006548412

• Torque distribution indicator is displayed when the ODO/TRIP indication on the combination meter is N
switched.
• The number of bars shows driving force distributed to each tire. (Maximum bars: 3)
O

JSDIA2067ZZ

DLN-13
 COMPONENT PARTS
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]

1. Front right side driving torque 2. Front left side driving torque 3. Rear right side driving torque
4. Rear left side driving torque

NOTE:
The driving force distribution may not match actual one. This is not a system malfunction.

DLN-14
 STRUCTURE AND OPERATION
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
STRUCTURE AND OPERATION
A
Sectional View INFOID:0000000006359896

DLN

I
JSDIA2068ZZ

1. Transfer cover 2. Ring gear shaft 3. Companion flange J

4. Drive pinion 5. Ring gear 6. Transfer case

Operation Principle INFOID:0000000006484157

K

POWER TRANSFER DIAGRAM

L

JSDIA2069ZZ
O
1. Engine 2. Transaxle 3. Transfer
4. Propeller shaft 5. Electric controlled coupling 6. Rear final drive
P
ELECTRIC CONTROLLED COUPLING

DLN-15
 STRUCTURE AND OPERATION
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
1. The 4WD control module supplies command current to each
electric controlled coupling (4WD solenoid).
2. Each of control clutch is engaged by electromagnet and torque
is detected in control clutch.
3. The cam operates in response to control clutch torque and
applies pressure to main clutch.
4. Each of main clutch transmits torque to right and left rear wheels
according to pressing power.
NOTE:
Change each pressing power according to 4WD mode atatus
and cornering conditions. JSDIA2157GB

• Transmission torque to the right and left rear wheels is deter-

mined according to command current.

SDIA1844E

DLN-16
 SYSTEM
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
SYSTEM
A
4WD SYSTEM
4WD SYSTEM : System Diagram INFOID:0000000006548414
B

DLN

J
JSDIA2070GB

INPUT/OUTPUT SIGNAL K
It transmits/receives each signal from the following 4WD control module via CAN communication line.

Component parts Signal item L

Mainly transmits the following signals via CAN communication line to 4WD control
module.
• Vehicle speed signal (ABS) M
ABS actuator and electric unit (control unit)· • Stop lamp switch signal (brake signal)
• Yaw rate signal
• Side G sensor signal
• Decel G sensor signal N
Mainly transmits the following signals via CAN communication line to 4WD control
module.
ECM • Accelerator pedal position signal
O
• Engine speed signal
• Engine torque signal
Mainly transmits the following signals via CAN communication line to 4WD control
module. P
• Next gear position signal
TCM • Current gear position signal
• Input shaft revolutional signal
• Output shaft revolutional signal
• CVT ratio signal

DLN-17
 SYSTEM
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
Component parts Signal item
Mainly transmits the following signals via CAN communication line to 4WD control
module.
• Parking brake switch signal

Combination meter Mainly receives the following signals via CAN communication line from 4WD control
module.
• 4WD warning lamp signal
• 4WD mode indicator lamp signal
• Torque distribution indicator signal
Mainly transmits the following signals via CAN communication line to 4WD control
Steering angle sensor module.
• Steering angle sensor signal

4WD SYSTEM : System Description INFOID:0000000006359897

• 4WD mode is selectable among 2WD, 4WD-V, and 4WD by operating the 4WD mode switch.
• When judging driving conditions and road surface conditions based on signals transmitted from each sensor
and switch, the 4WD system automatically controls torque distribution of front and rear wheels and both rear
wheels, depending on the situation.
• In accordance with fail-safe function, when system is malfunctioning, 4WD control stops, and the system
becomes rear wheel drive. Refer to DLN-19, "4WD SYSTEM : Fail-safe".
• When a high load status continues for electric controlled coupling, 4WD control temporarily becomes rear
wheel drive, according to protection function. Refer to DLN-21, "4WD SYSTEM : Protection Function".
4WD SYSTEM : Torque Split Control INFOID:0000000006543008

2WD mode
• Vehicle is in front-wheel drive.
4WD-V mode
Normal Control
• Pressing force of multiple disc clutch is controlled by electric control. Driving torque distribution of front and
rear wheels changes automatically between approximately 100 : 0 (Front wheel drive) and 50 : 50 (4WD) to
have an optimized torque distribution adapted to road condition change.
• When spin occurs on front wheel, distribute optimum torque to rear wheel and keep stable driving.
• On roads which do not require 4WD, it contributes to improved fuel economy by driving in conditions close to
front-wheel drive and it results in better fuel efficiency.

JSDIA2071GB

Cornering Control
• Torque between both rear wheels is automatically changed between 100 : 0 and 0 : 100 for distributing opti-
mum torque that depends on the driving conditions and road surface conditions.
• Producing a difference between both rear wheels enables sporty and smooth handling.

DLN-18
 SYSTEM
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
• The vehicle cornering status is judged according to information from each sensor, and the optimum torque is
distributed to rear wheels for preventing tight cornering/braking symptom. A

JSDIA2072GB DLN
4WD mode
• The 4WD mode controls torque for obtaining suitable torque for driving on slippery roads (e.g. snow-covered
roads) and provides more stable driving, compared to 4WD-V. E

4WD SYSTEM : Fail-safe INFOID:0000000006570277

When a system malfunction occurs, the 4WD warning lamp turns ON and the 4WD control becomes 2WD F
state.

Detected 4WD warning G

Possible cause Vehicle condition
DTC lamp status
P1804 Internal malfunction of 4WD control module OFF Normal control continues.
• ABS actuator and electric unit (control unit) H
- Malfunction of ABS actuator and electric unit (control unit) cir-
cuit error
P1808
- Wheel speed sensor error
• 4WD control module I
• CAN communication line
P1809 Internal malfunction of 4WD control module
Front and rear distribution control J
• Malfunction of 4WD control module power supply circuit (open ON
stops.
or short)
P1811
• Malfunction of 4WD control module
• Battery K
• 4WD mode switch
- Internal malfunction of 4WD mode switch
P1813
- Malfunction of 4WD mode switch circuit
• 4WD control module
L
P181B Self-shut of 4WD control module is incomplete. Front and rear distribution control
stops.
• ECM NOTE: M
ON
P181D • 4WD control module The state becomes 4WD only when
• CAN communication line a turning difference occurs between
front and rear wheels.
N
• Steering angle sensor
- Steering angle sensor error
Right and left rear wheels difference
P181E - Malfunction of steering angle sensor circuit OFF
control stops.
• Malfunction of 4WD control module O
• CAN communication line
Front and rear distribution control
P181F Writing unit parameter is incomplete. ON
stops. P
• ECM
P1820 • 4WD control module OFF Normal control continues.
• CAN communication line

DLN-19
 SYSTEM
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
Detected 4WD warning
Possible cause Vehicle condition
DTC lamp status
• ECM
P1829 • 4WD control module
• CAN communication line
• Internal malfunction of electric controlled coupling (LH)
• Malfunction of 4WD solenoid (LH) power supply circuit (open
P182D Front and rear distribution control
or short) ON
stops.
• Malfunction of 4WD control module
• Internal malfunction of electric controlled coupling (RH)
• Malfunction of 4WD solenoid (RH) power supply circuit (open
P182E
or short)
• Malfunction of 4WD control module
• Internal malfunction of electric controlled coupling (left) tem-
perature sensor
P182F • Malfunction of electric controlled coupling (left) temperature
sensor circuit
• Malfunction of 4WD control module
• ABS actuator and electric unit (control unit)
P1830 • 4WD control module
• CAN communication line
• ABS actuator and electric unit (control unit)
P1831 • 4WD control module OFF Normal control continues.
• CAN communication line
• ABS actuator and electric unit (control unit)
P1832 • 4WD control module
• CAN communication line
• Internal malfunction of electric controlled coupling (right) tem-
perature sensor
P183A • Malfunction of electric controlled coupling (right) temperature
sensor circuit
• Malfunction of 4WD control module
• Malfunction of 4WD solenoid power supply circuit
• Malfunction of 4WD control module
Front and rear distribution control
P183B • Malfunction of 4WD control module power supply circuit (open ON
stops.
or short)
• Battery

DLN-20
 SYSTEM
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
Detected 4WD warning
Possible cause Vehicle condition
DTC lamp status A
• ABS actuator and electric unit (control unit)
• Yaw rate/side/decel G sensor
P183C
• 4WD control module B
• CAN communication line
• ABS actuator and electric unit (control unit)
• Yaw rate/side/decel G sensor
P183D
• 4WD control module
C
• CAN communication line
• ABS actuator and electric unit (control unit)
• Yaw rate/side/decel G sensor DLN
P183E
• 4WD control module
• CAN communication line
• CVT sensor E
• TCM Right and left rear wheels difference
P183F OFF
• 4WD control module control stops.
• CAN communication line
• CVT sensor
F
• TCM
P1840
• 4WD control module
• CAN communication line G
• CVT sensor
• TCM
P1864
• 4WD control module
• CAN communication line
H

• CVT sensor
• TCM
P1865
• 4WD control module I
• CAN communication line
U1000 CAN communication error Front and rear distribution control
ON
U1010 Internal malfunction of 4WD control module stops. J

4WD SYSTEM : Protection Function INFOID:0000000006570278

K
4WD system activates its protection function (shuts down 4WD system temporarily) if 4WD system detects
high load continuously, the front wheel tire size differs from the rear tire size or the rear RH wheel tire size dif-
fers from the rear LH tire size. (4WD system is automatically restored if 4WD system no longer detects any
overload or the tire size difference is eliminated.) L

Detected
Warning lamp Possible cause Vehicle condition M
DTC
Turning difference remains between front and rear wheels or between
right and left rear wheels, resulting in an oil temperature rise in drive train
— Quick blinking*1 related parts. Shuts down 4WD system N
NOTE: temporarily
It is not malfunction.
— Slow blinking*2 Malfunction in each tire or different tire diameter O
*1: 2 times/second (blinking for approximately 1 minute and then turned OFF)
*2: 1 time/2 seconds (continuing to blink until ignition switch is turned OFF)
NOTE: P
• If the warning lamp blinks slowly during driving but remains OFF after the engine is restarted, the system is
normal. If it again blinks slowly after driving for some time, vehicle must be inspected.
• When there is a difference of revolution speed between the front and rear wheel the shift occasionally
changes to direct 4-wheel driving conditions automatically. This is not a malfunction.

DLN-21
 DIAGNOSIS SYSTEM (4WD CONTROL MODULE)
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
DIAGNOSIS SYSTEM (4WD CONTROL MODULE)
CONSULT-III Function INFOID:0000000006359899

APPLICATION ITEMS
CONSULT-III can display each diagnostic item using the diagnostic test modes as follows.

Diagnostic test mode Function

ECU Identification 4WD control module part number can be read.
Self Diagnostic Result Self-diagnostic results and freeze frame data can be read and erased quickly.*
Data Monitor Input/Output data in the 4WD control module can be read.
Diagnostic Test Mode in which CONSULT-III drives some actuators apart from the 4WD control
Active Test
module and also shifts some parameters in a specified range.
This mode enable a technican to adjust some devices faster and more accurately by following the
Work support
indication on the CONSULT-III.
*: The following diagnosis information is erased by erasing.
• DTC
• Freeze frame data (FFD)
ECU IDENTIFICATION
4WD control module part number can be read.
SELF DIAGNOSTIC RESULT
Refer to DLN-33, "DTC Index".
When “PRSNT” is displayed on self-diagnosis result.
• The system is presently malfunctioning.
When “PAST” is displayed on self-diagnosis result.
• System malfunction in the past is detected, but the system is presently normal.
FREEZE FRAME DATA (FFD)
The following vehicle status is recorded when DTC is detected and is displayed on CONSULT-III.

Freeze Frame Data Item Description

SOLENOID VOLT Power supply voltage of 4WD solenoid is displayed when DTC is detected.
TRGT SOL CRNT LH 4WD solenoid (LH) target current is displayed when DTC is detected.
SOLENOID CRNT LH 4WD solenoid (LH) control current is displayed when DTC is detected.
TRGT SOL CRNT RH 4WD solenoid (RH) target current is displayed when DTC is detected.
SOLENOID CRNT RH 4WD solenoid (RH) control current is displayed when DTC is detected.
COMPR VHCL SPEED Vehicle speed calculated by 4WD control module is displayed when DTC is detected.
VHCL/S SEN-FR Vehicle speed (front) average calculated by 4WD control module is displayed when DTC is detected.
VHCL/S SEN-RR Vehicle speed (rear) average calculated by 4WD control module is displayed when DTC is detected.
WHEEL SPD SEN FR Wheel speed (front RH) calculated by 4WD control module is displayed when DTC is detected.
WHEEL SPD SEN FL Wheel speed (front LH) calculated by 4WD control module is displayed when DTC is detected.
WHEEL SPD SEN RR Wheel speed (rear RH) calculated by 4WD control module is displayed when DTC is detected.
WHEEL SPD SEN RL Wheel speed (rear RH) calculated by 4WD control module is displayed when DTC is detected.
ABS OPERATION SIG ABS operation status via CAN communication line is displayed when DTC is detected.
VDC OPERATION SIG VDC operation status via CAN communication line is displayed when DTC is detected.
TCS OPERATION SIG TCS operation status via CAN communication line is displayed when DTC is detected.
Measured friction of load is displayed when vehicle starts.
HIGH M FLG 1 [0/1] • When “0” is displayed: It indicates that friction of load is not high.
• When “1” is displayed: It indicates that friction of load is high.

DLN-22
 DIAGNOSIS SYSTEM (4WD CONTROL MODULE)
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
Freeze Frame Data Item Description
A
Measured friction of load is displayed when vehicle throttles down.
HIGH M FLG 2 [0/1] • When “0” is displayed: It indicates that friction of load is not high.
• When “1” is displayed: It indicates that friction of load is high.
SLCT LVR POSI Current transmission gear via CAN communication line is displayed when DTC is detected. B
OPERATION MODE Control status of 4WD mode is displayed when DTC is detected.
The number of times that ignition switch is turned ON after the DTC is detected is displayed.
• When “0” is displayed: It indicates that the system is presently malfunctioning. C
• When except “0” is displayed: It indicates that system malfunction in the past is detected, but the
system is presently normal.
IGN COUNTER [0 - 39] NOTE: DLN
Each time when ignition switch is turned OFF to ON, numerical number increases in
1→2→3...38→39.
When the operation number of times exceeds 39, the number do not increase and “39” is displayed
until self-diagnosis is erased. E
DATA MONITOR
X: Applicable
F
SELECT MONITOR ITEM
Monitor item [Unit] ECU INPUT MAIN SIG- Remarks
SIGNALS NALS
G
SWITCH 1 [On/Off] X 4WD mode switch status (2WD) is displayed.
SWITCH 2 [On/Off] X 4WD mode switch status (4WD-V or 4WD) is displayed.
SWITCH 3 [On/Off] X 4WD mode switch status (4WD) is displayed. H
IGN SW [On/Off] X Ignition switch status is displayed.
WARNING LAMP [On/Off] X Control status of 4WD warning lamp is displayed.
I
R POSITION SW [On/Off] X X CVT shift selector is displayed.
ABS operation status via CAN communication line is dis-
ABS OPERATION SIG [On/Off]
played.
J
VDC operation status via CAN communication line is dis-
VDC OPERATION SIG [On/Off]
played.
TCS operation status via CAN communication line is dis-
TCS OPERATION SIG [On/Off]
played.
K

Parking brake switch signal status via CAN communica-

PKB SW [On/Off] X
tion line is displayed.
L
Stop lamp switch signal status via CAN communication
STOP LAMP SW [On/Off] X
line is displayed.
4WD MODE SW [2WD/4WD-A] X 4WD mode switch status is displayed.
M
4WD actuator relay (integrated in 4WD control module)
ACTUATOR RELAY [On/Off]
operation status is displayed.
OPERATION MODE [2WD/4WD-V/
4WD-A]
X Control status of 4WD mode is displayed. N

INDICATOR [2WD/4WD-V/4WD-A] X Control status of 4WD mode indicator lamp is displayed.

DRIVE MODE [1/2] X Snow mode (4WD mode) status is displayed.
O
TORQU DISTR RR LH [1/1-2/1-3/1-4/ Control status of torque distribution indicator (rear LH) is
OFF] displayed.
TORQU DISTR RR RH [1/1-2/1-3/1-4/ Control status of torque distribution indicator (rear RH) is P
OFF] displayed.
TORQU IND FRONT [1/1-2/1-3/1-4/ Control status of torque distribution indicator (front) is dis-
OFF] played.
Voltage of electric controlled coupling temperature sen-
TEMP SEN LEFT [V] X
sor (LH) is displayed.
Voltage of electric controlled coupling temperature sen-
TEMP SEN RIGHT [V] X
sor (RH) is displayed.

DLN-23
 DIAGNOSIS SYSTEM (4WD CONTROL MODULE)
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
SELECT MONITOR ITEM
Monitor item [Unit] ECU INPUT MAIN SIG- Remarks
SIGNALS NALS
Power supply voltage of 4WD control module is dis-
CONT MODUL VOLT [V] X
played.
SOLENOID VOLT [V] X Power supply voltage of 4WD solenoid is displayed.
TRGT SOL CRNT LH [A] X 4WD solenoid (LH) target current is displayed.
SOLENOID CRNT LH [A] X 4WD solenoid (LH) control current is displayed.
TRGT SOL CRNT RH [A] X 4WD solenoid (RH) target current is displayed.
SOLENOID CRNT RH [A] X 4WD solenoid (RH) control current is displayed.
Vehicle speed calculated by 4WD control module is dis-
COMPR VHCL SPEED [km/h] X
played.
Vehicle speed (front) average calculated by 4WD control
VHCL/S SEN-FR [km/h]
module is displayed.
Vehicle speed (rear) average calculated by 4WD control
VHCL/S SEN-RR [km/h]
module is displayed.
Throttle operation status via CAN communication line is
THRTL POS SEN [%]
displayed.
SLCT LVR POSI [2ND / 3RD / 4TH / 5TH Current transmission gear via CAN communication line is
X
/ 6TH / 7TH / 8TH / R / N/P / D] displayed.
Request drive torque from 4WD control module to ECM
TRGT DRIVE TORQU [Nm]
is displayed.
Request drive torque from ABS actuator and electric unit
RQST DRIVE TORQU [Nm]
(control unit) to 4WD control module is displayed.
Wheel speed (front RH) calculated by 4WD control mod-
WHEEL SPD SEN FR [km/h]
ule is displayed.
Wheel speed (front LH) calculated by 4WD control mod-
WHEEL SPD SEN FL [km/h]
ule is displayed.
Wheel speed (rear RH) calculated by 4WD control mod-
WHEEL SPD SEN RR [km/h]
ule is displayed.
Wheel speed (rear RH) calculated by 4WD control mod-
WHEEL SPD SEN RL [km/h]
ule is displayed.

ACTIVE TEST
Use this mode to determine and identify the details of a malfunction based on self-diagnostic results or data
monitor. 4WD control module gives drive signal to actuator with receiving command from CONSULT-III to
check operation of actuator.

Test item Condition Description

Change command current value to 4WD solenoid (LH), and then change driv-
ing mode. (Monitor value is normal if it is within approx. ±10% of command
• Vehicle stopped value.)
4WDSOL_L • Engine running • Qu: Increase current value in increments of 0.2 A
• No DTC detected • Qd: Decrease current value in increments of 0.2 A
• UP: Increase current value in increments of 0.02 A
• DOWN: Decrease current value in increments of 0.02 A
Change command current value to 4WD solenoid (RH), and then change
driving mode. (Monitor value is normal if it is within approx. ±10% of command
• Vehicle stopped value.)
4WDSOL_R • Engine running • Qu: Increase current value in increments of 0.2 A
• No DTC detected • Qd: Decrease current value in increments of 0.2 A
• UP: Increase current value in increments of 0.02 A
• DOWN: Decrease current value in increments of 0.02 A
CAUTION:
Never energize continuously for a long time.

DLN-24
 DIAGNOSIS SYSTEM (4WD CONTROL MODULE)
< SYSTEM DESCRIPTION > [TRANSFER: TY21B]
WORK SUPPORT
A
Function Description
UNIT CHARACTERISTICS DATA Display the unit parameter of electric controlled coupling written to 4WD control module.
UNIT CHARACTERISTICS WRITE Writes the unit parameter of electric controlled coupling to 4WD control module.
B

DLN

DLN-25
 4WD CONTROL MODULE
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY21B]

ECU DIAGNOSIS INFORMATION

4WD CONTROL MODULE
Reference Value INFOID:0000000006359900

VALUES ON THE DIAGNOSIS TOOL

Monitor item Condition Value/Status

4WD mode switch: 2WD On
SWITCH 1
4WD mode switch: 4WD-V or 4WD Off
4WD mode switch: 4WD-V or 4WD On
SWITCH 2
4WD mode switch: 2WD Off
4WD mode switch: 4WD On
SWITCH 3
4WD mode switch: 2WD or 4WD-V Off
Ignition SW: ON On
IGN SW
Ignition SW: OFF Off
4WD warning lamp: ON On
WARNING LAMP
4WD warning lamp: OFF Off
CVT shift selector: R On
R POSITION SW
CVT shift selector: Except R Off
ABS is operating On
ABS OPERATION SIG
ABS is not operating Off
VDC is operating On
VDC OPERATION SIG
VDC is not operating Off
TCS is operating On
TCS OPERATION SIG
TCS is not operating Off
Parking brake is operated On
PKB SW
Parking brake is not operated Off
Brake pedal is depressed On
STOP LAMP SW
Brake pedal is released Off
4WD mode switch: 2WD 2WD
4WD MODE SW
4WD mode switch: 4WD-V or 4WD 4WD-A
Engine stopped (Ignition switch: ON) Off
ACTUATOR RELAY
Engine running On
4WD mode: 2WD 2WD
OPERATION MODE 4WD mode: 4WD-V 4WD-V
4WD mode: 4WD 4WD-A
4WD mode indicator (4WD-V): OFF
2WD
4WD mode indicator (4WD): OFF
4WD mode indicator (4WD-V): ON
INDICATOR 4WD-V
4WD mode indicator (4WD): OFF
4WD mode indicator (4WD-V): ON
4WD-A
4WD mode indicator (4WD): ON
4WD mode: Except 4WD 1
DRIVE MODE
4WD mode: 4WD 2

DLN-26
 4WD CONTROL MODULE
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY21B]
Monitor item Condition Value/Status
A
The number of bars of torque distribution indicator (rear LH): 0 OFF
The number of bars of torque distribution indicator (rear LH): 1 1
TORQU DISTR RR LH The number of bars of torque distribution indicator (rear LH): 2 1-2 B
The number of bars of torque distribution indicator (rear LH): 3 1-3
The number of bars of torque distribution indicator (rear LH): 4 1-4
The number of bars of torque distribution indicator (rear RH): 0 OFF C
The number of bars of torque distribution indicator (rear RH): 1 1
TORQU DISTR RR RH The number of bars of torque distribution indicator (rear RH): 2 1-2
DLN
The number of bars of torque distribution indicator (rear RH): 3 1-3
The number of bars of torque distribution indicator (rear RH): 4 1-4
The number of bars of torque distribution indicator (front): 0 OFF E
The number of bars of torque distribution indicator (front): 1 1
TORQU IND FRONT The number of bars of torque distribution indicator (front): 2 1-2
F
The number of bars of torque distribution indicator (front): 3 1-3
The number of bars of torque distribution indicator (front): 4 1-4
Temperature of electric controlled coupling (LH) is 10 °C Aprrox. 3.5 V G
TEMP SEN LEFT Temperature of electric controlled coupling (LH) is 20 °C Aprrox. 3.2 V
Temperature of electric controlled coupling (LH) is 30 °C Aprrox. 2.8 V
H
Temperature of electric controlled coupling (RH) is 10 °C Aprrox. 3.5 V
TEMP SEN RIGHT Temperature of electric controlled coupling (RH) is 20 °C Aprrox. 3.2 V
Temperature of electric controlled coupling (RH) is 30 °C Aprrox. 2.8 V I
CONT MODUL VOLT Always Battery Voltage
SOLENOID VOLT Always Battery Voltage
Vehicle stopped 0.00 A
J
TRGT SOL CRNT LH Vehicle starting
Approx. 1.00 A
(Straight-ahead start on a dry road with accelerator angle 2/8)
K
Vehicle stopped 0.00 A
SOLENOID CRNT LH Vehicle starting
Approx. 1.00 A
(Straight-ahead start on a dry road with accelerator angle 2/8)
L
Vehicle stopped 0.00 A
TRGT SOL CRNT RH Vehicle starting
Approx. 1.00 A
(Straight-ahead start on a dry road with accelerator angle 2/8)
M
Vehicle stopped 0.00 A
SOLENOID CRNT RH Vehicle starting
Approx. 1.00 A
(Straight-ahead start on a dry road with accelerator angle 2/8) N
Vehicle stopped 0.00 km/h (0.00mph)

COMPR VHCL SPEED Vehicle driving

Approx. equal to the indication on
CAUTION: O
speedometer (inside of ±10 %)
Check air pressure of tire under standard condition.
Vehicle stopped 0.00 km/h (0.00mph)

VHCL/S SEN-FR Vehicle driving P

Approx. equal to the indication on
CAUTION:
speedometer (inside of ±10 %)
Check air pressure of tire under standard condition.
Vehicle stopped 0.00 km/h (0.00mph)

VHCL/S SEN-RR Vehicle driving

Approx. equal to the indication on
CAUTION:
speedometer (inside of ±10 %)
Check air pressure of tire under standard condition.

DLN-27
 4WD CONTROL MODULE
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY21B]
Monitor item Condition Value/Status
When depressing accelerator pedal
THRTL POS SEN 0 - 100 %
(Value rises gradually in response to throttle position)
1ST
2ND
3RD
CVT shift selector: Manual 4TH
mode 5TH
6TH
SLCT LVR POSI Engine running 7TH
8TH
CVT shift selector: R REVERSE
CVT shift selector: N or P N/P
CVT shift selector: D D
Request from 4WD control module to ECM. 0 - 507 Nm
TRGT DRIVE TORQU
No request from 4WD control module to ECM. 508 Nm
Request from ABS actuator and electric unit (control unit) to 4WD
0 - 1274 Nm
control module.
RQST DRIVE TORQU
No request from ABS actuator and electric unit (control unit) to
1275 Nm
4WD control module.
Vehicle stopped 0.00 km/h (0.00mph)

WHEEL SPD SEN FR Vehicle driving

Approx. equal to the indication on
CAUTION:
speedometer (inside of ±10 %)
Check air pressure of tire under standard condition.
Vehicle stopped 0.00 km/h (0.00mph)

WHEEL SPD SEN FL Vehicle driving

Approx. equal to the indication on
CAUTION:
speedometer (inside of ±10 %)
Check air pressure of tire under standard condition.
Vehicle stopped 0.00 km/h (0.00mph)

WHEEL SPD SEN RR Vehicle driving

Approx. equal to the indication on
CAUTION:
speedometer (inside of ±10 %)
Check air pressure of tire under standard condition.
Vehicle stopped 0.00 km/h (0.00mph)

WHEEL SPD SEN RL Vehicle driving

Approx. equal to the indication on
CAUTION:
speedometer (inside of ±10 %)
Check air pressure of tire under standard condition.

TERMINAL LAYOUT

JSDIA2078ZZ

PHYSICAL VALUES

DLN-28
 4WD CONTROL MODULE
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY21B]

Terminal No. A
Description
(Wire color)
Condition Value (Approx.)
Input/
+ - Signal name
Output
B
1 Power supply (4WD control
Ground Input Always 11 - 13 V
(GR) module)

3 Ignition switch: ON 11 - 13 V C
Ground Ignition switch Input
(LG) Ignition switch: OFF 0V
4 Input/
— CAN-H — —
(L) Output DLN
5 Input/
— CAN-L — —
(P) Output
Electric controlled coupling Ignition switch: ON 5V E
6
Ground (RH) temperature sensor Output
(SB) Ignition switch: OFF 0V
power supply.
Electric controlled coupling (RH) F
3.5 V
temperature: 10°C (50°F)
Rear final drive as-
Electric controlled coupling
7 sembly temperature Electric controlled coupling (RH)
Ground (RH) temperature sensor Input 3.2 V
(P) is the same as room temperature: 20°C (68°F)
signal. G
temperature.
Electric controlled coupling (RH)
2.8 V
temperature: 30°C (86°F)
4WD mode switch: 2WD 4.5 - 5 V
9 H
Ground 4WD mode SW (4WD-V) Input IGN ON 4WD mode switch: 4WD-V or
(W) 0V
4WD
10 I
Ground Ground — Always 0V
(B)
11
Ground Ground — Always 0V
(B)
J
12 Power supply (4WD sole-
Ground Input Always 11 - 13 V
(Y) noid)
4WD mode switch: 2WD 0V
13 K
Ground 4WD mode SW (2WD) Input IGN ON 4WD mode switch: 4WD-V or
(G) 4.5 - 5 V
4WD
Electric controlled coupling (LH) L
3.5 V
temperature: 10°C (50°F)
Rear final drive as-
Electric controlled coupling
16 sembly temperature Electric controlled coupling (LH)
Ground (LH) temperature sensor Input 3.2 V
(G) is the same as room temperature: 20°C (68°F)
signal.
temperature.
M
Electric controlled coupling (LH)
2.8 V
temperature: 30°C (86°F)
Electric controlled coupling Ignition switch: ON 5V
17 N
Ground (LH) temperature sensor Output
(L) Ignition switch: OFF 0V
power supply.
4WD mode switch: 2WD or
21 4.5 - 5 V O
Ground 4WD mode SW (4WD-V) Input IGN ON 4WD-V
(Y)
4WD mode switch: 4WD 0V

23 4WD solenoid (LH) power Engine speed: At idle 0V

Ground Output P
(R) supply Engine speed: 3,000 or more constant 2.5 V*
24
Ground 4WD solenoid (LH) ground Input Always 1.5 V or less
(V)

DLN-29
 4WD CONTROL MODULE
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY21B]
Terminal No.
Description
(Wire color)
Condition Value (Approx.)
Input/
+ - Signal name
Output

25 4WD solenoid (RH) power Engine speed: At idle 0V

Ground Output
(W) supply Engine speed: 3,000 or more constant 2.5 V*
26
Ground 4WD solenoid (RH) ground Input Always 1.5 V or less
(Y)
*: The values are changed by throttle opening and engine speed.
CAUTION:
When using circuit tester to measure voltage for inspection, be sure not to extend forcibly any con-
nector terminals.
Fail-safe INFOID:0000000006359898

When a system malfunction occurs, the 4WD warning lamp turns ON and the 4WD control becomes 2WD
state.

Detected 4WD warning

Possible cause Vehicle condition
DTC lamp status
P1804 Internal malfunction of 4WD control module OFF Normal control continues.
• ABS actuator and electric unit (control unit)
- Malfunction of ABS actuator and electric unit (control unit) cir-
cuit error
P1808
- Wheel speed sensor error
• 4WD control module
• CAN communication line
P1809 Internal malfunction of 4WD control module
Front and rear distribution control
• Malfunction of 4WD control module power supply circuit (open ON
stops.
or short)
P1811
• Malfunction of 4WD control module
• Battery
• 4WD mode switch
- Internal malfunction of 4WD mode switch
P1813
- Malfunction of 4WD mode switch circuit
• 4WD control module
P181B Self-shut of 4WD control module is incomplete. Front and rear distribution control
stops.
• ECM NOTE:
ON
P181D • 4WD control module The state becomes 4WD only when
• CAN communication line a turning difference occurs between
front and rear wheels.
• Steering angle sensor
- Steering angle sensor error
Right and left rear wheels difference
P181E - Malfunction of steering angle sensor circuit OFF
control stops.
• Malfunction of 4WD control module
• CAN communication line
Front and rear distribution control
P181F Writing unit parameter is incomplete. ON
stops.
• ECM
P1820 • 4WD control module OFF Normal control continues.
• CAN communication line

DLN-30
 4WD CONTROL MODULE
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY21B]
Detected 4WD warning
Possible cause Vehicle condition
DTC lamp status A
• ECM
P1829 • 4WD control module
• CAN communication line B
• Internal malfunction of electric controlled coupling (LH)
• Malfunction of 4WD solenoid (LH) power supply circuit (open
P182D Front and rear distribution control
or short) ON
• Malfunction of 4WD control module
stops. C
• Internal malfunction of electric controlled coupling (RH)
• Malfunction of 4WD solenoid (RH) power supply circuit (open
P182E DLN
or short)
• Malfunction of 4WD control module
• Internal malfunction of electric controlled coupling (left) tem-
perature sensor E
P182F • Malfunction of electric controlled coupling (left) temperature
sensor circuit
• Malfunction of 4WD control module
• ABS actuator and electric unit (control unit)
F
P1830 • 4WD control module
• CAN communication line
• ABS actuator and electric unit (control unit) G
P1831 • 4WD control module OFF Normal control continues.
• CAN communication line
• ABS actuator and electric unit (control unit) H
P1832 • 4WD control module
• CAN communication line
• Internal malfunction of electric controlled coupling (right) tem-
I
perature sensor
P183A • Malfunction of electric controlled coupling (right) temperature
sensor circuit
• Malfunction of 4WD control module J
• Malfunction of 4WD solenoid power supply circuit
• Malfunction of 4WD control module
Front and rear distribution control
P183B • Malfunction of 4WD control module power supply circuit (open ON
or short)
stops. K
• Battery

DLN-31
 4WD CONTROL MODULE
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY21B]
Detected 4WD warning
Possible cause Vehicle condition
DTC lamp status
• ABS actuator and electric unit (control unit)
• Yaw rate/side/decel G sensor
P183C
• 4WD control module
• CAN communication line
• ABS actuator and electric unit (control unit)
• Yaw rate/side/decel G sensor
P183D
• 4WD control module
• CAN communication line
• ABS actuator and electric unit (control unit)
• Yaw rate/side/decel G sensor
P183E
• 4WD control module
• CAN communication line
• CVT sensor
• TCM Right and left rear wheels difference
P183F OFF
• 4WD control module control stops.
• CAN communication line
• CVT sensor
• TCM
P1840
• 4WD control module
• CAN communication line
• CVT sensor
• TCM
P1864
• 4WD control module
• CAN communication line
• CVT sensor
• TCM
P1865
• 4WD control module
• CAN communication line
U1000 CAN communication error Front and rear distribution control
ON
U1010 Internal malfunction of 4WD control module stops.

Protection Function INFOID:0000000006542957

4WD system activates its protection function (shuts down 4WD system temporarily) if 4WD system detects
high load continuously, the front wheel tire size differs from the rear tire size or the rear RH wheel tire size dif-
fers from the rear LH tire size. (4WD system is automatically restored if 4WD system no longer detects any
overload or the tire size difference is eliminated.)

Detected
Warning lamp Possible cause Vehicle condition
DTC
Turning difference remains between front and rear wheels or between
right and left rear wheels, resulting in an oil temperature rise in drive train
— Quick blinking*1 related parts. Shuts down 4WD system
NOTE: temporarily
It is not malfunction.
— Slow blinking*2 Malfunction in each tire or different tire diameter

*1: 2 times/second (blinking for approximately 1 minute and then turned OFF)
*2: 1 time/2 seconds (continuing to blink until ignition switch is turned OFF)
NOTE:
• If the warning lamp blinks slowly during driving but remains OFF after the engine is restarted, the system is
normal. If it again blinks slowly after driving for some time, vehicle must be inspected.
• When there is a difference of revolution speed between the front and rear wheel the shift occasionally
changes to direct 4-wheel driving conditions automatically. This is not a malfunction.

DLN-32
 4WD CONTROL MODULE
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY21B]
DTC Inspection Priority Chart INFOID:0000000006359902

A
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
B
Priority Detected items (DTC)
• U1010 CONTROL UNIT (CAN)
1
• U1000 CAN COMM CIRCUIT
C
• P1808 VHCL SPEED SEN-ABS
• P1809 CONTROL UNIT 4
• P1811 BATTERY VOLTAGE
• P1813 4WD MODE SW DLN
2 • P181F INCOMP CALIBRATION
• P1829 THROTTLE POSI SEN
• P182D SOLENOID LEFT
• P182E SOLENOID RIGHT E
• P183B SOL POWER SUPPLY
• P181E STR ANGLE SEN
• P183C DECEL G SENSOR F
• P183D SIDE G SENSOR
• P183F GEAR POSI SIGNAL
3
• P183E YAWRATE SENSOR
• P1840 OUTPUT SPEED SIGNAL G
• P1864 INPUT SPEED SIGNAL
• P1865 GEAR RATIO
• P1804 CONTROL UNIT 3 H
• P181B INCOMP SELF SHUT
• P181D ENGINE SYSTEM
• P1820 ENGINE SPEED SIG
4 • P182F TEMP SENSOR LEFT I
• P1830 ABS OP SIG
• P1831 VDC OP SIG
• P1832 TCS OP SIG
• P183A TEMP SENSOR RIGHT J

DTC Index INFOID:0000000006359903

DTC Display Items Reference

P1804 CONTROL UNIT3 DLN-40, "DTC Logic" L
P1808 VHCL SPEED SEN-ABS DLN-41, "DTC Logic"
P1809 CONTROL UNIT4 DLN-40, "DTC Logic"
P1811 BATTERY VOLTAGE DLN-42, "DTC Logic" M
P1813 4WD MODE SW DLN-44, "DTC Logic"
P181B INCOMP SELF SHUT DLN-47, "DTC Logic"
N
P181D ENGINE SYSTEM DLN-49, "DTC Logic"
P181E STR ANGLE SEN DLN-50, "DTC Logic"
P181F INCOMP CALIBRATION DLN-51, "DTC Logic" O
P1820 ENGINE SPEED SIG DLN-52, "DTC Logic"
P1829 THROTTLE POSI SEN DLN-53, "DTC Logic"
P
P182D SOLENOID LEFT DLN-54, "DTC Logic"
P182E SOLENOID RIGHT DLN-57, "DTC Logic"
P182F TEMP SENSOR LEFT DLN-60, "DTC Logic"
P1830 ABS OP SIG DLN-62, "DTC Logic"
P1831 VDC OP SIG DLN-63, "DTC Logic"
P1832 TCS OP SIG DLN-64, "DTC Logic"

DLN-33
 4WD CONTROL MODULE
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY21B]
DTC Display Items Reference
P183A TEMP SENSOR RIGHT DLN-65, "DTC Logic"
P183B SOL POWER SUPPLY DLN-67, "DTC Logic"
P183C DECEL G SENSOR DLN-69, "DTC Logic"
P183D SIDE G SENSOR DLN-70, "DTC Logic"
P183E YAWRATE SENSOR DLN-71, "DTC Logic"
P183F GEAR POSI SIGNAL DLN-72, "DTC Logic"
P1840 OUTPUT SPEED SIGNAL DLN-73, "DTC Logic"
P1864 INPUT SPEED SIGNAL DLN-74, "DTC Logic"
P1865 GEAR RATIO DLN-75, "DTC Logic"
U1000 CAN COMM CIRCUIT DLN-76, "DTC Logic"
U1010 CONTROL UNIT (CAN) DLN-77, "DTC Logic"
NOTE:
If some DTCs are displayed at the same time, refer to DLN-33, "DTC Inspection Priority Chart".

DLN-34
 4WD SYSTEM
< WIRING DIAGRAM > [TRANSFER: TY21B]

WIRING DIAGRAM A
4WD SYSTEM
Wiring Diagram INFOID:0000000006359904
B

For connector terminal arrangements, harness layouts, and alphabets in a (option abbreviation; if not
described in wiring diagram), refer to GI-12, "Connector Information/Explanation of Option Abbreviation".
C

DLN

JCDWA0646GB

DLN-35
 DIAGNOSIS AND REPAIR WORK FLOW
< BASIC INSPECTION > [TRANSFER: TY21B]

BASIC INSPECTION
DIAGNOSIS AND REPAIR WORK FLOW
Work Flow INFOID:0000000006359905

DETAILED FLOW
1.INTERVIEW FROM THE CUSTOMER
Clarify customer complaints before inspection. First of all, perform an interview utilizing DLN-37, "Diagnostic
Work Sheet" and reproduce symptoms as well as fully understand it. Ask customer about his/her complaints
carefully. Check symptoms by driving vehicle with customer, if necessary.
CAUTION:
Customers are not professional. Never guess easily like “maybe the customer means that...,” or
“maybe the customer mentions this symptom”.

>> GO TO 2.
2.CHECK SYMPTOM
Reproduce the symptom that is indicated by the customer, based on the information from the customer
obtained by interview. Also check that the symptom is not caused by protection function. Refer to DLN-32,
"Protection Function".
CAUTION:
When the symptom is caused by normal operation, fully inspect each portion and obtain the under-
standing of customer that the symptom is not caused by a malfunction.

>> GO TO 3.
3.PERFORM SELF-DIAGNOSIS
With CONSULT-III
Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is any DTC detected?
YES >> Record or print self-diagnosis results. GO TO 4.
NO >> GO TO 6.
4.RECHECK SYMPTOM
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Perform DTC confirmation procedures for the error detected system.
NOTE:
If some DTCs are detected at the same time, determine the order for performing the diagnosis based on DLN-
33, "DTC Inspection Priority Chart".
Is any DTC detected?
YES >> GO TO 5.
NO >> Check harness and connectors based on the information obtained by interview. Refer to GI-42,
"Intermittent Incident".
5.REPAIR OR REPLACE ERROR-DETECTED PARTS
• Repair or replace error-detected parts.
• Reconnect part or connector after repairing or replacing.
• When DTC is detected, erase self-diagnostic results for “ALL MODE AWD/4WD”.

>> GO TO 7.
6.IDENTIFY ERROR-DETECTED SYSTEM BY SYMPTOM DIAGNOSIS
Estimate error-detected system based on symptom diagnosis and perform inspection.
Can the error-detected system be identified?

DLN-36
 DIAGNOSIS AND REPAIR WORK FLOW
< BASIC INSPECTION > [TRANSFER: TY21B]
YES >> GO TO 7.
NO >> Check harness and connectors based on the information obtained by interview. Refer to GI-42, A
"Intermittent Incident".
7.FINAL CHECK
B
With CONSULT-III
1. Check the reference value for 4WD control unit.
2. Recheck the symptom and check that symptom is not reproduced on the same conditions.
Is the symptom reproduced? C
YES >> GO TO 3.
NO >> INSPECTION END
DLN
Diagnostic Work Sheet INFOID:0000000006359972

Description E
• In general, customers have their own criteria for a problem. Therefore, it is important to understand the
symptom and status well enough by asking the customer about his/her concerns carefully. To systemize all
the information for the diagnosis, prepare the interview sheet referring to the interview points.
• In some cases, multiple conditions that appear simultaneously may cause a DTC to be detected. F

Interview sheet sample

G
Interview sheet
Registration Initial year
Customer number registration
MR/MS H
name
Vehicle type VIN
Storage date Engine Mileage km (Mile)
†Vehicle does not enter 4WD mode. I
†4WD warning lamp turns on.
†Heavy tight-corner braking symptom occurs
J
Symptom †Noise †Vibration
†Decrease in turning performance.
†Others K
( )
First occurrence †Recently †Others ( )
Frequency of occurrence †Always †Under a certain conditions of †Sometimes (time(s)/day) L
†Irrelevant

Climate con- Weather †Fine †Cloud †Rain †Snow †Others ( )

M
ditions Temperature †Hot †Warm †Cool †Cold †Temperature (Approx. °C)
Relative humidity †High †Moderate †Low
†Urban area †Suburb area †High way N
Road conditions
†Mounting road (uphill or down hill) †Rough road
†Irrelevant
†When engine starts †During idling
Operation conditions, etc. O
†During driving †During acceleration †At constant speed driving
†During deceleration †During cornering (right curve or left curve)

DLN-37
 DIAGNOSIS AND REPAIR WORK FLOW
< BASIC INSPECTION > [TRANSFER: TY21B]
Interview sheet
Registration Initial year
Customer number registration
MR/MS
name
Vehicle type VIN
Storage date Engine Mileage km (Mile)

Other conditions

Memo

DLN-38
 WRITING UNIT PARAMETER
< BASIC INSPECTION > [TRANSFER: TY21B]
WRITING UNIT PARAMETER
A
Description INFOID:0000000006581329

Perform writing unit parameter of electric controlled coupling after replacing 4WD control module, rear final B
drive assembly or electric controlled coupling. Refer to DLN-39, "Work Procedure".
Work Procedure INFOID:0000000006581330

C
1.WRITE UNIT PARAMETER
With CONSULT-III
1. Confirm the unit parameter (A) of electric controlled coupling DLN
(LH) and (B) of electric controlled coupling (RH).
NOTE:
• This illustration is sample. E
• For the illustration, the unit parameters are following.

Right side: 3B4D66BBE318

F
Left side: 3B4D66BBE32B
2. Turn the ignition switch OFF to ON.
3. Select “UNIT CHARACTERISTICS WRITE” of CONSULT-III G
“WORK SUPPORT” for “ALL MODE AWD/4WD”. JSDIA2079ZZ

4. Input unit parameters.

5. Select “Start”.
6. Check that “UNIT CHARACTERISTICS WRITE COMPLETED” is displayed. H

>> WORK END

I

DLN-39
 P1804, P1809 4WD CONTROL MODULE
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]

DTC/CIRCUIT DIAGNOSIS
P1804, P1809 4WD CONTROL MODULE
DTC Logic INFOID:0000000006359976

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

Malfunction is detected in the memory
P1804 CONTROL UNIT 3 (EEOROM) system of 4WD control mod-
ule. Internal malfunction of 4WD control
module.
AD converter system of 4WD control
P1809 CONTROL UNIT 4
module is malfunctioning.

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Turn the ignition switch OFF to ON.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Are DTC′s “P1804 or P1809” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-40, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006359977

1.PERFORM SELF-DIAGNOSIS
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Turn the ignition switch OFF, and then wait 10 seconds and more.
3. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Are DTC′s “P1804 or 1809” detected?
YES >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Check 4WD control module pin terminals for damage or loose connection with harness connector.
If any items are damaged, repair or replace error-detected parts.

DLN-40
 P1808 WHEEL SPEED SENSOR
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P1808 WHEEL SPEED SENSOR
A
DTC Logic INFOID:0000000006359979

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

• ABS actuator and electric unit (control C
• Malfunction is detected in vehicle unit)
speed signal that is output from ABS - Malfunction of ABS actuator and elec-
P1808 VHCL SPEED SEN-ABS actuator and electric unit (control unit) tric unit (control unit) circuit error
through CAN communication. - Wheel speed sensor error DLN
• Improper signal is input while driving. • 4WD control module
• CAN communication line
E
DTC CONFIRMATION PROCEDURE
1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and F
wait at least 10 seconds before conducting the next test.

>> GO TO 2. G
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III H
1. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1minute.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P1808” detected? I
YES >> Proceed to diagnosis procedure. Refer to DLN-41, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006359980
J

1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS

K
With CONSULT-III
Perform self-diagnosis for “ABS”.
Is any DTCs detected?
L
YES >> Check the DTCs. Refer to BRC-142, "DTC Index".
NO >> GO TO 2.
2.ERASE SELF-DIAGNOSTIC RESULT M
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Start the engine and drive vehicle at 30 km/h (19 MPH) or more. N
3. Check that ABS warning lamp turns OFF.
Does ABS warning lamp turn OFF?
YES >> GO TO 3. O
NO >> Refer to BRC-212, "Diagnosis Procedure".
3.CHECK TERMINALS AND HARNESS CONNECTORS
P
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P1808” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-41
 P1811 POWER SUPPLY CIRCUIT FOR 4WD CONTROL MODULE
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P1811 POWER SUPPLY CIRCUIT FOR 4WD CONTROL MODULE
DTC Logic INFOID:0000000006359982

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

• Malfunction of 4WD control module
When 4WD control module power sup-
P1811 BATTERY VOLTAGE power supply circuit (open or short)
ply is lower or higher than normal
• Malfunction of 4WD control module

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Turn the ignition switch OFF to ON.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P1811” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-42, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006359983

1.CHECK 4WD CONTROL MODULE POWER SUPPLY (1)

1. Turn the ignition switch OFF.
2. Disconnect 4WD control module harness connector.
3. Check the voltage between 4WD control module harness connector and ground.

4WD control module

— Voltage
Connector Terminal
B47 1 Ground Battery voltage
4. Turn the ignition switch ON.
CAUTION:
Never start the engine.
5. Check the voltage between 4WD control module harness connector and ground.

4WD control module

— Voltage
Connector Terminal
B47 1 Ground Battery voltage
Is the inspection result normal?
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK 4WD CONTROL MODULE POWER SUPPLY (2)
1. Turn the ignition switch OFF.
2. Check the 10A fuse (#33).
3. Check the harness for open or short between 4WD control module harness connector No.1 terminal and
10A (#33).
Is the inspection result normal?

DLN-42
 P1811 POWER SUPPLY CIRCUIT FOR 4WD CONTROL MODULE
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-10, "Wiring Diagram - BAT-
TERY POWER SUPPLY -". A
NO >> Repair or replace error-detected parts.
3.CHECK 4WD CONTROL MODULE POWER SUPPLY (3)
B
1. Turn the ignition switch OFF.
2. Check the voltage between 4WD control module harness connector and ground.

4WD control module

C
— Voltage
Connector Terminal
B47 3 Ground 0V DLN
3. Turn the ignition switch ON.
CAUTION:
Never start the engine. E
4. Check the voltage between 4WD control module harness connector and ground.

4WD control module F

— Voltage
Connector Terminal
B47 3 Ground Battery voltage
Is the inspection result normal? G
YES >> GO TO 5.
NO >> GO TO 4.
H
4.CHECK 4WD CONTROL MODULE POWER SUPPLY (4)
1. Turn the ignition switch OFF.
2. Check the 10A fuse (#3). I
3. Check the harness for open or short between 4WD control module harness connector No.3 terminal and
10A (#3).
Is the inspection result normal? J
YES >> Perform the trouble diagnosis for ignition power supply circuit. Refer to PG-15, "Wiring Diagram -
IGNITION POWER SUPPLY -".
NO >> Repair or replace error-detected parts.
K
5.CHECK 4WD CONTROL MODULE GROUND
1. Turn the ignition switch OFF.
2. Check the continuity between 4WD control module harness connector and ground. L

4WD control module

— Continuity
Connector Terminal M
10
B47 Ground Existed
11
N
Is the inspection result normal?
YES >> GO TO 6.
NO >> Repair or replace error-detected parts. O
6.CHECK TERMINALS AND HARNESS CONNECTORS
Check the 4WD control module pin terminals for damage or loose connection with harness connector.
P
Is the inspection result normal?
YES >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-43
 P1813 4WD MODE SWITCH
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P1813 4WD MODE SWITCH
DTC Logic INFOID:0000000006359989

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

• 4WD mode switch
- Internal malfunction of 4WD mode
Multiple signals received from 4WD shift switch
P1813 4WD MODE SW
switch are detected. - Malfunction of 4WD mode switch cir-
cuit
• 4WD control module

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Turn the ignition switch OFF to ON.
2. Turn the 4WD mode switch 2WD⇒4WD-V⇒4WD⇒4WD-V⇒4WD.
3. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P1813” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-44, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006359990

1.CHECK 4WD MODE SWITCH

Check 4WD mode switch. Refer to DLN-45, "Component Inspection".
Is the inspection result normal?
YES >> GO TO 2.
NO >> Replace 4WD mode switch. Refer to DLN-92, "Removal and Installation".
2.CHECK 4WD MODE SWITCH CIRCUIT (1)
1. Disconnect 4WD control module harness connector.
2. Check the continuity between 4WD control module harness connector and 4WD mode switch harness
connector.

DLN-44
 P1813 4WD MODE SWITCH
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]

4WD control module 4WD mode switch A

Continuity
Connector Terminal Connector Terminal
1 Existed
B
9 5 Not existed
6 Not existed
1 Not existed C
B47 13 M48 5 Existed
6 Not existed
DLN
1 Not existed
21 5 Not existed
6 Existed E
Is the inspection result normal?
YES >> GO TO 3.
NO >> Repair or replace error-detected parts. F
3.CHECK 4WD MODE SWITCH CIRCUIT (2)
Check the continuity between 4WD mode switch harness connector and ground. G

4WD mode switch

— Continuity
Connector Terminal H
M48 3 Ground Not existed
Is the inspection result normal?
I
YES >> GO TO 4.
NO >> Repair or replace error-detected parts.
4.CHECK TERMINALS AND HARNESS CONNECTORS J
• Check 4WD control module pin terminals for damage or loose connection with harness connector.
• Check 4WD mode switch pin terminals for damage or loose connection with harness connector.
Is the inspection result normal? K
YES >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.
L
Component Inspection INFOID:0000000006359991

1.CHECK 4WD MODE SWITCH

M
1. Turn the ignition switch OFF.
2. Remove 4WD mode switch. Refer to DLN-92, "Removal and Installation".
3. Check the continuity between 4WD mode switch harness connector terminals.
N
4WD switch assembly
Condition Continuity
Terminal
O
4WD shift switch: 2WD Not existed
1 3
4WD shift switch: 4WD-V or 4WD Existed
4WD shift switch: 2WD Existed P
5 3
4WD shift switch: 4WD-V or 4WD Not existed
4WD shift switch: 2WD or 4WD-V Not existed
6 3
4WD shift switch: 4WD Existed
Is the inspection result normal?
YES >> INSPECTION END

DLN-45
 P1813 4WD MODE SWITCH
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
NO >> Replace 4WD mode switch. Refer to DLN-92, "Removal and Installation".

DLN-46
 P181B INCOMPLETE SELFSHUT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P181B INCOMPLETE SELFSHUT
A
DTC Logic INFOID:0000000006360005

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

When ignition switch is OFF and 4WD C
Self-shut of 4WD control module is in-
P181B IMCOMP SELFSHUT control module power supply is lower or
complete.
higher than normal

DTC CONFIRMATION PROCEDURE DLN

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and E
wait at least 10 seconds before conducting the next test.

>> GO TO 2. F
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III G
1. Turn the ignition switch OFF.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P181B” detected? H
YES >> Proceed to diagnosis procedure. Refer to DLN-47, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360006 I

1.CHECK 4WD CONTROL MODULE POWER SUPPLY (1)

1. Turn the ignition switch OFF. J
2. Disconnect 4WD control module harness connector.
3. Check the voltage between 4WD control module harness connector and ground.
K
4WD control module
— Voltage
Connector Terminal
L
B47 1 Ground Battery voltage
4. Turn the ignition switch ON.
CAUTION: M
Never start the engine.
5. Check the voltage between 4WD control module harness connector and ground.

N
4WD control module
— Voltage
Connector Terminal
B47 1 Ground Battery voltage O
Is the inspection result normal?
YES >> GO TO 3.
NO >> GO TO 2. P
2.CHECK 4WD CONTROL MODULE POWER SUPPLY (2)
1. Turn the ignition switch OFF.
2. Check the 10A fuse (#33).
3. Check the harness for open or short between 4WD control module harness connector No.1 terminal and
10A (#33).
Is the inspection result normal?

DLN-47
 P181B INCOMPLETE SELFSHUT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-10, "Wiring Diagram - BAT-
TERY POWER SUPPLY -".
NO >> Repair or replace error-detected parts.
3.CHECK 4WD CONTROL MODULE GROUND
1. Turn the ignition switch OFF.
2. Check the continuity between 4WD control module harness connector and ground.

4WD control module

— Continuity
Connector Terminal
10
E60 Ground Existed
11
Is the inspection result normal?
YES >> GO TO 4.
NO >> Repair or replace error-detected parts.
4.CHECK TERMINALS AND HARNESS CONNECTORS
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P181B” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-48
 P181D ENGINE TORQUE SIGNAL
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P181D ENGINE TORQUE SIGNAL
A
DTC Logic INFOID:0000000006360018

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

Malfunction is detected in engine torque • ECM C
P181D ENGINE SYSTEM signal that is output from ECM through • 4WD control module
CAN communication. • CAN communication line

DTC CONFIRMATION PROCEDURE DLN

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and E
wait at least 10 seconds before conducting the next test.

>> GO TO 2. F
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III G
1. Start the engine and drive at 20 km/h (12 MPH) or more.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P181D” detected? H
YES >> Proceed to diagnosis procedure. Refer to DLN-54, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360019 I

1.PERFORM ECM SELF-DIAGNOSIS

J
With CONSULT-III
Perform self-diagnosis for “ENGINE”.
Is any DTCs detected?
K
YES >> Check the DTCs. Refer to EC-108, "DTC Index".
NO >> GO TO 2.
2.ERASE SELF-DIAGNOSTIC RESULT L
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Turn the ignition switch OFF. M
3. Start the engine and drive vehicle for a while.
4. Check that malfunction indicator lamp (MIL) turns OFF.
Does malfunction indicator lamp (MIL) turn OFF?
N
YES >> GO TO 3.
NO >> Refer to EC-436, "Diagnosis Procedure".
3.CHECK TERMINALS AND HARNESS CONNECTORS O
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC P
“P181D” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-49
 P181E STEERING ANGLE SENSOR
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P181E STEERING ANGLE SENSOR
DTC Logic INFOID:0000000006360002

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

• Steering angle sensor
- Steering angle sensor error
Malfunction is detected in steering angle
- Malfunction of steering angle sensor
P181E ST ANGLE SEN SIG sensor signal through CAN communica-
circuit
tion.
• Malfunction of 4WD control module
• CAN communication line

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Turn the ignition switch OFF to ON.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P181E” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-50, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360003

1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS

With CONSULT-III
Perform self-diagnosis for “ABS”.
Is DTC “C1143” detected?
YES >> Proceed to diagnosis procedure. Refer to BRC-189, "Diagnosis Procedure".
NO >> GO TO 2.
2.CHECK CAN COMMUNICATION LINE
Check communication line. Refer to LAN-44, "Diagnosis Procedure".
Is inspection result normal?
YES >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-50
 P181F INCOMPLETE CALIBRATION
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P181F INCOMPLETE CALIBRATION
A
DTC Logic INFOID:0000000006360025

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

When incomplete writing unit parameter C
P181F INCOMP CALIBRATION Writing unit parameter is incomplete.
of rear final drive is detected.

DTC CONFIRMATION PROCEDURE

DLN
1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test. E

>> GO TO 2.
F
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Turn the ignition switch OFF to ON. G
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P181F” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-51, "Diagnosis Procedure". H
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360026

I
1.PERFORM WRITING UNIT PARAMETER
1. Erase self-diagnostic result for “ALL MODE AWD/4WD”.
2. Perform writing unit parameter. Refer to DLN-39, "Work Procedure". J
3. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is any DTC except “P181F” detected?
K
YES >> Check DTC.
NO >> GO TO 2.
2.PERFORM SELF-DIAGNOSIS L
With CONSULT-III
1. Erase self-diagnostic result for “ALL MODE AWD/4WD”.
2. Turn the ignition switch OFF, and then wait 10 seconds or more. M
3. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P181F” detected?
YES >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation". N
NO >> Check 4WD control module pin terminals for damage or loose connection with harness connector.
If any items are damaged, repair or replace the error-detected parts.
O

DLN-51
 P1820 ENGINE SPEED SIGNAL
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P1820 ENGINE SPEED SIGNAL
DTC Logic INFOID:0000000006360023

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

Malfunction is detected in engine speed • ECM
P1820 ENGINE SPEED SIG signal that is output from ECM through • 4WD control module
CAN communication. • CAN communication line

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Start the engine and drive at 20 km/h (12 MPH) or more.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P1820” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-52, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360024

1.PERFORM ECM SELF-DIAGNOSIS

With CONSULT-III
Perform self-diagnosis for “ENGINE”.
Is any DTCs detected?
YES >> Check the DTCs. Refer to EC-108, "DTC Index".
NO >> GO TO 2.
2.ERASE SELF-DIAGNOSTIC RESULT
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Turn the ignition switch OFF.
3. Start the engine and drive vehicle for a while.
4. Check that malfunction indicator lamp (MIL) turns OFF.
Does malfunction indicator lamp (MIL) turn OFF?
YES >> GO TO 3.
NO >> Refer to EC-436, "Diagnosis Procedure".
3.CHECK TERMINALS AND HARNESS CONNECTORS
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P1820” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-52
 P1829 ACCELERATOR PEDAL POSITION SENSOR
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P1829 ACCELERATOR PEDAL POSITION SENSOR
A
DTC Logic INFOID:0000000006360029

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

Malfunction is detected in accelerator • ECM C
P1829 THROTTLE POSI SEN pedal position signal that is output from • 4WD control module
ECM through CAN communication. • CAN communication line

DTC CONFIRMATION PROCEDURE DLN

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and E
wait at least 10 seconds before conducting the next test.

>> GO TO 2. F
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III G
1. Start the engine and drive at 30 km/h (19 MPH) or more.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P1829” detected? H
YES >> Proceed to diagnosis procedure. Refer to DLN-53, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360030 I

1.PERFORM ECM SELF-DIAGNOSIS

J
With CONSULT-III
Perform self-diagnosis for “ENGINE”.
Is any DTCs detected?
K
YES >> Check the DTCs. Refer to EC-108, "DTC Index".
NO >> GO TO 2.
2.ERASE SELF-DIAGNOSTIC RESULT L
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Turn the ignition switch OFF. M
3. Start the engine and drive vehicle for a while.
4. Check that malfunction indicator lamp (MIL) turns OFF.
Does malfunction indicator lamp (MIL) turn OFF?
N
YES >> GO TO 3.
NO >> Refer to EC-436, "Diagnosis Procedure".
3.CHECK TERMINALS AND HARNESS CONNECTORS O
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC P
“P1829” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-53
 P182D 4WD SOLENOID LEFT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P182D 4WD SOLENOID LEFT
DTC Logic INFOID:0000000006360058

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

• Internal malfunction of electric con-
trolled coupling (LH)
Malfunction related to 4WD solenoid
P182D SOLENOID LEFT • Malfunction of 4WD solenoid (LH)
(LH) has been detected.
power supply circuit (open or short)
• Malfunction of 4WD control module

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE (1)
With CONSULT-III
1. Turn the ignition switch OFF to ON, and then wait for 5 seconds or more.
2. Turn the ignition switch OFF.
3. Turn the ignition switch ON, and then wait for 5 seconds or more.
4. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P182D” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-54, "Diagnosis Procedure".
NO >> GO TO 3.
3.DTC REPRODUCTION PROCEDURE (2)
With CONSULT-III
1. Lift up the vehicle.
2. Start the engine, and run at idle for 1 second.
3. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P182D” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-54, "Diagnosis Procedure".
NO >> GO TO 4.
4.DTC REPRODUCTION PROCEDURE (3)
With CONSULT-III
1. Drive the vehicle at 30 km/h (19 MPH) or more less for approximately 1 minute.
2. Stop the vehicle.
3. Drive the vehicle at 30 km/h (19 MPH) or more less for approximately 1 minute.
4. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P182D” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-54, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360059

1.CHECK 4WD SOLENOID CIRCUIT (1)

1. Check the resistance between 4WD control module harness connector.

DLN-54
 P182D 4WD SOLENOID LEFT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]

4WD control module A

Condition Resistance (Approx.)
Connector Terminal
10 °C (50 °F) 2.5 Ω
B
B47 23 24 20 °C (68 °F) 2.7 Ω
30 °C (86 °F) 2.8 Ω
Is the inspection result normal? C
YES >> GO TO 4.
NO >> GO TO 2.
2.CHECK 4WD SOLENOID CIRCUIT (2) DLN

1. Check the continuity between 4WD control module harness connector and rear final drive assembly har-
ness connector.
E

4WD control module Rear final drive assembly

Continuity
Connector Terminal Connector Terminal F
23 4
B47 B64 Existed
24 8
G
2. Check the continuity between 4WD control module harness connector and the ground.

4WD control module

— Continuity H
Connector Terminal
23
B47 Ground Not existed
24 I
Is the inspection result normal?
YES >> GO TO 3.
NO >> Repair or replace the error-detected parts. J

3.CHECK 4WD SOLENOID

Check 4WD solenoid. Refer to DLN-55, "Component Inspection". K
Is the inspection result normal?
YES >> GO TO 4.
NO >> 4WD solenoid is malfunctioning (LH). Replace electric controlled coupling. Refer to DLN-139, L
"Removal and Installation".
4.CHECK TERMINALS AND HARNESS CONNECTORS
M
1. Check 4WD control module pin terminals for damage or loose connection with harness connector.
2. Check rear final drive assembly pin terminals for damage or loose connection with harness connector.
Is the inspection result normal?
N
YES >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace the error-detected parts.
Component Inspection INFOID:0000000006360060 O

1.CHECK 4WD SOLENOID

1. Turn the ignition switch OFF. P
2. Disconnect rear final drive assembly harness connector.
3. Check the resistance between rear final drive assembly connector terminals.

DLN-55
 P182D 4WD SOLENOID LEFT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]

Rear final drive assembly

Condition Resistance (Approx.)
Terminal
10 °C (50 °F) 2.5 Ω
4 8 20 °C (68 °F) 2.7 Ω
30 °C (86 °F) 2.8 Ω
Is the inspection result normal?
YES >> INSPECTION END
NO >> 4WD solenoid (LH) is malfunctioning. Replace electric controlled coupling. Refer to DLN-139,
"Removal and Installation".

DLN-56
 P182E 4WD SOLENOID RIGHT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P182E 4WD SOLENOID RIGHT
A
DTC Logic INFOID:0000000006360061

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

• Internal malfunction of electric con- C
trolled coupling (RH)
Malfunction related to 4WD solenoid
P182E SOLENOID RIGHT • Malfunction of 4WD solenoid (RH)
(RH) has been detected.
power supply circuit (open or short)
• Malfunction of 4WD control module DLN

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and E
wait at least 10 seconds before conducting the next test.

>> GO TO 2. F

2.DTC REPRODUCTION PROCEDURE (1)

With CONSULT-III G
1. Turn the ignition switch OFF to ON, and then wait for 5 seconds or more.
2. Turn the ignition switch OFF.
3. Turn the ignition switch ON, and then wait for 5 seconds or more. H
4. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P182E” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-57, "Diagnosis Procedure". I
NO >> GO TO 3.
3.DTC REPRODUCTION PROCEDURE (2)
With CONSULT-III J
1. Lift up the vehicle.
2. Start the engine, and run at idle for 1 second.
3. Perform self-diagnosis for “ALL MODE AWD/4WD”. K
Is DTC “P182E” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-57, "Diagnosis Procedure".
NO >> GO TO 4. L
4.DTC REPRODUCTION PROCEDURE (3)
With CONSULT-III M
1. Drive the vehicle at 30 km/h (19 MPH) or more less for approximately 1 minute.
2. Stop the vehicle.
3. Drive the vehicle at 30 km/h (19 MPH) or more less for approximately 1 minute.
4. Perform self-diagnosis for “ALL MODE AWD/4WD”. N
Is DTC “P182E” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-57, "Diagnosis Procedure".
NO >> INSPECTION END O

Diagnosis Procedure INFOID:0000000006360062

P
1.CHECK 4WD SOLENOID CIRCUIT (1)
1. Check the resistance between 4WD control module harness connector.

DLN-57
 P182E 4WD SOLENOID RIGHT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]

4WD control module

Condition Resistance (Approx.)
Connector Terminal
10 °C (50 °F) 2.5 Ω
B47 25 26 20 °C (68 °F) 2.7 Ω
30 °C (86 °F) 2.8 Ω
Is the inspection result normal?
YES >> GO TO 4.
NO >> GO TO 2.
2.CHECK 4WD SOLENOID CIRCUIT (2)
1. Check the continuity between 4WD control module harness connector and rear final drive assembly har-
ness connector.

4WD control module Rear final drive assembly

Continuity
Connector Terminal Connector Terminal
25 2
B47 B64 Existed
26 6
2. Check the continuity between 4WD control module harness connector and the ground.

4WD control module

— Continuity
Connector Terminal
25
B47 Ground Not existed
26
Is the inspection result normal?
YES >> GO TO 3.
NO >> Repair or replace the error-detected parts.
3.CHECK 4WD SOLENOID
Check 4WD solenoid. Refer to DLN-58, "Component Inspection".
Is the inspection result normal?
YES >> GO TO 4.
NO >> 4WD solenoid is malfunctioning (RH). Replace electric controlled coupling. Refer to DLN-139,
"Removal and Installation".
4.CHECK TERMINALS AND HARNESS CONNECTORS
1. Check 4WD control module pin terminals for damage or loose connection with harness connector.
2. Check rear final drive assembly pin terminals for damage or loose connection with harness connector.
Is the inspection result normal?
YES >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace the error-detected parts.
Component Inspection INFOID:0000000006360063

1.CHECK 4WD SOLENOID

1. Turn the ignition switch OFF.
2. Disconnect rear final drive assembly harness connector.
3. Check the resistance between rear final drive assembly connector terminals.

DLN-58
 P182E 4WD SOLENOID RIGHT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]

Rear final drive assembly A

Condition Resistance (Approx.)
Terminal
10 °C (50 °F) 2.5 Ω
B
2 6 20 °C (68 °F) 2.7 Ω
30 °C (86 °F) 2.8 Ω
Is the inspection result normal? C
YES >> INSPECTION END
NO >> 4WD solenoid (RH) is malfunctioning. Replace electric controlled coupling. Refer to DLN-139,
"Removal and Installation". DLN

DLN-59
 P182F COUPLING TEMPERATURE SENSOR LEFT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P182F COUPLING TEMPERATURE SENSOR LEFT
DTC Logic INFOID:0000000006360031

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

Electric controlled coupling (LH) temper-
ature
When electric controlled coupling (LH)
• Malfunction of electric controlled cou-
temperature is lower than normal
pling (LH) temperature sensor circuit
(open)
P182F TEMP SENSOR LEFT
Electric controlled coupling (LH) temper-
ature
When electric controlled coupling (LH)
• Malfunction of electric controlled cou-
temperature is higher than normal
pling (LH) temperature sensor circuit
(short)

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Turn the ignition switch OFF to ON.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P182F” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-60, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360032

1.CHECK ELECTRIC CONTROLLED COUPLING (LH) TEMPERATURE SENSOR POWER SUPPLY

1. Turn the ignition switch OFF.
2. Disconnect transfer fluid temperature sensor harness connector.
3. Turn the ignition switch ON.
CAUTION:
Never start the engine.
4. Check the voltage between rear final drive assembly harness connector terminals.

+ −
Rear final drive assembly Voltage
Connector Terminal
B64 3 7 Approx. 5 V
Is the inspection result normal?
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK ELECTRIC CONTROLLED COUPLING (LH) TEMPERATURE SENSOR CIRCUIT
1. Turn the ignition switch OFF.
2. Disconnect 4WD control module harness connector.
3. Check the continuity between 4WD control module harness connector and rear final drive assembly har-
ness connector.

DLN-60
 P182F COUPLING TEMPERATURE SENSOR LEFT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]

4WD control module Rear final drive assembly A

Continuity
Connector Terminal Connector Terminal
16 7
B47 B64 Existed B
17 3
4. Check the continuity between transfer fluid temperature sensor harness connector and ground.
C
Rear final drive assembly
— Continuity
Connector Terminal
DLN
B64 7 Ground Not existed
Is the inspection result normal?
YES >> GO TO 4. E
NO >> Repair or replace error-detected parts.
3.CHECK ELECTRIC CONTROLLED COUPLING (LH) TEMPERATURE SENSOR
Check the electric controlled coupling (LH) temperature sensor. Refer to DLN-61, "Component Inspection". F
Is the inspection result normal?
YES >> GO TO 4.
NO >> Electric controlled coupling (LH) temperature sensor is malfunctioning. Replace electric controlled G
coupling (LH). Refer to DLN-139, "Removal and Installation".
4.CHECK TERMINALS AND HARNESS CONNECTORS H
Check the pin terminals for damage or loose connection with each harness connector.
Is the inspection result normal?
YES >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation". I
NO >> Repair or replace error-detected parts.
Component Inspection INFOID:0000000006360033
J
1.CHECK ELECTRIC CONTROLLED COUPLING (LH) TEMPERATURE SENSOR
1. Turn the ignition switch OFF.
K
2. Disconnect rear final drive assembly harness connector.
3. Check the resistance between transfer control fluid temperature sensor connector terminals.

L
Rear final drive assembly Resistance (Ap-
Condition
Terminal prox.)

10 °C (50 °F) 9.8 kΩ M

3 7 20 °C (68 °F) 6.5 kΩ
30 °C (86 °F) 4.4 kΩ
Is the inspection result normal? N
YES >> INSPECTION END
NO >> Electric controlled coupling (LH) temperature sensor is malfunctioning. Replace electric controlled
coupling (LH). Refer to DLN-139, "Removal and Installation". O

DLN-61
 P1830 ABS OPERATION SIGNAL
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P1830 ABS OPERATION SIGNAL
DTC Logic INFOID:0000000006360037

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

Malfunction is detected in ABS operation
signal that is output from ABS actuator
P1830 ABS OP SIG Malfunction of ABS system
and electric unit (control unit) through
CAN communication.

DTC CONFIRMATION PROCEDURE

1.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Start the engine and drive at 30 km/h (19 MPH) or more.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P1830” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-62, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360038

1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS

With CONSULT-III
Perform self-diagnosis for “ABS”.
Is any DTCs detected?
YES >> Check the DTCs. Refer to BRC-142, "DTC Index".
NO >> GO TO 2.
2.ERASE SELF-DIAGNOSTIC RESULT
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Start the engine and drive vehicle at 30 km/h (19 MPH) or more.
3. Check that ABS warning lamp turns OFF.
Does ABS warning lamp turn OFF?
YES >> GO TO 3.
NO >> Refer to BRC-212, "Diagnosis Procedure".
3.CHECK TERMINALS AND HARNESS CONNECTORS
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P1830” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-62
 P1831 VDC OPERATION SIGNAL
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P1831 VDC OPERATION SIGNAL
A
DTC Logic INFOID:0000000006360039

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

Malfunction is detected in VDC opera- C
tion signal that is output from ABS actu-
P1831 VDC OP SIG Malfunction of ABS system
ator and electric unit (control unit)
through CAN communication.
DLN
DTC CONFIRMATION PROCEDURE
1.DTC REPRODUCTION PROCEDURE E
With CONSULT-III
1. Start the engine and drive at 30 km/h (19 MPH) or more.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”. F
Is DTC “P1831” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-63, "Diagnosis Procedure".
NO >> INSPECTION END G
Diagnosis Procedure INFOID:0000000006360040

1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS H

With CONSULT-III
Perform self-diagnosis for “ABS”.
I
Is any DTCs detected?
YES >> Check the DTCs. Refer to BRC-142, "DTC Index".
NO >> GO TO 2.
J
2.ERASE SELF-DIAGNOSTIC RESULT
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”. K
2. Start the engine and drive vehicle at 30 km/h (19 MPH) or more.
3. Check that ABS warning lamp turns OFF.
Does ABS warning lamp turn OFF? L
YES >> GO TO 3.
NO >> Refer to BRC-212, "Diagnosis Procedure".
3.CHECK TERMINALS AND HARNESS CONNECTORS M
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
N
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P1831” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.
O

DLN-63
 P1832 TCS OPERATION SIGNAL
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P1832 TCS OPERATION SIGNAL
DTC Logic INFOID:0000000006360041

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

Malfunction is detected in TCS operation
signal that is output from ABS actuator
P1832 TCS OP SIG Malfunction of TCS system
and electric unit (control unit) through
CAN communication.

DTC CONFIRMATION PROCEDURE

1.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Start the engine and drive at 30 km/h (19 MPH) or more.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P1832” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-64, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360042

1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS

With CONSULT-III
Perform self-diagnosis for “ABS”.
Is any DTCs detected?
YES >> Check the DTCs. Refer to BRC-142, "DTC Index".
NO >> GO TO 2.
2.ERASE SELF-DIAGNOSTIC RESULT
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Start the engine and drive vehicle at 30 km/h (19 MPH) or more.
3. Check that ABS warning lamp turns OFF.
Does ABS warning lamp turn OFF?
YES >> GO TO 3.
NO >> Refer to BRC-212, "Diagnosis Procedure".
3.CHECK TERMINALS AND HARNESS CONNECTORS
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P1832” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-64
 P183A COUPLING TEMPERATURE SENSOR RIGHT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P183A COUPLING TEMPERATURE SENSOR RIGHT
A
DTC Logic INFOID:0000000006360034

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

Electric controlled coupling (RH) tem- C
perature
When electric controlled coupling (RH)
• Malfunction of electric controlled cou-
temperature is lower than normal
pling (RH) temperature sensor circuit
(open) DLN
P183A TEMP SENSOR RIGHT
Electric controlled coupling (RH) tem-
perature
When electric controlled coupling (RH)
• Malfunction of electric controlled cou- E
temperature is higher than normal
pling (RH) temperature sensor circuit
(short)

DTC CONFIRMATION PROCEDURE F

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and G
wait at least 10 seconds before conducting the next test.

>> GO TO 2. H
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III I
1. Turn the ignition switch OFF to ON.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P183A” detected?
J
YES >> Proceed to diagnosis procedure. Refer to DLN-65, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360035 K

1.CHECK ELECTRIC CONTROLLED COUPLING (RH) TEMPERATURE SENSOR POWER SUPPLY

1. Turn the ignition switch OFF. L
2. Disconnect transfer fluid temperature sensor harness connector.
3. Turn the ignition switch ON.
CAUTION: M
Never start the engine.
4. Check the voltage between rear final drive assembly harness connector terminals.
N
+ −
Rear final drive assembly Voltage
Connector Terminal O
B64 1 5 Approx. 5 V
Is the inspection result normal?
P
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK ELECTRIC CONTROLLED COUPLING (RH) TEMPERATURE SENSOR CIRCUIT
1. Turn the ignition switch OFF.
2. Disconnect 4WD control module harness connector.
3. Check the continuity between 4WD control module harness connector and rear final drive assembly har-
ness connector.

DLN-65
 P183A COUPLING TEMPERATURE SENSOR RIGHT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]

4WD control module Rear final drive assembly

Continuity
Connector Terminal Connector Terminal
6 1
B47 B64 Existed
7 5
4. Check the continuity between transfer fluid temperature sensor harness connector and ground.

Rear final drive assembly

— Continuity
Connector Terminal
B64 1 Ground Not existed
Is the inspection result normal?
YES >> GO TO 4.
NO >> Repair or replace error-detected parts.
3.CHECK ELECTRIC CONTROLLED COUPLING (RH) TEMPERATURE SENSOR
Check the electric controlled coupling (RH) temperature sensor. Refer to DLN-66, "Component Inspection".
Is the inspection result normal?
YES >> GO TO 4.
NO >> Electric controlled coupling (RH) temperature sensor is malfunctioning. Replace electric controlled
coupling (RH). Refer to DLN-139, "Removal and Installation".
4.CHECK TERMINALS AND HARNESS CONNECTORS
Check the pin terminals for damage or loose connection with each harness connector.
Is the inspection result normal?
YES >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.
Component Inspection INFOID:0000000006360036

1.CHECK ELECTRIC CONTROLLED COUPLING (RH) TEMPERATURE SENSOR

1. Turn the ignition switch OFF.
2. Disconnect rear final drive assembly harness connector.
3. Check the resistance between transfer control fluid temperature sensor connector terminals.

Rear final drive assembly Resistance

Condition
Terminal (Approx.)

10 °C (50 °F) 9.8 kΩ

1 5 20 °C (68 °F) 6.5 kΩ
30 °C (86 °F) 4.4 kΩ
Is the inspection result normal?
YES >> INSPECTION END
NO >> Electric controlled coupling (RH) temperature sensor is malfunctioning. Replace electric controlled
coupling (RH). Refer to DLN-139, "Removal and Installation".

DLN-66
 P183B SOLENOID POWER SUPPLY
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P183B SOLENOID POWER SUPPLY
A
DTC Logic INFOID:0000000006360064

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

• Malfunction of 4WD solenoid power C
SOLENOID POWER SUP- When 4WD solenoid power supply volt-
P183B supply circuit
PLY age is lower or higher than normal.
• Malfunction of 4WD control module

DTC CONFIRMATION PROCEDURE DLN

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and E
wait at least 10 seconds before conducting the next test.

>> GO TO 2. F
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III G
1. Turn the ignition switch OFF to ON.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P183B” detected? H
YES >> Proceed to diagnosis procedure. Refer to DLN-67, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360065 I

1.CHECK 4WD SOLENOID POWER SUPPLY (1)

1. Turn the ignition switch OFF. J
2. Disconnect 4WD control module harness connector.
3. Check the voltage between 4WD control module harness connector and ground.
K
4WD control module
— Voltage
Connector Terminal
L
B47 12 Ground Battery voltage
4. Turn the ignition switch OFF to ON.
CAUTION: M
Never start the engine.
5. Check the voltage between 4WD control module harness connector and ground.

N
4WD control module
— Voltage
Connector Terminal
B47 12 Ground Battery voltage O
Is the inspection result normal?
YES >> GO TO 3.
NO >> GO TO 2. P
2.CHECK 4WD SOLENOID POWER SUPPLY (2)
1. Turn the ignition switch OFF.
2. Check the 10A fuse (#12).
3. Check the harness for open or short between 4WD control module harness connector No.12 and the 10A
fuse (#12).
Is the inspection result normal?

DLN-67
 P183B SOLENOID POWER SUPPLY
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
YES >> Perform the trouble the diagnosis for power supply circuit. Refer to PG-10, "Wiring Diagram -
BATTERY POWER SUPPLY -".
NO >> Repair or replace error-detected parts.
3.CHECK 4WD CONTROL MODULE POWER SUPPLY (1)
1. Turn the ignition switch OFF.
2. Check the voltage between 4WD control module harness connector and ground.

4WD control module

— Voltage
Connector Terminal
B47 3 Ground 0V
3. Turn the ignition switch ON.
CAUTION:
Never start the engine.
4. Check the voltage between 4WD control module harness connector and ground.

4WD control module

— Voltage
Connector Terminal
B47 3 Ground Battery voltage
Is the inspection result normal?
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK 4WD CONTROL MODULE POWER SUPPLY (2)
1. Turn the ignition switch OFF.
2. Check the 10A fuse (#3).
3. Check the harness for open or short between 4WD control module harness connector No.3 terminal and
10A (#3).
Is the inspection result normal?
YES >> Perform the trouble diagnosis for ignition power supply circuit. Refer to PG-15, "Wiring Diagram -
IGNITION POWER SUPPLY -".
NO >> Repair or replace error-detected parts.
5.CHECK 4WD SOLENOID GROUND
Check the continuity between 4WD control module harness connector and ground.

4WD control module

— Continuity
Connector Terminal
10
B47 Ground Existed
11
Is the inspection result normal?
YES >> GO TO 6.
NO >> Repair or replace the error-detected parts.
6.CHECK TERMINALS AND HARNESS CONNECTORS
1. Check 4WD control module pin terminals for damage or loose connection with harness connector.
2. Check 4WD solenoid pin terminals for damage or loose connection with harness connector.
Is the inspection result normal?
YES >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace the error-detected parts.

DLN-68
 P183C DECEL G SENSOR
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P183C DECEL G SENSOR
A
DTC Logic INFOID:0000000006360043

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

• ABS actuator and electric unit (control C
Malfunction is detected in decel G sen-
unit)
sor signal that is output from ABS actua-
P183C DECEL G SENSOR • Yaw rate/side/decel G sensor
tor and electric unit (control unit) through
• 4WD control module
CAN communication. DLN
• CAN communication line

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING E

If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.
F

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE G
With CONSULT-III
1. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1minute.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”. H
Is DTC “P183C” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-71, "Diagnosis Procedure".
NO >> INSPECTION END I

Diagnosis Procedure INFOID:0000000006360044

J
1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS
With CONSULT-III
Perform self-diagnosis for “ABS”. K
Is any DTCs detected?
YES >> Check the DTCs. Refer to BRC-142, "DTC Index".
NO >> GO TO 2. L
2.ERASE SELF-DIAGNOSTIC RESULT
With CONSULT-III M
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Start the engine and drive vehicle at 30 km/h (19 MPH) or more.
3. Check that ABS warning lamp turns OFF.
Does ABS warning lamp turn OFF? N
YES >> GO TO 3.
NO >> Refer to BRC-212, "Diagnosis Procedure".
O
3.CHECK TERMINALS AND HARNESS CONNECTORS
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal? P
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P183C” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-69
 P183D SIDE G SENSOR
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P183D SIDE G SENSOR
DTC Logic INFOID:0000000006360045

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

• ABS actuator and electric unit (control
Malfunction is detected in side G sensor
unit)
signal that is output from ABS actuator
P183D SIDE G SENSOR • Yaw rate/side/decel G sensor
and electric unit (control unit) through
• 4WD control module
CAN communication.
• CAN communication line

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1minute.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P183D” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-70, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360046

1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS

With CONSULT-III
Perform self-diagnosis for “ABS”.
Is any DTCs detected?
YES >> Check the DTCs. Refer to BRC-142, "DTC Index".
NO >> GO TO 2.
2.ERASE SELF-DIAGNOSTIC RESULT
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Start the engine and drive vehicle at 30 km/h (19 MPH) or more.
3. Check that ABS warning lamp turns OFF.
Does ABS warning lamp turn OFF?
YES >> GO TO 3.
NO >> Refer to BRC-212, "Diagnosis Procedure".
3.CHECK TERMINALS AND HARNESS CONNECTORS
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P183D” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-70
 P183E YAW RATE SENSOR
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P183E YAW RATE SENSOR
A
DTC Logic INFOID:0000000006360048

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

• ABS actuator and electric unit (control C
Malfunction is detected in yaw rate sen-
unit)
sor signal that is output from ABS actua-
P183E YAWRATE SENSOR • Yaw rate/side/decel G sensor
tor and electric unit (control unit) through
• 4WD control module
CAN communication. DLN
• CAN communication line

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING E

If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.
F

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE G
With CONSULT-III
1. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1minute.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”. H
Is DTC “P183E” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-71, "Diagnosis Procedure".
NO >> INSPECTION END I

Diagnosis Procedure INFOID:0000000006360049

J
1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS
With CONSULT-III
Perform self-diagnosis for “ABS”. K
Is any DTCs detected?
YES >> Check the DTCs. Refer to BRC-142, "DTC Index".
NO >> GO TO 2. L
2.ERASE SELF-DIAGNOSTIC RESULT
With CONSULT-III M
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Start the engine and drive vehicle at 30 km/h (19 MPH) or more.
3. Check that ABS warning lamp turns OFF.
Does ABS warning lamp turn OFF? N
YES >> GO TO 3.
NO >> Refer to BRC-212, "Diagnosis Procedure".
O
3.CHECK TERMINALS AND HARNESS CONNECTORS
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal? P
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P183E” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-71
 P183F GEAR POSITION SIGNAL
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P183F GEAR POSITION SIGNAL
DTC Logic INFOID:0000000006360050

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

• CVT sensor
Malfunction is detected in current gear
• TCM
P183F GEAR POSI SIGNAL position signal that is output from TCM
• 4WD control module
through CAN communication.
• CAN communication line

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1minute.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P183F” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-72, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360051

1.PERFORM TCM SELF-DIAGNOSIS

With CONSULT-III
Perform self-diagnosis for “TRANSMISSION”.
Is any DTCs detected?
YES >> Check the DTC. Refer to TM-171, "DTC Index".
NO >> GO TO 2.
2.ERASE SELF-DIAGNOSTIC RESULT
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Start the engine and drive vehicle at 30 km/h (19 MPH) or more.
3. Check that A/T CHECK indictor lamp turns OFF.
Does A/T CHECK indicator lamp turn OFF?
YES >> GO TO 3.
NO >> Refer to TM-259, "Symptom Table".
3.CHECK TERMINALS AND HARNESS CONNECTORS
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P183F” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-72
 P1840 OUTPUT SPEED SIGNAL
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P1840 OUTPUT SPEED SIGNAL
A
DTC Logic INFOID:0000000006360052

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

• CVT sensor C
Malfunction is detected in output shaft
• TCM
P1840 OUTPUT SPEED SIGNAL revolution signal that is output from TCM
• 4WD control module
through CAN communication.
• CAN communication line
DLN
DTC CONFIRMATION PROCEDURE
1.PRECONDITIONING E
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.
F
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
G
With CONSULT-III
1. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1minute.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
H
Is DTC “P1840” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-73, "Diagnosis Procedure".
NO >> INSPECTION END
I
Diagnosis Procedure INFOID:0000000006360053

1.PERFORM TCM SELF-DIAGNOSIS J

With CONSULT-III
Perform self-diagnosis for “TRANSMISSION”.
Is any DTCs detected? K
YES >> Check the DTC. Refer to TM-171, "DTC Index".
NO >> GO TO 2.
2.ERASE SELF-DIAGNOSTIC RESULT L

With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”. M
2. Start the engine and drive vehicle at 30 km/h (19 MPH) or more.
3. Check that A/T CHECK indictor lamp turns OFF.
Does A/T CHECK indicator lamp turn OFF?
N
YES >> GO TO 3.
NO >> Refer to TM-259, "Symptom Table".
3.CHECK TERMINALS AND HARNESS CONNECTORS O
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC P
“P1840” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-73
 P1864 INPUT SPEED SIGNAL
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P1864 INPUT SPEED SIGNAL
DTC Logic INFOID:0000000006360054

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

• CVT sensor
Malfunction is detected in input shaft
• TCM
P1864 INPUT SPEED SIGNAL revolution signal that is output from TCM
• 4WD control module
through CAN communication.
• CAN communication line

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1minute.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “P1864” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-74, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006360055

1.PERFORM TCM SELF-DIAGNOSIS

With CONSULT-III
Perform self-diagnosis for “TRANSMISSION”.
Is any DTCs detected?
YES >> Check the DTC. Refer to TM-171, "DTC Index".
NO >> GO TO 2.
2.ERASE SELF-DIAGNOSTIC RESULT
With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Start the engine and drive vehicle at 30 km/h (19 MPH) or more.
3. Check that A/T CHECK indictor lamp turns OFF.
Does A/T CHECK indicator lamp turn OFF?
YES >> GO TO 3.
NO >> Refer to TM-259, "Symptom Table".
3.CHECK TERMINALS AND HARNESS CONNECTORS
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P1864” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-74
 P1865 GEAR RATIO SIGNAL
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
P1865 GEAR RATIO SIGNAL
A
DTC Logic INFOID:0000000006360056

DTC DETECTION LOGIC B

DTC Display item Malfunction detected condition Possible cause

• CVT sensor C
Malfunction is detected in CVT ratio sig-
• TCM
P1865 GEAR RATIO nal that is output from TCM through CAN
• 4WD control module
communication.
• CAN communication line
DLN
DTC CONFIRMATION PROCEDURE
1.PRECONDITIONING E
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.
F
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
G
With CONSULT-III
1. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1minute.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
H
Is DTC “P1865” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-75, "Diagnosis Procedure".
NO >> INSPECTION END
I
Diagnosis Procedure INFOID:0000000006360057

1.PERFORM TCM SELF-DIAGNOSIS J

With CONSULT-III
Perform self-diagnosis for “TRANSMISSION”.
Is any DTCs detected? K
YES >> Check the DTC. Refer to TM-171, "DTC Index".
NO >> GO TO 2.
2.ERASE SELF-DIAGNOSTIC RESULT L

With CONSULT-III
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”. M
2. Start the engine and drive vehicle at 30 km/h (19 MPH) or more.
3. Check that A/T CHECK indictor lamp turns OFF.
Does A/T CHECK indicator lamp turn OFF?
N
YES >> GO TO 3.
NO >> Refer to TM-259, "Symptom Table".
3.CHECK TERMINALS AND HARNESS CONNECTORS O
Check 4WD control module pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC P
“P1865” is detected, Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.

DLN-75
 U1000 CAN COMM CIRCUIT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
U1000 CAN COMM CIRCUIT
Description INFOID:0000000006359919

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring.
Each control unit communicate data but selectively reads required data only.
DTC Logic INFOID:0000000006359920

DTC DETECTION LOGIC

DTC Display item Malfunction detected condition Possible cause

4WD control module is not transmitting/
• CAN communication error
U1000 CAN COMM CIRCUIT receiving CAN communication signal for
• Malfunction of 4WD control module
2 seconds or more.

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT-III
1. Turn the ignition switch OFF to ON.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “U1000” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-76, "Diagnosis Procedure".
NO >> INSPECTION END
Diagnosis Procedure INFOID:0000000006359921

Proceed to LAN-17, "Trouble Diagnosis Flow Chart".

DLN-76
 U1010 CONTROL UNIT (CAN)
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
U1010 CONTROL UNIT (CAN)
A
Description INFOID:0000000006359922

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul- B
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring. C
Each control unit communicate data but selectively reads required data only.
DTC Logic INFOID:0000000006359923
DLN

DTC DETECTION LOGIC

E
DTC Display item Malfunction detected condition Possible cause
Detecting error during the initial diagno-
Internal malfunction of 4WD control
U1010 CONTROL UNIT (CAN) sis of CAN controller of 4WD control
module F
module.

DTC CONFIRMATION PROCEDURE

1.PRECONDITIONING G
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.
H

>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE I
With CONSULT-III
1. Turn the ignition switch OFF to ON.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”. J
Is DTC “U1010” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-77, "Diagnosis Procedure".
NO >> INSPECTION END K

Diagnosis Procedure INFOID:0000000006359924

L
1.CHECK 4WD CONTROL MODULE
Check 4WD control module harness connector for disconnection and deformation.
Is the inspection result normal? M
YES >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace error-detected parts.
N

DLN-77
 POWER SUPPLY AND GROUND CIRCUIT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
POWER SUPPLY AND GROUND CIRCUIT
Diagnosis Procedure INFOID:0000000006359926

1.CHECK 4WD CONTROL MODULE POWER SUPPLY (1)

1. Turn the ignition switch OFF.
2. Disconnect 4WD control module harness connector.
3. Check the voltage between 4WD control module harness connector and ground.

4WD control module

— Voltage
Connector Terminal
B47 1 Ground Battery voltage
4. Turn the ignition switch ON.
CAUTION:
Never start the engine.
5. Check the voltage between 4WD control module harness connector and ground.

4WD control module

— Voltage
Connector Terminal
B47 1 Ground Battery voltage
Is the inspection result normal?
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK 4WD CONTROL MODULE POWER SUPPLY (2)
1. Turn the ignition switch OFF.
2. Check the 10A fuse (#33).
3. Check the harness for open or short between 4WD control module harness connector No.1 terminal and
10A (#33).
Is the inspection result normal?
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-10, "Wiring Diagram - BAT-
TERY POWER SUPPLY -".
NO >> Repair or replace error-detected parts.
3.CHECK 4WD CONTROL MODULE POWER SUPPLY (3)
1. Turn the ignition switch OFF.
2. Check the voltage between 4WD control module harness connector and ground.

4WD control module

— Voltage
Connector Terminal
B47 3 Ground 0V
3. Turn the ignition switch ON.
CAUTION:
Never start the engine.
4. Check the voltage between 4WD control module harness connector and ground.

4WD control module

— Voltage
Connector Terminal
B47 3 Ground Battery voltage
Is the inspection result normal?
YES >> GO TO 5.
NO >> GO TO 4.

DLN-78
 POWER SUPPLY AND GROUND CIRCUIT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]

4.CHECK 4WD CONTROL MODULE POWER SUPPLY (4) A

1. Turn the ignition switch OFF.
2. Check the 10A fuse (#3).
3. Check the harness for open or short between 4WD control module harness connector No.3 terminal and
B
10A (#3).
Is the inspection result normal?
YES >> Perform the trouble diagnosis for ignition power supply circuit. Refer to PG-15, "Wiring Diagram -
C
IGNITION POWER SUPPLY -".
NO >> Repair or replace error-detected parts.
5.CHECK 4WD SOLENOID POWER SUPPLY (1) DLN
1. Turn the ignition switch OFF.
2. Disconnect 4WD control module harness connector.
3. Check the voltage between 4WD control module harness connector and ground. E

4WD control module

— Voltage
Connector Terminal F
B47 12 Ground Battery voltage
4. Turn the ignition switch OFF to ON.
CAUTION: G
Never start the engine.
5. Check the voltage between 4WD control module harness connector and ground.
H
4WD control module
— Voltage
Connector Terminal
I
B47 12 Ground Battery voltage
Is the inspection result normal?
YES >> GO TO 7. J
NO >> GO TO 6.
6.CHECK 4WD SOLENOID POWER SUPPLY (2)
1. Turn the ignition switch OFF. K
2. Check the 10A fuse (#12).
3. Check the harness for open or short between 4WD control module harness connector No.12 and the 10A
fuse (#12). L
Is the inspection result normal?
YES >> Perform the trouble the diagnosis for power supply circuit. Refer to PG-10, "Wiring Diagram -
BATTERY POWER SUPPLY -". M
NO >> Repair or replace error-detected parts.
7.CHECK 4WD CONTROL MODULE GROUND
N
1. Turn the ignition switch OFF.
2. Check the continuity between 4WD control module harness connector and ground.

O
4WD control module
— Continuity
Connector Terminal
10 P
B47 Ground Existed
11
Is the inspection result normal?
YES >> INSPECTION END
NO >> Repair or replace error-detected parts.

DLN-79
 4WD WARNING LAMP
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
4WD WARNING LAMP
Component Function Check INFOID:0000000006359927

1.CHECK 4WD WARNING LAMP FUNCTION

1. Turn the ignition switch ON.
2. Check that 4WD warning lamp turns on.
Is the inspection result normal?
YES >> INSPECTION END
NO >> Proceed to diagnosis procedure. Refer to DLN-80, "Diagnosis Procedure".
Diagnosis Procedure INFOID:0000000006359928

1.CHECK POWER SUPPLY AND GROUND CIRCUIT

Perform the trouble diagnosis for power supply and ground circuit. Refer to DLN-78, "Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 2.
NO >> Repair or replace the error-detected parts.
2.PERFORM SELF-DIAGNOSIS
With CONSULT-III
Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is any DTC detected?
YES >> Check the DTC. Refer to DLN-33, "DTC Index".
NO >> GO TO 3.
3.CHECK 4WD WARNING LAMP SIGNAL
With CONSULT-III
1. Turn the ignition switch ON.
CAUTION:
Never start the engine.
2. Check “WARNING LAMP” of CONSULT-III “DATA MONITOR” for “ALL MODE AWD/4WD”.
Does the item on “DATA MONITOR” indicate “On”?
YES >> Perform the trouble diagnosis for combination meter power supply circuit. Refer to MWI-51,
"COMBINATION METER : Diagnosis Procedure".
NO >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".

DLN-80
 4WD MODE INDICATOR LAMP (4WD-V)
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
4WD MODE INDICATOR LAMP (4WD-V)
A
Component Function Check INFOID:0000000006359929

1.4WD MODE INDICATOR LAMP OPERATION CHECK B

1. Turn the ignition switch ON.
2. Change 4WD mode switch to “4WD-V”.
3. Check that 4WD mode indicator lamp (4WD-V) turns on. C
Is the inspection result normal?
YES >> INSPECTION END
NO >> Proceed to diagnosis procedure. Refer to DLN-81, "Diagnosis Procedure". DLN

Diagnosis Procedure INFOID:0000000006359930

1.CHECK 4WD WARNING LAMP E

Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute.
Does 4WD warning lamp turn ON? F
YES >> Proceed to DLN-80, "Diagnosis Procedure".
NO >> GO TO 2.
2.CHECK 4WD MODE SWITCH G
Perform the trouble diagnosis for 4WD mode switch. Refer to DLN-44, "Diagnosis Procedure".
Is the inspection result normal?
H
YES >> GO TO 3.
NO >> Repair or replace the error-detected parts.
3.CHECK 4WD MODE INDICATOR LAMP SIGNAL I
With CONSULT-III
1. Start the engine.
CAUTION: J
Stop the vehicle.
2. Change 4WD mode switch to “4WD-V” from “2WD”.
3. Check “INDICATOR” of CONSULT-III “DATA MONITOR” for “ALL MODE AWD/4WD”.
K
Does the item on “DATA MONITOR” indicate “4WD-V”?
YES >> GO TO 4.
NO >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
L
4.CHECK COMBINATION METER POWER SUPPLY CIRCUIT
Perform the trouble diagnosis for combination meter power supply circuit. Refer to MWI-51, "COMBINATION
METER : Diagnosis Procedure". M
Is the inspection result normal?
YES >> INSPECTION END
NO >> Repair or replace the error-detected parts. N

DLN-81
 4WD MODE INDICATOR LAMP (4WD)
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21B]
4WD MODE INDICATOR LAMP (4WD)
Component Function Check INFOID:0000000006598699

1.4WD MODE INDICATOR LAMP OPERATION CHECK

Check that 4WD mode indicator lamp (4WD) turns on for approximately 1 second after the ignition switch is
turned ON.
Is the inspection result normal?
YES >> INSPECTION END
NO >> Proceed to diagnosis procedure. Refer to DLN-82, "Diagnosis Procedure".
Diagnosis Procedure INFOID:0000000006598700

1.CHECK 4WD WARNING LAMP

Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute.
Does 4WD warning lamp turn ON?
YES >> Proceed to DLN-80, "Diagnosis Procedure".
NO >> GO TO 2.
2.CHECK 4WD MODE SWITCH
Perform the trouble diagnosis for 4WD mode switch. Refer to DLN-44, "Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 3.
NO >> Repair or replace the error-detected parts.
3.CHECK 4WD MODE INDICATOR LAMP SIGNAL
With CONSULT-III
1. Start the engine.
CAUTION:
Stop the vehicle.
2. Change 4WD mode switch to “4WD” from “4WD-V”.
3. Check “INDICATOR” of CONSULT-III “DATA MONITOR” for “ALL MODE AWD/4WD”.
Does the item on “DATA MONITOR” indicate “4WD”?
YES >> GO TO 4.
NO >> Replace 4WD control module. Refer to DLN-91, "Removal and Installation".
4.CHECK COMBINATION METER POWER SUPPLY CIRCUIT
Perform the trouble diagnosis for combination meter power supply circuit. Refer to MWI-51, "COMBINATION
METER : Diagnosis Procedure".
Is the inspection result normal?
YES >> INSPECTION END
NO >> Repair or replace the error-detected parts.

DLN-82
 4WD WARNING LAMP DOES NOT TURN ON
< SYMPTOM DIAGNOSIS > [TRANSFER: TY21B]

SYMPTOM DIAGNOSIS A
4WD WARNING LAMP DOES NOT TURN ON
Description INFOID:0000000006359934
B
4WD warning lamp does not turn ON when the ignition switch is turned to ON.
Diagnosis Procedure INFOID:0000000006359935 C

1.CHECK 4WD WARNING LAMP

Perform the trouble diagnosis for 4WD warning lamp. Refer to DLN-80, "Diagnosis Procedure". DLN
Is the inspection result normal?
YES >> Check each harness connector pin terminal for malfunction or disconnection.
NO >> Repair or replace the error-detected parts. E

DLN-83
 4WD WARNING LAMP DOES NOT TURN OFF
< SYMPTOM DIAGNOSIS > [TRANSFER: TY21B]
4WD WARNING LAMP DOES NOT TURN OFF
Description INFOID:0000000006359936

4WD warning lamp does not turn OFF several seconds after the engine started.
Diagnosis Procedure INFOID:0000000006359937

1.PERFORM SELF-DIAGNOSIS
With CONSULT-III
Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is any DTC detected?
YES >> Check the DTC. Refer to DLN-33, "DTC Index".
NO >> GO TO 2.
2.CHECK 4WD WARNING LAMP
Perform the trouble diagnosis of the 4WD warning lamp. Refer to DLN-80, "Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 3.
NO >> Repair or replace the error-detected parts.
3.CHECK 4WD CONTROL MODULE POWER SUPPLY AND GRAUND CIRCUIT
Perform the trouble diagnosis of power supply and ground circuit. Refer to MWI-51, "COMBINATION METER
: Diagnosis Procedure".
Is the inspection result normal?
YES >> Check each harness connector pin terminal for malfunction or disconnection.
NO >> Repair or replace the error-detected parts.

DLN-84
 HEAVY TIGHT-CORNER BRAKING SYMPTOM OCCURS
< SYMPTOM DIAGNOSIS > [TRANSFER: TY21B]
HEAVY TIGHT-CORNER BRAKING SYMPTOM OCCURS
A
Description INFOID:0000000006359938

Heavy tight-corner braking symptom occurs when the vehicle is driven and the steering wheel is turned fully to B
either side after the engine is started.
NOTE:
Light tight-corner braking symptom may occur depending on driving conditions. This is not malfunction.
C
Diagnosis Procedure INFOID:0000000006359939

1.PERFORM ECM SELF-DIAGNOSIS DLN

With CONSULT-III
Perform self-diagnosis for “ENGINE”.
Is any DTC detected? E
YES >> Check the DTC. Refer to EC-108, "DTC Index".
NO >> GO TO 2.
2.PERFORM SELF-DIAGNOSIS F

With CONSULT-III
Perform self-diagnosis for “ALL MODE AWD/4WD”.
G
Is any DTC detected?
YES >> Check the DTC. Refer to DLN-33, "DTC Index".
NO >> GO TO 3. H
3.CHECK 4WD SOLENOID
Perform the trouble diagnosis of the 4WD solenoid. Refer to DLN-54, "Diagnosis Procedure" (left), DLN-57,
"Diagnosis Procedure" (right). I
Is the inspection result normal?
YES >> GO TO 4.
NO >> Repair or replace the error-detected parts. J
4.CHECK ELECTRIC CONTROLLED COUPLING
1. Turn the ignition switch OFF. K
2. Set the transmission to neutral. Release the parking brake.
3. Lift up the vehicle.
4. Rotate the rear propeller shaft.
5. Hold the front propeller shaft lightly. L
Does the front propeller shaft rotate?
YES >> Replace electric controlled coupling for mechanical malfunction (clutch sticking etc.). Refer to
DLN-139, "Removal and Installation". M
NO >> Check each harness connector pin terminal for disconnection.

DLN-85
 VEHICLE DOES NOT ENTER 4WD MODE
< SYMPTOM DIAGNOSIS > [TRANSFER: TY21B]
VEHICLE DOES NOT ENTER 4WD MODE
Description INFOID:0000000006359940

Vehicle does not enter 4-wheel drive mode even though 4WD warning lamp turned to OFF.
Diagnosis Procedure INFOID:0000000006359941

1.CHECK 4WD WARNING LAMP

Turn the ignition switch ON.
Does 4WD warning lamp turn ON?
YES >> GO TO 2.
NO >> Proceed to diagnosis procedure. Refer to DLN-80, "Diagnosis Procedure".
2.CHECK PARKING BRAKE SWITCH SIGNAL
With CONSULT-III
Check “PKB SW” of CONSULT-III “DATA MONITOR” for “ALL MODE AWD/4WD”.

Monitor Item Condition Status

When the parking brake switch is operation. On
PKB SW
When the parking brake switch is not operation. Off
Is the inspection result normal?
YES >> GO TO 3.
NO >> Proceed to diagnosis procedure. Refer to BRC-208, "Diagnosis Procedure".
3.CRUISE TEST
Drive the vehicle for a period of time.
Does any symptom occur?
YES >> Replace electric controlled coupling for mechanical malfunction (mechanical engagement of
clutch is not possible). Refer to DLN-139, "Removal and Installation".
NO >> Check each harness connector pin terminal for disconnection.

DLN-86
 4WD WARNING LAMP BLINKS QUICKLY
< SYMPTOM DIAGNOSIS > [TRANSFER: TY21B]
4WD WARNING LAMP BLINKS QUICKLY
A
Description INFOID:0000000006359942

While driving, 4WD warning lamp blinks 2 times in 1 second and it turns OFF after 1 minute. B
NOTE:
• This symptom protects drivetrain parts when a heavy load is applied to the electric controlled coupling and
multiple disc clutch temperature increases. Also, optional distribution of torque sometimes becomes rigid
before lamp blinks quickly. Both cases are not malfunction. Refer to DLN-32, "Protection Function". C
• When this symptom occurs, stop vehicle and allow it to idle for some times. Blinking will stop and system will
be restored.
DLN

DLN-87
 4WD WARNING LAMP BLINKS SLOWLY
< SYMPTOM DIAGNOSIS > [TRANSFER: TY21B]
4WD WARNING LAMP BLINKS SLOWLY
Description INFOID:0000000006359943

4WD warning lamp blinks at approximately 2 seconds intervals while driving.

Diagnosis Procedure INFOID:0000000006359944

1.CHECK TIRE
Check the following.
• Tire pressure
• Wear condition
• Front and rear tire size (There is no difference between front and rear tires.)
Is the inspection result normal?
YES >> GO TO 2.
NO >> Repair or replace error-detected parts. And then, drive the vehicle at speed of 20 km/h (12 MPH)
or more for 5 seconds or more. Improper size information is initialized accordingly.
2.TERMINAL INSPECTION
Check 4WD control unit harness connector for disconnection.
Is the inspection result normal?
YES >> Replace 4WD control unit. Refer to DLN-91, "Removal and Installation".
NO >> Repair or replace the error-detected parts.

DLN-88
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [TRANSFER: TY21B]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
A
NVH Troubleshooting Chart INFOID:0000000006359951

Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these B
parts.

DLN-95, "Exploded View"

DLN-95, "Exploded View"

DLN-107, "Inspection"

DLN-111, "Inspection"
DLN-90, "Inspection"
C

Reference

DLN

TRANSFER OIL (Level too high)

BEARING (Worn or damaged)

OIL SEAL (Worn or damaged)
LIQUID GASKET (Damaged)
TRANSFER OIL (Level low)

GEAR (Worn or damaged)

TRANSFER OIL (Wrong)
F
SUSPECTED PARTS
(Possible cause)
G

H
Noise 1 2 3 3 3
Symptom
Transfer oil leakage 3 1 2 2
I

DLN-89
 TRANSFER OIL
< PERIODIC MAINTENANCE > [TRANSFER: TY21B]

PERIODIC MAINTENANCE
TRANSFER OIL
Inspection INFOID:0000000006359775

OIL LEAKAGE
Check transfer surrounding area (oil seal, drain plug, filler plug, and transfer case etc.) for oil leakage.
OIL LEVEL
1. Remove filler plug (1) and gasket. Then check that oil is filled up
from mounting hole for the filler plug.

: Vehicle front
CAUTION:
Never start engine while checking oil level.
2. Before installing filler plug, set a new gasket. Install filler plug on
transfer and tighten to the specified torque. Refer to DLN-113,
"Exploded View".
CAUTION:
JSDIA2080ZZ
Never reuse gasket.
Draining INFOID:0000000006359776

1. Run the vehicle to warm up the transfer unit sufficiently.

2. Stop the engine and remove the drain plug (1) and gascket to
drain the transfer oil.
3. Before installing drain plug, set a new gasket. Install drain plug
on the transfer and tighten to the specified torque. Refer to DLN-
113, "Exploded View".

: Vehicle front
CAUTION:
Never reuse gasket.
JSDIA2081ZZ

Refilling INFOID:0000000006359777

1. Remove filler plug (1) and gasket. Then fill oil up to mounting
hole for the filler plug.

: Vehicle front

Oil and viscosity : Refer to MA-13, "Fluids

and Lubricants".
Oil capacity : Refer to DLN-117, "Gener-
al Specifications".
CAUTION: JSDIA2080ZZ

Carefully fill the oil. (Fill up for approximately 3 minutes.)

2. Leave the vehicle for 3 minutes, and check the oil level again.
3. Before installing filler plug, set a new gasket. Install filler plug on transfer and tighten to the specified
torque. Refer to DLN-113, "Exploded View".
CAUTION:
Never reuse gasket.

DLN-90
 4WD CONTROL MODULE
< REMOVAL AND INSTALLATION > [TRANSFER: TY21B]

REMOVAL AND INSTALLATION A

4WD CONTROL MODULE
Removal and Installation INFOID:0000000006598861
B

REMOVAL
1. Turn the ignition switch OFF. C
2. Remove front (left side) seat. Refer to SE-27, "Removal and Installation".
3. Remove floor carpet. Refer to INT-23, "Removal and Installation".
4. Remove G sensor. Refer to TM-282, "Removal and Installation". DLN
5. Disconnect 4WD control module harness connector.
6. Remove 4WD control module mounting nuts.
E
7. Remove 4WD control module.
INSTALLATION
Note the following, and install in the reverse order of removal. F
• Perform “G SENSOR CALIBRATION”. Refer to TM-182, "Description".
• When installing 4WD control module, install it following procedure.
1. Align the securing holes (A) of bracket as shown in the figure G
and temporarily tighten mounting bolts.

: Vehicle front
H
2. When replace 4WD control module, hold 4WD control module
and remove protector paper on the adhesion area of bracket to
bond to the front floor (LH). I
3. Tighten mounting bolts to the specified torque.

Tightening torque : 8.0 N·m (0.82 kg-m, 71in-lb) J

• When replacing 4WD control module, perform writing unit parame-
ter. Refer to DLN-39, "Work Procedure".
K

M
JSDIA2082GB

DLN-91
 4WD MODE SWITCH
< REMOVAL AND INSTALLATION > [TRANSFER: TY21B]
4WD MODE SWITCH
Removal and Installation INFOID:0000000006607877

REMOVAL
1. Remove instrument lower panel. Refer to IP-12, "Exploded View".
2. Remove 4WD mode switch.
INSTALLATION
Install in the reverse order of removal.

DLN-92
 TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: TY21B]

UNIT REMOVAL AND INSTALLATION A

TRANSFER ASSEMBLY
Exploded View INFOID:0000000006359778
B

DLN

JSDIA2083GB
H
1. Transfer gusset 2. Transfer assembly 3. Heat insulator

: Vehicle front I
: N·m (kg-m, ft-lb)

Removal and Installation INFOID:0000000006359779 J

REMOVAL
1. Separate the rear propeller shaft. Refer to DLN-121, "Removal and Installation". K
2. Remove right side drive shaft. Refer to FAX-24, "RIGHT SIDE : Removal and Installation".
3. Remove catalyst convertor support bracket (RH). EM-35, "4WD : Removal and Installation".
L
4. Remove heat insulator (1).

O
JSDIA2311ZZ

DLN-93
 TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: TY21B]
5. Remove transfer gusset (1).
6. Remove catalyst convertor upport bracket rear. EM-59, "4WD :
Removal and Installation".
7. Remove rear torque rod and rear torque rod bracket. Refer to
EM-59, "4WD : Removal and Installation".
8. Remove the mounting bolts of transaxle assembly and transfer
assembly.

JSDIA2084ZZ

9. Remove transfer assembly from the vehicle.

: Vehicle front
CAUTION:
Never damage ring gear shaft.

JSDIA2085ZZ

INSTALLATION
Note the following, and install in the reverse order of removal.
• When installing the transfer to the transaxle, install the mounting
bolts following the standard below.

Bolt symbol A B
Installation direction Transfer ⇒ Transaxle Transaxle ⇒ Transfer
CAUTION:
• When installing transfer assembly to transaxle assembly,
replace the side oil seal (transfer joint). Refer to TM-292,
"Removal and Installation".
• Never damage side oil seal (the joint part of transfer). JSDIA2086ZZ

• When installing heat insulator (1), install the mounting bolts and
nut following procedure.

Tightening order 1 2 3 4 5 6
Bolt symbol A B C A B C
Tightening torque Temporary tightening Specified torque
• Check oil level and check for oil leakage after installation. Refer to
DLN-90, "Inspection".

JSDIA2312ZZ

DLN-94
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]

UNIT DISASSEMBLY AND ASSEMBLY A

RING GEAR SHAFT
Exploded View INFOID:0000000006359785
B

DLN

JSDIA2087GB K

1. Pinion lock nut 2. Companion flange 3. Drive pion oil seal

4. Pinon rear bearing 5. Transfer case 6. Gasket L
7. Filler plug 8. Collapsible spacer 9. Drive pinion adjust shim
10. Drive pinion 11. Pinion front bearing 12. Ring gear
13. Ring gear shaft 14. Ring gear bearing (right) 15. Ring gear bearing adjust shim (right) M
16. Spacer (right) 17. Transfer case oil seal (right) 18. Drive shaft oil seal
19. Transfer cover 20. Oil defense 21. Ring gear bearing (left)
22. Ring gear bearing adjust shim (left) 23. Spacer (left) 24. Transfer case oil seal (left) N
25. Drain plug 26. Dowel pin
A. Oil seal lip B. Transfer case mounting face
O
: N·m (kg-m, ft-lb)
: Always replace after every disassembly.
P
: Apply gear oil.

: Apply anti-corrosive oil.

: Apply multi purpose grease
: Apply Genuine Liquid Gasket 1215 or equivalent.

: Select with proper thickness.

DLN-95
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
Disassembly INFOID:0000000006359786

1. Remove transfer cover. Refer to DLN-114, "Disassembly".

2. Remove transfer case oil seal (right and left side).
3. Remove ring gear shaft assembly from transfer case.
4. Remove ring gear bearing outer race (right and left side) from ring gear shaft assembly.
5. Remove ring gear bearing adjust shim (right and left side) from ring gear shaft assembly.
6. Remove spacer (right and left side) from ring gear shaft assembly.
7. Remove gear ring bearing inner race (left side) from ring gear
shaft with the drift (A) and a replacer (B).

A : Drift (SST:ST33200000)
B : Replacer (commercial service tool)

JSDIA2165ZZ

8. Remove gear ring bearing inner race (right side) from ring gear
shaft with a replacer (A) (commercial service tool).
9. Remove the ring gear mounting bolts.

JSDIA2166ZZ

10. Lightly tap adapter case with a plastic hammer to remove drive
gear from ring gear shaft.

SDIA1807J

11. Remove drive shaft oil seal from the gear ring with a puller (A)
(SST: KV381054S0).
12. Perform inspection after disassembly. Refer to DLN-107,
"Inspection".

JPDIE0032ZZ

DLN-96
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
Assembly INFOID:0000000006359787

A
1. Select ring gear bearing adjust shim (right and left side). Refer to DLN-98, "Adjustment".
2. Install drive shaft oil seal until it becomes flush with ring gear
shaft end, using the drift (A) (SST: ST33230000). B
CAUTION:
• Never reuse the oil seal.
• When installing, never incline oil seal. C
• Apply multi-purpose grease to oil seal lip.

DLN

JPDIE0037ZZ
E
3. Install the gear ring bearing inner race (right side) to gear ring
with the drift (A) (commercial service tool).
CAUTION: F
• Never reuse the ring gear bearing.
• Apply gear oil to gear ring bearing inner race.
G

H
JSDIA1055ZZ

4. Install the gear ring bearing inner race (left side) to gear ring with I
the drift (A) (commercial service tool).
CAUTION:
• Never reuse the ring gear bearing.
• Apply gear oil to gear ring bearing inner race. J
5. Install spacer (right and left side) to ring gear shaft assembly.
6. Install selected ring gear bearing adjust shim (right and left side)
to ring gear shaft assembly. K
7. Install ring gear bearing outer race (right and left side) to ring
gear shaft assembly.
CAUTION: JSDIA1056ZZ L
• Never reuse the ring gear bearing.
• Apply gear oil to gear ring bearing outer race.
8. Set the drifts (A and B) to right and left side spacers individually. M
Compress ring gear shaft assembly and ring gear bearing to
install ring gear shaft assembly to transfer case.
N
A : Drift (commercial service tool)
B : Drift (commercial service tool)
CAUTION: O
• The drift shall be placed on the center of the spacers.
• The pressure shall be as low as to install ring gear shaft
assembly into transfer case. The maximum pressure shall
be 10 kN (1 ton, 1.0 Imp ton). JSDIA1106ZZ P
• If the adjusting shims and spacers are installed by tap-
ping, the transfer case may be damaged. Avoid tapping.
9. Install transfer cover.Refer to DLN-114, "Assembly".
10. Check backlash, tooth contact, total preload and companion flange runout. Refer to DLN-98, "Adjust-
ment".
CAUTION:
Measure the total preload without the adapter case oil seal.
DLN-97
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
11. Install the transfer case oil seal (left and right side). Refer to DLN-114, "Assembly".
Adjustment INFOID:0000000006359788

Adjusting shim selection

Measurement point

JSDIA2169ZZ

1. Transfer assembly

Ring gear bearing adjusting shim (right side)

1. Measure the dimensions of each measuring point with the following procedure:
Dimension “A” measurement

DLN-98
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
• Measure dimension (A) of transfer case with a pair of vernier
calipers. Refer to “Measuring point”. A

JSDIA2170ZZ

DLN
Dimension “X” measurement
• Measure the diameter (X) of transfer case with a pair of vernier
calipers. Refer to “Measuring point”. E

JSDIA2171ZZ

H
Dimension “Y” measurement
• Measure dimension (Y) of transfer case with a pair of vernier
calipers. Refer to “Measuring point”. I

JSDIA2173ZZ

L
Dimension “Z” measurement
• Measure dimension (Z) of transfer case with a pair of vernier
calipers and straightedge. Refer to “Measuring point”. M

JSDIA2174ZZ

P
Dimension “V” measurement

DLN-99
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
• Measure dimension (V) of ring gear shaft with a pair of vernier
calipers. Refer to “Measuring point”.

JSDIA2175ZZ

Dimension “W” measurement

• Measure dimension (W) of ring gear shaft with a pair of vernier
calipers. Refer to “Measuring point”.

JSDIA2176ZZ

Dimension “E” measurement

• Measure dimension (E) of ring gear shaft with a pair of vernier
calipers. Refer to “Measuring point”.

JSDIA2177ZZ

Dimension “F” measurement

• Measure dimension (F) from outer race edge surface of ring
gear shaft bearing (right side) to inner race edge surface with
a pair of vernier calipers and straightedge. Refer to “Measur-
ing point”.

JSDIA2178ZZ

Dimension “G” measurement

DLN-100
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
• Measure thickness (G) of spacer (right side) with a pair of ver-
nier calipers. Refer to “Measuring point”. A

JSDIA2179ZZ

DLN
2. Calculate dimension “B” by the formula below.

B = Z − Y − (X × 0.5) E
3. Calculate dimension “D” by the formula below.

D=E−V+W F

4. Calculate the thickness of the ring gear bearing adjusting shim (right side) “T1” by the formula below.
G
T1 = A − B + C + D − E − F − G + 0.045 mm (0.0018 in)
NOTE:
Calculate dimension “C” as 56.0 mm (2.20 in) H
5. Select ring gear bearing adjusting shim (right side).
CAUTION:
• Only one adjusting shim can be selected.
• Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with I
the calculated value is available.
Ring gear bearing adjusting shim (right side)
J
1. Measure the dimensions of each measuring point with the following procedure:
Dimension “X” measurement
• Measure the diameter (X) of transfer case with a pair of vernier K
calipers. Refer to “Measuring point”.

JSDIA2171ZZ N

Dimension “Y” measurement

• Measure dimension (Y) of transfer case with a pair of vernier O
calipers. Refer to “Measuring point”.

JSDIA2173ZZ

DLN-101
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]

Dimension “Z” measurement

• Measure dimension (Z) of transfer case with a pair of vernier
calipers and straightedge. Refer to “Measuring point”.

JSDIA2174ZZ

Dimension “H” measurement

• Measure dimension (H) from outer race edge surface of ring
gear shaft bearing (left side) to inner race edge surface with a
pair of vernier calipers and straightedge. Refer to “Measuring
point”.

JSDIA2180ZZ

Dimension “I” measurement

• Measure thickness (I) of spacer (left side) with a pair of vernier
calipers. Refer to “Measuring point”.

JSDIA2181ZZ

2. Calculate dimension “B” by the formula below.

B = Z − Y − (X × 0.5)
3. Calculate dimension “D” by the formula below.

D=E−V+W
4. Calculate the thickness of the ring gear bearing adjusting shim (left side) “T2” by the formula below.

T2 = B − C − D − H − I + 0.045 mm (0.0018 in)

NOTE:
Calculate dimension “C” as 56.0 mm (2.20 in)
5. Select ring gear bearing adjusting shim (left side).
CAUTION:
• Only one adjusting shim can be selected.
• Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with
the calculated value is available.

DLN-102
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
Drive pinion adjusting shim
1. Measure the dimensions of each measuring point with the following procedure: A

Dimension “L” measurement

• Measure dimension (L) from outer race edge surface of pinion
rear bearing to inner race edge surface with a pair of vernier B
calipers and straightedge. Refer to “Measuring point”.

DLN

JSDIA2182ZZ
E

Dimension “Q” measurement

• Measure dimension (Q) of transfer case with a pair of vernier F
calipers and straightedge. Refer to “Measuring point”.

JSDIA2183ZZ I

Dimension “R” measurement

• Measure dimension (R) of transfer case with a pair of vernier J
calipers and straightedge. Refer to “Measuring point”.

JSDIA2184ZZ M

Dimension “S” measurement

• Measure the diameter (S) of transfer case with a pair of vernier N
calipers. Refer to “Measuring point”.

JSDIA2185ZZ

2. Calculate dimension “J” by the formula below.

DLN-103
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]

J = Q − R − (S × 0.5)
3. Calculate the thickness of the drive pinion adjusting shim “T3” by the formula below.

T3 = J − K − L
NOTE:
Calculate dimension “K” as 70.85 mm (2.7894 in)
4. Select drive pinion adjusting shim.
CAUTION:
• Only one adjusting shim can be selected.
• Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with
the calculated value is available.
DRIVE PINION BEARING PRELOAD
1. Remove ring gear shaft assembly from the transfer case. Refer to DLN-96, "Disassembly".
2. Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking,
and so on.
3. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
4. Measure the drive pinion bearing preload with a preload gauge
(A) (SST: ST3127S000).

Drive pinion bearing preload : Refer to DLN-117, "Pre-

load Torque".
CAUTION:
• Each rotational part should rotate smoothly with the spec-
ified gear oil.
• Disassemble the drive pinion assembly to check and
adjust each part if outside the standard.
JSDIA2186ZZ

TOTAL PRELOAD
1. Measure drive pinion bearing preload (P1). Refer to DLN-117, "Preload Torque".
CAUTION:
Check that the drive pinion bearing preload is within the standard.
2. Assemble the ring gear shaft assembly to the transfer case. Refer to DLN-97, "Assembly"
3. Install transfer cover. Refer to DLN-114, "Assembly".
4. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
5. Measure the total preload with a preload gauge (A) (SST:
ST3127S000).

Total preload :Refer to DLN-117, "Preload

Torque".
CAUTION:
• Each rotational part should rotate smoothly with the spec-
ified gear oil.
• Disassemble the transfer assembly to check and adjust
each part if outside the standard. Measure it with the
transfer case oil seals removed when measuring total pre- JSDIA2186ZZ

load after disassembly. Then install transfer case oil

seals.
BACKLASH

DLN-104
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
1. Install the bolt (A) to the companion flange.
2. Fit a dial indicator onto the bolt. A
3. Measure the circumference backlash of the companion flange.

Backlash : Refer to DLN-117, "Backlash". B

4. If outside the standard, disassemble the transfer assembly to

check and adjust each part.
C

JSDIA2187ZZ

DLN
TOOTH CONTACT
1. Remove transfer cover. Refer to DLN-114, "Disassembly".
2. Remove ring gear shaft assembly from transfer case. Then E
apply red lead onto the ring gear. Refer to DLN-96, "Disassem-
bly".
CAUTION:
Apply red lead to both faces of 3 to 4 gears at 4 locations F
evenly spaced on the ring gear.
3. Assemble the ring gear shaft assembly to the transfer case.
Refer to DLN-97, "Assembly". G
4. Install transfer cover. Refer to DLN-114, "Assembly".
5. Rotate the companion flange back and forth several times.
JSDIA2188ZZ H
6. Remove ring gear shaft assembly from transfer case. Then
check drive pinion to ring gear tooth contact

Tooth Contact Judgment Guide I

JSDIA2189GB

DLN-105
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
7. Follow the procedure below to adjust pinion height (dimension
X) if tooth contact is improper.
CAUTION:
If no adjusting shim with the calculated value is available,
select the thicker and closest one.

SDIA3158J

• Thicken the drive pinion adjusting shim to move the drive pin-
ion closer to the ring gear in case of face contact or heel con-
tact.
CAUTION:
Only one adjusting shim can be selected.

PDIA0440E

• Thin the drive pinion adjusting shim to move the drive pinion
farther from the ring gear in case of flank contact or toe con-
tact.
CAUTION:
Only one adjusting shim can be selected.
8. Assemble the plug to the transfer case.
CAUTION:
• Remove old gasket on mounting surface, then remove
any moisture, oil, and foreign material on the application
and mounting surfaces.
• Apply liquid gasket to the thread, and tighten to the speci- PDIA0441E
fied torque when installing plug.
COMPANION FLANGE RUNOUT
1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft bolt holes).
2. Rotate the companion flange to check for runout.

Companion flange runout : Refer to DLN-117, "Com-

panion Flange Runout".

JSDIA2190ZZ

DLN-106
 RING GEAR SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
3. Fit a test indicator to the inner side of the companion flange
(socket diameter). A
4. Rotate the companion flange to check for runout.

Companion flange runout : Refer to DLN-117, "Com- B

panion Flange Runout".
5. Follow the procedure below to adjust if runout value is outside
the repair limit. C
CAUTION:
Replace collapsible spacer to check and adjust each part JSDIA2191ZZ
when companion flange is adjusted or replaced. DLN
a. Check for runout while changing the phase between companion flange and drive pinion in 90° steps. Then
search for the minimum point.
b. Replace companion flange if runout value is still outside the limit after the phase has been changed. E
c. Adjust assembly status of the drive pinion bearings and drive pinion, or replace drive pinion bearings if
runout is outside the standard after the companion flange is replaced.
Inspection INFOID:0000000006359789
F

INSPECTION AFTER DISASSEMBLY

Check items below. If necessary, replace them with new ones. G

Gear and Shaft

Check gear face and shaft for wear, cracks, damage, and seizure.
H
CAUTION:
Replace ring gear and drive pinion as a set (hypoid gear set) if any malfunction is detected on the ring
gear or drive pinion.
I
Bearing
Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.
CAUTION: J
Always replace inner race and outer race as a pair when replacing the bearing.
Shim
Check for seizure, damage, and unusual wear. K
Case
Check the bearing mounting surface for wear, cracks and damages.
CAUTION: L
Replace transfer case and transfer cover as a set if any malfunction is detected on transfer case or
transfer cover.
M

DLN-107
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
DRIVE PINION
Exploded View INFOID:0000000006359780

JSDIA2087GB

1. Pinion lock nut 2. Companion flange 3. Drive pion oil seal

4. Pinon rear bearing 5. Transfer case 6. Gasket
7. Filler plug 8. Collapsible spacer 9. Drive pinion adjust shim
10. Drive pinion 11. Pinion front bearing 12. Ring gear
13. Ring gear shaft 14. Ring gear bearing (right) 15. Ring gear bearing adjust shim (right)
16. Spacer (right) 17. Transfer case oil seal (right) 18. Drive shaft oil seal
19. Transfer cover 20. Oil defense 21. Ring gear bearing (left)
22. Ring gear bearing adjust shim (left) 23. Spacer (left) 24. Transfer case oil seal (left)
25. Drain plug 26. Dowel pin
A. Oil seal lip B. Transfer case mounting face

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

: Apply gear oil.

: Apply anti-corrosive oil.

: Apply multi purpose grease
: Apply Genuine Liquid Gasket 1215 or equivalent.

: Select with proper thickness.

DLN-108
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
Disassembly INFOID:0000000006359781

A
1. Remove transfer cover. Refer to DLN-114, "Disassembly".
2. Remove ring gear shaft assembly. Refer to DLN-96, "Disassembly".
3. Remove lock nut from the drive pinion. B
4. Put matching marks (A) on screw ends of companion flange (1)
and drive pinion.
CAUTION: C
Use paint to avoid scratching the surface.

DLN

JSDIA2192ZZ

5. Remove companion flange from drive pinion with a puller (A). F

JSDIA2193ZZ
I

6. Remove drive pinion oil seal from the transfer case with a puller
(A) (SST: KV381054S0). J
CAUTION:
Never damage transfer case.
K

JSDIA2194ZZ

M
7. Remove drive pinion assembly (1) from transfer case while tap-
ping the drive pinion lightly with a plastic hammer.
CAUTION:
Never drop the drive pinion assembly. N
8. Remove collapsible spacer from the drive pinion.
9. Remove inner race of drive pinion bearing (rear side) from trans-
fer case. O

P
JSDIA2195ZZ

DLN-109
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
10. Remove inner race of drive pinion bearing (front side) from drive
pinion with a replacer (A) (commercial service tool).
11. Remove drive pinion adjusting shim from the drive pinion.
12. Perform inspection after disassembly. Refer to DLN-111,
"Inspection".

JPDIE0028ZZ

Assembly INFOID:0000000006359782

1. Select drive pinion adjusting shim. Refer to DLN-98, "Adjustment".

2. Install selected drive pinion adjusting shim to drive pinion.
3. Install inner race of drive pinion bearing (front side) to drive pin-
ion with a drift (A) (SST: ST35272000).
CAUTION:
• Never reuse drive pinion bearing (front side).
• Apply gear oil to the drive pinion bearing (front side).
4. Assemble the inner race of drive pinion bearing (rear side) into
the transfer case.
CAUTION:
• Never reuse drive pinion bearing (rear side).
• Apply gear oil to the drive pinion bearing (rear side).
JSDIA2196ZZ

5. Install drive pinion oil seal to transfer case with drifts so that it
becomes flush with case end surface with the drifts (A and B).

A : Drift (SST: KV38102510)

B : Drift (SST: ST30720000)
CAUTION:
• Never reuse oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference.
6. Assemble a collapsible spacer onto the drive pinion.
JSDIA2197ZZ
CAUTION:
Never reuse the collapsible spacer.
7. Assemble drive pinion assembly into the transfer case, and then
install companion flange (1) to drive pinion.
NOTE:
Align matching marks (A) on the thread edge of companion
flange and drive pinion and install companion flange if drive pin-
ion is reused.

JSDIA2192ZZ

DLN-110
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
8. Tap the companion flange (1) with a plastic hammer as far as
the lock nut can be tightened. A
CAUTION:
Never damage drive pinion oil seal.
9. Apply anti-corrosive oil to the thread and seat of the lock nut, B
and temporarily tighten lock nut to the drive pinion.
CAUTION:
Never reuse lock nut.
C

JSDIA2198ZZ

DLN
10. Tighten lock nut within the specified torque range with a preload
gauge (A) (SST: ST3127S000) so that the drive pinion bearing
preload is within standard.
E
Drive pinion bearing preload : Refer to DLN-117, "Pre-
load Torque".
F
CAUTION:
• Start the tightening of lock nut from lower limit of the
specified torque. Check the preload every 5° to 10° while
tightening the lock nut. G
• Replace the collapsible spacer and tighten it again to JSDIA2186ZZ

adjust if preload exceeds the specified value. Never

loosen lock nut to adjust preload. H
• After adjustment, rotate the drive pinion back and forth from 2 to 3 times to check for unusual
noise, sticking, binding, and so on.
11. Install ring gear shaft assembly. Refer to DLN-97, "Assembly". I
12. Install transfer cover. Refer to DLN-114, "Assembly".
13. Check backlash, tooth contact, total preload and companion flange runout. Refer to DLN-98, "Adjust-
ment". J
CAUTION:
Measure the total preload without the transfer case oil seal.
Adjustment INFOID:0000000006359783 K

About adjusting of drive pinion, refer to DLN-98, "Adjustment".

Inspection INFOID:0000000006359784
L

INSPECTION AFTER DISASSEMBLY

Check items below. If necessary, replace them with new ones. M
Gear and Shaft
Check gear face and shaft for wear, cracks, damage, and seizure.
CAUTION: N
Replace ring gear and drive pinion as a set (hypoid gear set) if any malfunction is detected on the ring
gear or drive pinion.
Bearing O
Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.
CAUTION: P
Always replace inner race and outer race as a pair when replacing the bearing.
Shim
Check for seizure, damage, and unusual wear.
Case
Check the bearing mounting surface for wear, cracks and damages.
CAUTION:

DLN-111
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
Replace transfer case and transfer cover as a set if any malfunction is detected on transfer case or
transfer cover.

DLN-112
 TRANSFER CASE
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
TRANSFER CASE
A
Exploded View INFOID:0000000006359790

DLN

J
JSDIA2087GB

1. Pinion lock nut 2. Companion flange 3. Drive pion oil seal K

4. Pinon rear bearing 5. Transfer case 6. Gasket
7. Filler plug 8. Collapsible spacer 9. Drive pinion adjust shim
10. Drive pinion 11. Pinion front bearing 12. Ring gear L
13. Ring gear shaft 14. Ring gear bearing (right) 15. Ring gear bearing adjust shim (right)
16. Spacer (right) 17. Transfer case oil seal (right) 18. Drive shaft oil seal
19. Transfer cover 20. Oil defense 21. Ring gear bearing (left) M
22. Ring gear bearing adjust shim (left) 23. Spacer (left) 24. Transfer case oil seal (left)
25. Drain plug 26. Dowel pin
A. Oil seal lip B. Transfer case mounting face N

: N·m (kg-m, ft-lb)

O
: Always replace after every disassembly.

: Apply gear oil.

P
: Apply anti-corrosive oil.
: Apply multi purpose grease
: Apply Genuine Liquid Gasket 1215 or equivalent.

: Select with proper thickness.

DLN-113
 TRANSFER CASE
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
Disassembly INFOID:0000000006359791

1. Remove transfer cover mounting bolts.

2. Lightly tap (A) position of transfer cover with a plastic hammer to
remove transfer cover.
3. Remove ring gear shaft assembly. Refer to DLN-96, "Disassem-
bly",

JSDIA2199ZZ

4. Tap the outer race of drive pinion bearing from transfer case with
a brass rod to remove outer race of drive pinion bearing (front
side and rear side).
CAUTION:
Never damage transfer case.
5. Remove dowel pin.
CAUTION:
Never remove dowel pin, if it is not necessary to replace.
6. Remove the filler plug and drain plug from the transfer case, and
then remove each gasket.
7. Remove oil defense from transfer cover.
8. Perform inspection after disassembly. Refer to DLN-116,
"Inspection".

JSDIA2200ZZ

Assembly INFOID:0000000006359792

1. Install the oil defense to transfer cover.

2. Install gaskets onto filler plug and drain plug and install them into transfer case.
CAUTION:
• Never reuse gaskets.
• Install filler plug after oil is filled.
3. Install the dowel pin to transfer case.
CAUTION:
Never reuse the dowel pin.

DLN-114
 TRANSFER CASE
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
4. Install outer race of drive pinion bearing (front side) to the trans-
fer case with drift (A) (SST: ST17130000). A
CAUTION:
• Never reuse drive pinion bearing (front side).
• Apply gear oil to the drive pinion bearing (front side)
B

JSDIA2201ZZ

DLN
5. Install outer race of drive pinion bearing (rear side) to transfer
case with a drift (A) (SST: ST33230000).
CAUTION:
E
• Never reuse drive pinion bearing (rear side).
• Apply gear oil to the drive pinion bearing (rear side).
6. Install drive pinion assembly to transfer case. Refer to DLN-110,
"Assembly". F
7. Install ring gear shaft assembly to transfer case. Refer to DLN-
97, "Assembly".
G
JSDIA2202ZZ

8. Set the drifts (A and B) to right and left side spacers individually. H
Compress ring gear shaft assembly and ring gear bearing to
install transfer cover to transfer case.

A : Drift (commercial service tool) I

B : Drift (commercial service tool)
CAUTION:
• Clean the mounting surface of transfer case and transfer J
cover to degrease sufficiently.
• Never apply gasket fluid on the mounting surface.
• The drift shall be placed on the center of the spacers. JSDIA1105ZZ
K
• The pressure shall be as low as to install ring gear shaft
assembly into transfer case. The maximum pressure shall be 10 kN (1 ton, 1.0 Imp ton).
• If the adjusting shims and spacers are installed by tapping, the transfer cover may be damaged.
Avoid tapping. L
9. Check backlash, tooth contact, total preload and companion flange runout. Refer to DLN-98, "Adjust-
ment".
CAUTION: M
Measure the total preload without the transfer case oil seals.
10. Remove transfer cover. Refer to DLN-114, "Disassembly".
11. Apply liquid gasket (1) to mating surface of rear cover. N
CAUTION:
• Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adher- O
ing to the mounting surfaces.
• Overlap both ends of the bead for at least 3 mm (0.12 in).
P

JSDIA2203ZZ

DLN-115
 TRANSFER CASE
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21B]
12. Set the drifts (A and B) to right and left side spacers individually.
Compress ring gear shaft assembly and ring gear bearing to
install transfer cover to transfer case.

A : Drift (commercial service tool)

B : Drift (commercial service tool)
CAUTION:
• Immediately install after applying gasket.
• The drift shall be placed on the center of the spacers.
• The pressure shall be as low as to install ring gear shaft
assembly into transfer case. The maximum pressure shall JSDIA1105ZZ

be 10 kN (1 ton, 1.0 Imp ton).

• If the adjusting shims and spacers are installed by tapping, the transfer cover may be damaged.
Avoid tapping.
13. Tighten rear cover mounting bolts to the specified torque.
14. Install transfer case oil seal (right side) until it becomes flush
with ring gear shaft end, using the drifts (A and B).

A : Drift (SST: ST30720000)

B : Drift (SST: ST19820000)
CAUTION:
• Never reuse oil seals.
• When installing, do not incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.
• Immediately install after installing transfer cover. JSDIA2205ZZ

15. Install transfer case oil seal (left side) until it becomes flush with
ring gear shaft end, using the drift (A) (SST: KV40100620).
CAUTION:
• Never reuse oil seals.
• When installing, do not incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.
• Immediately install after installing transfer cover.
• After installing oil seal, immediately wipe out gasket
squeezed out inward of transfer case.
JSDIA2206ZZ

Inspection INFOID:0000000006359793

INSPECTION AFTER DISASSEMBLY

Check items below. If necessary, replace them with new ones.
Case
Check the bearing mounting surface for wear, cracks and damages.
CAUTION:
Replace transfer case and transfer cover as a set if any malfunction is detected on transfer case or
transfer cover.

DLN-116
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [TRANSFER: TY21B]

SERVICE DATA AND SPECIFICATIONS (SDS) A

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications INFOID:0000000006360067
B

Applied model 4WD

C
Transfer model TY21B
Oil capacity (Approx.) (lmp pt) 0.37 (5/8)
Gear ratio 0.404 DLN
Ring gear 42
Number of teeth
Drive pinion 17
E
Preload Torque INFOID:0000000006360068

Unit: N·m (kg-m, in-lb) F

Item Standard
Drive pinion bearing preload (P1) 0.30 – 0.80 (0.03 – 0.08, 3.0 – 7.0)
With all oil seals P1 + 0.55 – 0.80 (0.06 – 0.08, 5.0 – 7.0) G
Total preload
Without adapter case oil seal P1 + 0.35 – 0.60 (0.04 – 0.06, 3.0 – 5.0)

Backlash INFOID:0000000006360069
H

Unit: mm (in)

Item Standard I
Ring gear to drive pinion 0.16 – 0.21 (0.0063 – 0.0083)

Companion Flange Runout INFOID:0000000006360070 J

Unit: mm (in)

Item Limit K
Companion flange face (inner side of the propeller shaft bolt holes) 0.15 (0.0059)
Inside of companion flange (socket diameter) 0.2 (0.008)
L

DLN-117
 PRECAUTIONS
< PRECAUTION > [REAR PROPELLER SHAFT: 3Fφ16-ETJ75]

PRECAUTION
PRECAUTIONS
Service Notice or Precautions for Rear Propeller Shaft INFOID:0000000006359815

• Replace the propeller shaft assembly if there is a breakage or deflection on tube.

• Never hit the tube or apply an impact on it during repair service. Never damage the tube as well.
• The joint cannot be disassembled. Never disassemble it.

DLN-118
 Symptom
Reference

×: Applicable
< SYMPTOM DIAGNOSIS >

Noise
Shake
Vibration
Possible cause and SUSPECTED PARTS
NVH Troubleshooting Chart
SYMPTOM DIAGNOSIS

Uneven rotating torque DLN-120, "Inspection"

×
×
Center bearing improper installation DLN-123, "Inspection"

×
×
×
Excessive center bearing axial end play —

×
×
Center bearing mounting (insulator) cracks, damage or deterioration DLN-123, "Inspection"

×
×

DLN-119
Excessive joint angle —

×
×
×
Rotation imbalance DLN-123, "Inspection"

×
×
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.

Excessive runout DLN-120, "Inspection"

×
×
DIFFERENTIAL NVH of REAR FINAL DRIVE in this section

×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU section

×
×
×
TIRE NVH in WT section

×
×
×
ROAD WHEEL NVH in WT section

×
×
DRIVE SHAFT NVH in FAX and RAX section

×
×
×
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

BRAKE NVH in BR section

×
×
STEERING NVH in ST section

×
×
×
[REAR PROPELLER SHAFT: 3Fφ16-ETJ75]

INFOID:0000000006600701

L
F

P
K
E
B
A

N
H
C

O
G

M
DLN
 REAR PROPELLER SHAFT
< PERIODIC MAINTENANCE > [REAR PROPELLER SHAFT: 3Fφ16-ETJ75]

PERIODIC MAINTENANCE
REAR PROPELLER SHAFT
Inspection INFOID:0000000006359818

APPEARANCE AND NOISE

• Check the propeller shaft tube surface for dents or cracks. If damaged, replace propeller shaft assembly.
• If center bearing is noisy or damaged, replace propeller shaft assembly.
VIBRATION
If vibration is present at high speed, inspect propeller shaft runout first.
1. With a dial indicator, measure propeller shaft runout at runout
measuring points by rotating final drive companion flange with
hands.

Propeller shaft runout : Refer to DLN-125, "Pro-

peller Shaft Runout".

JPDID0419ZZ

• Propeller shaft runout measuring point (Point “ ”)

: Front

Dimension A: 542 mm (21.34 in)

B: 516.5 mm (20.33 in)
2. If runout still exceeds specifications, separate propeller shaft at
final drive companion flange or transfer companion flange; then
change the phase between companion flange and propeller
shaft by the one bolt hole at a time and install propeller shaft. JSDIA2286ZZ

3. Check runout again. If runout still exceeds specifications,

replace propeller shaft assembly.
4. Check the vibration by driving vehicle.

DLN-120
 REAR PROPELLER SHAFT
< REMOVAL AND INSTALLATION > [REAR PROPELLER SHAFT: 3Fφ16-ETJ75]

REMOVAL AND INSTALLATION A

REAR PROPELLER SHAFT
Exploded View INFOID:0000000006359819
B

DLN

JPDID0420GB
G

1. Propeller shaft assembly

H
: Vehicle front

: N·m (kg-m, ft-lb)

I
: Always replace after every disassembly.

Removal and Installation INFOID:0000000006359820

J
REMOVAL
1. Shift the transaxle to the neutral position, and then release the parking brake.
K
2. Put matching marks on propeller shaft flange yoke and final drive companion flanges.
CAUTION:
For matching marks, use paint. Never damage propeller shaft flange yoke and final drive compan-
ion flange. L
3. Put matching marks on propeller shaft flange yoke and transfer companion flanges.
CAUTION:
For matching marks, use paint. Never damage propeller shaft flange yoke and transfer companion M
flange.
4. Loosen mounting nuts of center bearing mounting bracket.
NOTE: N
Tighten mounting nuts temporarily.
5. Remove propeller shaft assembly fixing bolts and nuts.
6. Remove center bearing mounting bracket fixing nuts. O
7. Remove propeller shaft assembly.
CAUTION:
• This procedure requires 2 workers. Constant velocity joint must be handled with care. P

DLN-121
 REAR PROPELLER SHAFT
< REMOVAL AND INSTALLATION > [REAR PROPELLER SHAFT: 3Fφ16-ETJ75]
• If constant velocity joint was bent during propeller shaft
assembly removal, installation, or transportation, its boot
(1) may be damaged. Wrap boot interference area to metal
part (2) with shop cloth or rubber to protect boot from
breakage.

PDIA0982J

• Since no retaining pin is included in sliding direction, the

boot may be damaged or dropped if the constant velocity
joint is slid out 25 mm (0.98 in) or more from the original
length. Therefore, handle constant velocity joint by slid-
ing it inward.
8. Perform inspection after removal. Refer to DLN-123, "Inspec-
tion".

PDIA0983J

INSTALLATION
Note the following, and install in the reverse order of removal.
• Align matching marks to install propeller shaft assembly to final drive and transfer companion flanges.
• To install, adjust front and rear position of mount bracket to avoid deflection (front-rear direction of the vehi-
cle) to the center bearing insulator.
• Perform inspection after installation. Refer to DLN-123, "Inspection".
• After tightening the bolts and nuts to the specification torque,
check that the bolts (3) on the flange side is tightened as shown in
the figure.

1. Final drive assembly

2. Propeller shaft assembly

JSDIA0196ZZ

• If propeller shaft assembly or final drive assembly has been replaced, connect them as follows:
CAUTION:
Constant velocity joint of a new propeller shaft has a pre-
installed protector (1). Protector must be removed after
installing propeller shaft.

JSDIA2289ZZ

DLN-122
 REAR PROPELLER SHAFT
< REMOVAL AND INSTALLATION > [REAR PROPELLER SHAFT: 3Fφ16-ETJ75]
1. Install propeller shaft (1) while aligning its matching mark (A) of
propeller shaft with the matching mark (B) of final drive (2) on A
the joint as close as possible.
2. Temporary tighten bolts and nuts.
B

JSDIA2287ZZ

DLN
3. Press down propeller shaft (1) with matching mark (C) of final
drive (2) facing upward. Then tighten fixing bolts and nuts to the
specified torque.
E

G
JSDIA2288ZZ

Inspection INFOID:0000000006359821 H

INSPECTION AFTER REMOVAL

Appearance I
Check the propeller shaft for bend and damage. If damage is detected, replace propeller shaft assembly.
Propeller Shaft Runout
J
Check propeller shaft runout at measuring points with a dial indica-
tor. If runout exceeds specifications, replace propeller shaft assem-
bly.
K
Propeller shaft runout : Refer to DLN-125, "Pro-
peller Shaft Runout".
L

M
JSDIA0193ZZ

• Propeller shaft runout measuring point (Point “ ”)

N
: Front

O
Dimension A: 542 mm (21.34 in)
B: 516.5 mm (20.33 in)
P

JSDIA2286ZZ

Journal Axial Play

DLN-123
 REAR PROPELLER SHAFT
< REMOVAL AND INSTALLATION > [REAR PROPELLER SHAFT: 3Fφ16-ETJ75]
As shown in the figure, while fixing yoke on one side, check axial
play of joint. If it is outside the standard, replace propeller shaft
assembly.

Journal axial play : Refer to DLN-125, "Jour-

nal Axial Play".
CAUTION:
Never disassemble joints.

PDA0005D

Center Bearing
Check center bearing for noise and damage. If noise or damage is detected, replace propeller shaft assembly.
CAUTION:
Never disassemble center bearing.
INSPECTION AFTER INSTALLATION
After assembly, perform a driving test to check propeller shaft vibration. If vibration occurred, separate propel-
ler shaft from final drive or transfer. Reinstall companion flange by changing the phase between companion
flange and propeller shaft by the one bolt hole at a time. Then perform driving test and check propeller shaft
vibration again at each point.

DLN-124
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR PROPELLER SHAFT: 3Fφ16-ETJ75]

SERVICE DATA AND SPECIFICATIONS (SDS) A

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications INFOID:0000000006360071
B

Applied model 4WD

C
Propeller shaft model 3Fφ16-ETJ75
Number of joints 3
1st (Spider to CVJ joint center) 1051 mm (41.38 in) DLN
Shaft length
2nd (CVJ joint center to spider) 1000 mm (39.37 in)
1st 57 mm (2.500 in)
Shaft outer diameter E
2nd 75 mm (2.95 in)
1st joint Sell type
Type of journal bearings
2nd joint CVJ type F
(Non-disassembly type)
3rd joint Shell type
Transfer side Flange type
Coupling method
Rear final drive side Flange type G

Propeller Shaft Runout INFOID:0000000006360072

H
Unit: mm (in)
Item Limit
Propeller shaft runout 1.0 (0.031) I
Journal Axial Play INFOID:0000000006360073

Unit: mm (in) J
Item Standard
Journal axial play 0 (0)
K

DLN-125
 PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: RTVS]

PRECAUTION
PRECAUTIONS
Service Notice or Precautions for Rear Final Drive INFOID:0000000006359829

• Check for the correct installation status prior to removal or disassembly. If matching marks are required, be
certain they do not interfere with the function of the parts when applied.
• Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
• Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of
the unit, preventing them from entering into the unit during disassembly or assembly.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new one if necessary.
• Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tight-
ening sequence is specified, observe it.
• Clean and flush the parts sufficiently and blow-dry them.
• Never damage sliding surfaces and mating surfaces.
• When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
• Always use shop paper for cleaning the inside of components.
• Avoid using cotton gloves or shop rags to prevent entering of lint.
• During assembly, observe the specified tightening torque, and apply new gear oil, petroleum jelly, or multi-
purpose grease as specified for each vehicle, if necessary.

DLN-126
 PREPARATION
< PREPARATION > [REAR FINAL DRIVE: RTVS]

PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000006706411
B

Tool number
Description C
Tool name
ST3127S000 Measuring pinion bearing preload and total
Preload gauge preload
DLN

E
ZZA0806D

KV38100200 Installing side oil seal (right side)

Drift F
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
G

ZZA1143D
H
KV38100500 Installing side oil seal (left side)
Drift
a: 85 mm (3.35 in) dia.
b: 60 mm (2.36 in) dia. I

J
ZZA0811D

KV38109700 Installing electric controlled coupling oil seal

Drift
K

JSDIA2282ZZ

KV38109820 • Removing and Installing rear cover M

Drift • Removing and Installing center stem as-
a: 54.6 mm (2.150 in) dia. sembly

JPDID0368ZZ O
KV38109210 • Removing and Installing rear cover
Base tube • Removing and Installing center stem as-
a: 79.9 mm (3.146 in) dia. sembly P
b: 60 mm (2.36 in) dia.

ZZA0832D

DLN-127
 PREPARATION
< PREPARATION > [REAR FINAL DRIVE: RTVS]
Tool number
Description
Tool name
ST33052000 Removing side bearing inner race
Drift
a: 28 mm (1.10 in) dia.
b: 22 mm (0.87 in) dia.

ZZA1000D

ST33220000 Removing center stem

Drift
a: 37 mm (1.46 in) dia.
b: 22 mm (0.87 in) dia.

NT084

ST33052000 Installing center stem

Drift
a: 28 mm (1.10 in) dia.
b: 22 mm (0.87 in) dia.

ZZA1000D

KV40104810 Installing side bearing inner race

Attachment
A: 49 mm (1.93 in)
B: 42 mm (1.65 in)
C: 25 mm (0.98 in)

ZZA1133D

KV381096S0 • Checking backlash

Dummy cover set • Checking drive gear runout
1. KV38109610 • Checking tooth contact
Bearing guide 90
2. KV38109620
Bearing guide 68
3. KV38109630
Dammy cap spacer 90
4. KV38109640
Dammy cap spacer 68 JSDIA2283ZZ
5. KV38109640
Angle
ST17130000 Installing pinion front bearing outer race.
Drift
a: 31.8 mm (1.252 in) dia.
b: 58 mm (2.28 in) dia.

ZZA0836D

DLN-128
 PREPARATION
< PREPARATION > [REAR FINAL DRIVE: RTVS]
Tool number
Description
Tool name A
KV38100300 Installing pinion rear bearing outer race.
Drift
a: 54 mm (2.13 in) dia. B
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.

C
ZZA1046D

KV37710000 Installing pinion rear bearing outer race.

Drift DLN
a: 38 mm (1.50 in) dia.
b: 60 mm (2.36 in) dia.
c: 77 mm (3.03 in) dia.
E

JSDIA2284ZZ
F
Commercial Service Tools INFOID:0000000006706412

G
Tool name Description
Flange wrench Removing and installing drive pinion lock nut
H

NT035

Puller Removing companion flange J

ZZA0119D L
Drift Installing front oil seal
a: 76 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia. M

N
ZZA0811D

Replacer Removing pinion rear bearing inner race

O

ZZA0700D

DLN-129
 STRUCTURE AND OPERATION
< SYSTEM DESCRIPTION > [REAR FINAL DRIVE: RTVS]

SYSTEM DESCRIPTION
STRUCTURE AND OPERATION
Sectional View INFOID:0000000006359833

JSDIA2112ZZ

1. 4WD solenoid (RH) 2. Pinion rear bearing 3. Collapsible spacer

4. Pinion front bearing 5. Companion flange 6. Drive pinion
7. Gear carrier 8. Drive gear 9. 4WD solenoid (LH)
10. Electric controlled coupling (LH) 11. Side bearing (LH) 12. Center stem
13. Rear cover 14. Side bearing (RH) 15. Electric controlled coupling (RH)

Electric controlled coupling INFOID:0000000006603826

The electric controlled coupling operates as the 4WD system. For the operation, refer to DLN-15, "Operation
Principle".

DLN-130
 Symptom
Reference

×: Applicable
< SYMPTOM DIAGNOSIS >

Noise
Possible cause and SUSPECTED PARTS
NVH Troubleshooting Chart
SYMPTOM DIAGNOSIS

Gear tooth rough DLN-157, "Inspection"

×
Gear contact improper DLN-154, "Adjustment"

DLN-131
Tooth surfaces worn DLN-157, "Inspection"

×
Backlash incorrect DLN-154, "Adjustment"

×
Companion flange excessive runout DLN-154, "Adjustment"

×
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.

Gear oil improper DLN-132, "Inspection"

×
PROPELLER SHAFT NVH of REAR PROPELLER SHAFT in this section

×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections

×
TIRE NVH in WT section

×
ROAD WHEEL NVH in WT section
×
DRIVE SHAFT NVH in FAX and RAX section
×
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING

BRAKE NVH in BR section

×

STEERING NVH in ST section

×
[REAR FINAL DRIVE: RTVS]

INFOID:0000000006600702

L
F

P
K
E
B
A

N
H
C

O
G

M
DLN
 REAR DIFFERENTIAL GEAR OIL
< PERIODIC MAINTENANCE > [REAR FINAL DRIVE: RTVS]

PERIODIC MAINTENANCE
REAR DIFFERENTIAL GEAR OIL
Inspection INFOID:0000000006359834

OIL LEAKAGE
Check rear final drive surrounding area (oil seal, drain plug, filler plug, and carrier case, etc.) for oil leakage.
OIL LEVEL
1. Remove filler plug (1) and check oil level from filler plug mount-
ing hole as shown in the figure.
CAUTION:
Never start engine while checking oil level.
2. Set a new gasket on filler plug and install it on final drive assem-
bly. Refer to DLN-151, "Exploded View".
CAUTION:
Never reuse gasket.

JSDIA2113ZZ

Draining INFOID:0000000006359835

1. Stop engine.
2. Remove drain plug (1) and drain gear oil.
3. Set a new gasket on drain plug and install it to final drive assem-
bly and tighten to the specified torque. Refer to DLN-151,
"Exploded View".
CAUTION:
Never reuse gasket.

JSDIA2114ZZ

Refilling INFOID:0000000006359836

1. Remove filler plug (1). Fill with new gear oil until oil level reaches
the specified level near filler plug mounting hole.

Oil grade and viscosity : Refer to MA-13, "Fluids

and Lubricants".
Oil capacity : Refer to DLN-167, "Gen-
eral Specification".
2. After refilling oil, check oil level. Set a new gasket to filler plug,
then install it to final drive assembly. Refer to DLN-151,
"Exploded View". JSDIA2113ZZ

CAUTION:
Never reuse gasket.

DLN-132
 FRONT OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]

REMOVAL AND INSTALLATION A

FRONT OIL SEAL
Exploded View INFOID:0000000006361778
B

DLN

JSDIA2115GB
G

1. Rear final drive assembly 2. Front oil seal 3. Companion flange

4. Companion flange lock nut H
A. Oil seal lip

: Vehicle front I
: N·m (kg-m, ft-lb)
: Never reuse parts
J
: Apply multi purpose grease

: Apply gear oil.

K
Removal and Installation INFOID:0000000006361779

REMOVAL L
CAUTION:
Verify identification stamp of replacement frequency put in the lower part of gear carrier to determine
replacement for collapsible spacer when replacing front oil seal. Refer to “Identification stamp of
M
replacement frequency of front oil seal”. If collapsible spacer replacement is necessary, remove final
drive assembly and disassemble it to replace front oil seal and collapsible spacer. Refer to DLN-144,
"Removal and Installation" and DLN-160, "Disassembly".
NOTE: N
The reuse of collapsible spacer is prohibited in principle. However, it is reusable on a one-time basis
only in cases when replacing front oil seal.
Identification stamp of replacement frequency of front oil seal O

DLN-133
 FRONT OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]
• The diagonally shaded area in the figure shows stamping point for
replacement frequency of front oil seal.
• The following table shows if collapsible spacer replacement is
needed before replacing front oil seal.
When collapsible spacer replacement is required, disassemble
final drive assembly to replace collapsible spacer and front oil seal.
Refer to DLN-160, "Disassembly".

Stamp collapsible spacer replacement

No stamp Not required
JSDIA2116ZZ
“0” or “0” on the far right of stamp Required
“01” or “1” on the far right of stamp Not required
CAUTION:
Make a stamping after replacing front oil seal.
• After replacing front oil seal, make a stamping on the stamping point in accordance with the table below in
order to identify replacement frequency.
CAUTION:
Make a stamping from left to right.

Stamp before stamping Stamping on the far right Stamping

No stamp 0 0
“0”
1 01
(Front oil seal was replaced once.)
“01”
0 010
(Collapsible spacer and front oil seal were replaced last time.)
“0” is on the far right.
1 ...01
(Only front oil seal was replaced last time.)
“1” is on the far right.
0 ...010
(Collapsible spacer and front oil seal were replaced last time.)
1. Make a judgment if a collapsible spacer replacement is required.
2. Remove rear propeller shaft. Refer to DLN-121, "Removal and Installation".
3. Measure the total preload with the preload gauge (A) (SST:
ST3127S000).
NOTE:
Record the preload measurement.

JSDIA2117ZZ

4. Put matching mark (B) on the end of the drive pinion. The
matching mark (B) should be in line with the matching mark (A)
on companion flange (1).
CAUTION:
For matching mark, use paint. Never damage companion
flange and drive pinion.

JSDIA2118ZZ

DLN-134
 FRONT OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]
5. Remove companion flange lock nut using the flange wrench (A)
(commercial service tool). A

JSDIA2119ZZ

DLN
6. Remove companion flange using pullers (A) (commercial ser-
vice tool).
7. Remove front oil seal using a suitable tool. E
CAUTION:
Never damage carrier case.
F

G
JSDIA2120ZZ

INSTALLATION
H
1. Apply multi-purpose grease to front oil seal lips.
2. Install front oil seal using the drift (A) (commercial service tool)
as shown in figure.
CAUTION: I
• Never reuse oil seal.
• Never incline oil seal when installing.
J

JSDIA2122ZZ

3. Align the matching mark (B) of drive pinion with the matching L
mark (A) of companion flange (1), and then install the compan-
ion flange (1).
M

O
JSDIA2118ZZ

DLN-135
 FRONT OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]
4. Temporarily tighten drive pinion lock nut to drive pinion, using
flange wrench (commercial service tool).
CAUTION:
• Never reuse drive pinion lock nut.
• Apply anti-corrosion oil to the thread and seat of new
drive pinion lock nut.
5. Tighten drive pinion lock nut within the limits of specified torque
so as to keep the pinion bearing preload within a standard val-
ues, using preload gauge (A) (SST: ST3127S000).

Total preload torque : A value that add 0.1 – 0.4

N·m (0.01 – 0.04 kg-m, 0.1 –
0.3 in-lb) to the measured
value before removing.
CAUTION:
• Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
• If the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Never
loosen drive pinion lock nut to adjust the preload torque.

JSDIA2123ZZ

6. Fit a dial indicator onto the companion flange face (inner side of
the rear propeller shaft mounting bolt holes).
7. Rotate companion flange to check for runout.

Companion flange runout : Refer toDLN-167, "Com-

panion Flange Runout".
8. Fit a test indicator to the inner side of companion flange (socket
diameter).
9. Rotate companion flange to check for runout.
PDIA0439E

Companion flange runout : Refer toDLN-167, "Com-

panion Flange Runout".
10. If the runout value is outside the runout limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90° step, and
search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, replace companion flange.
c. If the runout value is still outside of the limit after companion flange has been replaced, possible cause will
be an assembly malfunction of drive pinion and electric controlled coupling, malfunctioning coupling bear-
ing, or malfunctioning of electric controlled coupling.
11. Make a stamping for identification of front oil seal replacement frequency. Refer to “Identification stamp of
replacement frequency of front oil seal”.
CAUTION:
Make a stamping after replacing front oil seal.
12. Install rear propeller shaft. Refer to DLN-121, "Removal and Installation".
13. Check the final drive for oil leakage. Refer to DLN-132, "Inspection".

DLN-136
 SIDE OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]
SIDE OIL SEAL
A
Exploded View INFOID:0000000006361780

DLN

JSDIA2233GB

1. Rear final drive assembly 2. Side oil seal (right) 3. Electric controlled coupling (right) G
4. Reamer bolt 5. Side oil seal (left) 6. Electric controlled coupling (left)
A. Oil seal lip B. Gear carrier mouting face
H
: Vehicle front

: N·m (kg-m, ft-lb)

I
: Always replace after every disassembly.
: Apply multi purpose grease
J
: Apply gear oil.
: Apply Genuine Liquid Gasket 1217 or equivalent.

K
Removal and Installation INFOID:0000000006361781

REMOVAL
L
1. Remove electric controlled couplings. Refer to DLN-139, "Removal and Installation".
2. Remove side oil seals with a suitable tool.
CAUTION:
M
Never damage gear carrier and rear cover.

JSDIA2234ZZ

INSTALLATION P

DLN-137
 SIDE OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]
1. Install side oil seal (right side) until it becomes flush with the car-
rier end, using the drift (A) (SST: KV38100200).
CAUTION:
• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.

JSDIA2235ZZ

2. Install side oil seal (left side) until it becomes flush with the car-
rier end, using the drift (A) (SST: KV38100500).
CAUTION:
• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.
3. Install electric controlled couplings. Refer to DLN-139, "Removal
and Installation".
4. When oil leaks while removing, check oil level after the installa-
tion. Refer to DLN-132, "Inspection". JSDIA2236ZZ

DLN-138
 ELECTRIC CONTROLLED COUPLING
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]
ELECTRIC CONTROLLED COUPLING
A
Exploded View INFOID:0000000006361782

DLN

JSDIA2237GB

1. Sub-harness 2. Rear final drive assembly 3. Electric controlled coupling (right) G

4. Reamer bolt 5. Electric controlled coupling (left)
A. Gear carrier mouting face
H
: Vehicle front

: N·m (kg-m, ft-lb)

I
: Apply Genuine Liquid Gasket 1217 or equivalent.

Removal and Installation INFOID:0000000006361783

J

REMOVAL
1. Remove rear drive shaft. Refer to RAX-17, "Removal and Installation". K
2. Disconnect electric controlled coupling connector (1) from sub-
harness (2).
L

N
JSDIA2238ZZ

3. Remove connector clip ( ) from final drive assembly. O

JSDIA2239ZZ

DLN-139
 ELECTRIC CONTROLLED COUPLING
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]
4. Remove electric controlled coupling from final drive assembly.
5. Remove sub-harness from final drive assembly.
CAUTION:
Remove sub-harness only when necessary.

JSDIA2240ZZ

INSTALLATION
1. Install new sub-harness clip to sub-harness.
CAUTION:
• Check original mounting dimensions to install clip to the original position.
• Baffle pin must be functioning normally.
2. Install sub-harness to final drive assembly.
CAUTION:
Check the area around the rotating object to see that there is no interference.
3. Apply liquid gasket (1) to mating surface of coupling cover.
CAUTION:
• Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adher-
ing to the mounting surfaces.
• Overlap both ends of the bead for at least 3 mm (0.12 in).

JSDIA2241ZZ

4. Install electric controlled coupling (1) to spline of stem center

with grommet of harness facing upward, temporarily tighten
reamer bolts (2) to the positions shown in the figure.
5. Tighten reamer bolts and coupling cover mounting bolts to the
specified torque.

: Vehicle front
CAUTION:
Never allow harness to get caught in the bolt.

JSDIA2242GB

DLN-140
 ELECTRIC CONTROLLED COUPLING
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]
6. Install the new connector clip ( ) to final drive assembly.
CAUTION: A
Never reuse connector clip.

JSDIA2239ZZ

DLN
7. Connect electric controlled coupling connector (1) to sub-har-
ness (2).
8. Install rear drive shaft. Refer to RAX-17, "Removal and Installa- E
tion".
9. When oil leaks while removing, check oil level after the installa-
tion. Refer to DLN-132, "Inspection".
F
10. When replacing electric controlled coupling, perform writing unit
parameter. Refer to DLN-39, "Work Procedure".
G
JSDIA2238ZZ

DLN-141
 ELECTRIC CONTROLLED COUPLING OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]
ELECTRIC CONTROLLED COUPLING OIL SEAL
Exploded View INFOID:0000000006361896

JSDIA2243ZZ

1. Rear final drive assembly 2. Electric controlled coupling oil seal

A. Oil seal lip

: Vehicle front
: Always replace after every disassembly.
: Apply multi purpose grease

: Apply gear oil.

Removal and Installation INFOID:0000000006361897

REMOVAL
1. Remove rear drive shafts. Refer to RAX-17, "Removal and Installation".
2. Remove electric controlled coupling oil seals from electric con-
trolled coupling, using a suitable tool.
CAUTION:
Never damage electric controlled coupling.

JSDIA2244ZZ

INSTALLATION
1. Install electric controlled coupling oil seals to electric controlled
coupling, using the drift (A) (SST: KV38109700).
NOTE:
The use of the special service tool satisfies the mounting dimen-
sions.
CAUTION:
• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.
JSDIA2245ZZ

DLN-142
 ELECTRIC CONTROLLED COUPLING OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]
2. Install rear drive shafts. Refer to RAX-17, "Removal and Installation".
3. When oil leaks while removing, check oil level after the installation. Refer to DLN-132, "Inspection". A

DLN

DLN-143
 REAR FINAL DRIVE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]

UNIT REMOVAL AND INSTALLATION

REAR FINAL DRIVE ASSEMBLY
Exploded View INFOID:0000000006361898

JSDIA2134GB

1. Final drive mounting bracket 2. Washer 3. Rear final drive assembly

: Vehicle front

: N·m (kg-m, ft-lb)

: Never reuse parts
: Apply multi purpose grease

: Apply gear oil.

Removal and Installation INFOID:0000000006361899

REMOVAL
1. Remove rear propeller shaft assembly. Refer to DLN-121, "Removal and Installation".
2. Remove rear drive shaft. Refer to RAX-17, "Removal and Installation".
3. Disconnect sub-harness connector (1).
4. Remove rear final drive breather hose.
5. Support rear final drive assembly with a suitable jack.

JSDIA2135ZZ

DLN-144
 REAR FINAL DRIVE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: RTVS]
6. Remove rear final drive mounting bolt ( ) at rear suspension
member. A

JSDIA2136ZZ

DLN
7. Remove final drive mounting bolts and nuts ( ), and then
remove rear final drive assembly from final drive mounting
bracket. E
CAUTION:
Secure final drive assembly to a suitable jack while remov-
ing it.
8. Remove fuel tank. Refer to FL-23, "4WD : Removal and Installa- F
tion".
9. Remove final drive mounting bracket.
G
JSDIA2137ZZ

INSTALLATION
Note the following, and install in the reverse order of removal. H
• Install the breather hose (1) to breather tube until dimension (A)
shown as follows.
I
A:
Final drive side : 20mm (0.79 in)
Breather side : 20mm (0.79 in) J
CAUTION:
• Never reuse hose clamps.
• Install the hose clamps, with the tab facing vehicle rear. K
JPDID0020ZZ

• If remove breather hose, install breather hose (1) as shown in the L

figure.

: Vehicle front M
- Install breather hose with paint mark (A) facing vehicle rear.
• When oil leaks while removing final drive assembly, check oil level
after the installation. Refer to DLN-132, "Inspection". N
• When replacing rear final drive assembly, perform writing unit
parameter. Refer to DLN-39, "Work Procedure".

JSDIA2138ZZ
O

DLN-145
 ELECTRIC CONTROLLED COUPLING
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]

UNIT DISASSEMBLY AND ASSEMBLY

ELECTRIC CONTROLLED COUPLING
Exploded View INFOID:0000000006361900

JSDIA2246GB

1. Filler plug 2. Gasket 3. Drain plug

4. Breather tube 5. Clip 6. Breather hose
7. Breather 8. sub-harness clip 9. sub-harness
10. Rear cover 11. Center stem 12. Side bearing (right)
13. Side bearing adjusting shim (right) 14. Side oil seal (right) 15. Connector clip
16. Electric controlled coupling (right) 17. Electric controlled coupling oil seal 18. Reamer bolt
19. Drive pinion 20. Drive pinion adjusting shim 21. Pinion rear bearing
22. Collapsible spacer 23. Breather 24. Gear carrier
25. Carrier bracket (right) 26. Pinion front bearing 27. Front oil seal
28. Companion flange 29. Drive pinion lock nut 30. Carrier bracket (left)
31. Drive gear 32. Side bearing (left) 33. Side bearing adjusting shim (left)
34. Electric controlled coupling (left) 35. Side oil seal (left)
A. Oil seal lip B. Gear carrier mounting face

: N·m (kg-m, ft-lb)

: Always replace after every disassembly.

: Apply gear oil.

: Apply anti-corrosive oil.

: Apply multi purpose grease

DLN-146
 ELECTRIC CONTROLLED COUPLING
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
: Apply Genuine Liquid Gasket 1217 or equivalent.
A
: Select with proper thickness.

Disassembly INFOID:0000000006361901
B
1. Disconnect electric controlled coupling connector (1) from sub-
harness (2).
C

DLN

E
JSDIA2238ZZ

2. Remove connector clip ( ) from final drive assembly. F

JSDIA2239ZZ I

3. Remove electric controlled coupling from final drive assembly.

4. Remove sub-harness from final drive assembly. J
CAUTION:
Remove sub-harness only when necessary.
K

JSDIA2240ZZ

M
5. Remove electric controlled coupling oil seals from electric con-
trolled coupling, using a suitable tool.
CAUTION:
Never damage electric controlled coupling. N

P
JSDIA2297ZZ

DLN-147
 ELECTRIC CONTROLLED COUPLING
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
6. Remove side oil seals with a suitable tool.
CAUTION:
Never damage gear carrier and rear cover.
7. Perform inspection after disassembly. Refer to DLN-150,
"Inspection".

JSDIA2298ZZ

Assembly INFOID:0000000006361902

1. Install side oil seal (right side) until it becomes flush with the car-
rier end, using the drift (A) (SST: KV38100200).
CAUTION:
• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.

JSDIA2299ZZ

2. Install side oil seal (left side) until it becomes flush with the car-
rier end, using the drift (A) (SST: KV38100500).
CAUTION:
• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.

JSDIA2300ZZ

3. Install electric controlled coupling oil seals to electric controlled

coupling, using the drift (A) (SST: KV38109700).
NOTE:
The use of the special service tool satisfies the mounting dimen-
sions.
CAUTION:
• Never reuse oil seals.
• When installing, never incline oil seals.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.
4. Install new sub-harness clip to sub-harness. JSDIA2301ZZ
CAUTION:
• Check original mounting dimensions to install clip to the original position.
• Baffle pin must be functioning normally.
5. Install sub-harness to final drive assembly.

DLN-148
 ELECTRIC CONTROLLED COUPLING
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
6. Apply liquid gasket (1) to mating surface of coupling cover.
CAUTION: A
• Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adher-
ing to the mounting surfaces.
B
• Overlap both ends of the bead for at least 3 mm (0.12 in).

JSDIA2241ZZ

DLN
7. Install electric controlled coupling (1) to spline of stem center
with grommet of harness facing upward, temporarily tighten
reamer bolts (2) to the positions shown in the figure.
E
8. Tighten reamer bolts and coupling cover mounting bolts to the
specified torque.
F
: Vehicle front
CAUTION:
Never allow harness to get caught in the bolt.
G

JSDIA2242GB
K
9. Install the new connector clip ( ) to final drive assembly.
CAUTION:
Never reuse connector clip. L

N
JSDIA2239ZZ

10. Connect electric controlled coupling connector (1) to sub-har- O

ness (2).
11. When oil leaks while removing, check oil level after the installa-
tion. Refer to DLN-132, "Inspection". P

JSDIA2238ZZ

DLN-149
 ELECTRIC CONTROLLED COUPLING
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
Inspection INFOID:0000000006361904

INSPECTION AFTER DISASSEMBLY

Oil Seal
• Whenever disassembled, replace.
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace them.

DLN-150
 CENTER STEM ASSEMBLY
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
CENTER STEM ASSEMBLY
A
Exploded View INFOID:0000000006363655

DLN

J
JSDIA2246GB

1. Filler plug 2. Gasket 3. Drain plug K

4. Breather tube 5. Clip 6. Breather hose
7. Breather 8. sub-harness clip 9. sub-harness
10. Rear cover 11. Center stem 12. Side bearing (right) L
13. Side bearing adjusting shim (right) 14. Side oil seal (right) 15. Connector clip
16. Electric controlled coupling (right) 17. Electric controlled coupling oil seal 18. Reamer bolt
19. Drive pinion 20. Drive pinion adjusting shim 21. Pinion rear bearing M
22. Collapsible spacer 23. Breather 24. Gear carrier
25. Carrier bracket (right) 26. Pinion front bearing 27. Front oil seal
28. Companion flange 29. Drive pinion lock nut 30. Carrier bracket (left) N
31. Drive gear 32. Side bearing (left) 33. Side bearing adjusting shim (left)
34. Electric controlled coupling (left) 35. Side oil seal (left)
A. Oil seal lip B. Gear carrier mounting face O

: N·m (kg-m, ft-lb)

P
: Always replace after every disassembly.

: Apply gear oil.

: Apply anti-corrosive oil.

: Apply multi purpose grease

DLN-151
 CENTER STEM ASSEMBLY
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
: Apply Genuine Liquid Gasket 1217 or equivalent.

: Select with proper thickness.

Disassembly INFOID:0000000006363656

1. Remove carrier bracket.

2. Remove electric controlled coupling. Refer to DLN-147, "Disassembly".
3. Remove side oil seal. Refer to DLN-147, "Disassembly".
4. Remove rear cover mounting bolts.
5. Set drifts (A and B) to the right and left side bearing adjusting
shims individually. Press center stem assembly with side bear-
ing to remove gear carrier assembly and rear cover assembly.

A : Drift (SST: KV38109820)

B : Drift (SST: KV38109810)
CAUTION:
The pressure shall be as low as possible to remove gear
carrier assembly and rear cover assembly. The maximum
pressure shall be 10 kN (1 ton, 1.0 Imp ton).
NOTE: JSDIA2247ZZ

Center stem assembly, side bearings, and adjusting shims are

compressed and integrated in gear carrier and rear cover.
6. Remove drain plug and filler plug.
7. Remove side bearing adjusting shims and side bearing outer races.
CAUTION:
Mark the side bearing adjusting shims so that the original mounting positions (right/left) can be
identified later.
8. Remove side bearing inner race, using a puller (A) and drift (B).

A : Puller (commercial service tool)

B : Drift (SST: ST33052000)

JSDIA2248ZZ

9. Remove drive gear from center stem, using a drift (A)

(SST:ST33220000).
10. Perform inspection after diassembly. Refer to DLN-157, "Inspec-
tion".

JSDIA2249ZZ

DLN-152
 CENTER STEM ASSEMBLY
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
Assembly INFOID:0000000006363657

A
1. Press drive gear to center stem, using a drift (A)
(SST:ST33052000).
B

DLN
JSDIA2250ZZ

2. Press side bearing inner race to center stem assembly, using a E

drift (A) (SST: KV40104840).
3. Install new side bearing adjusting shims (2 pieces for one side)
with the same thickness as the ones installed prior to disassem- F
bly or re-install the old ones, with side bearing outer race to cen-
ter stem assembly.
If side bearing adjusting shims have been already selected, use
them. G
CAUTION:
• Never reuse side bearing outer race.
• Apply gear oil to side bearings. JSDIA2251ZZ H

4. Set drifts (A and B) to the right and left side bearing adjusting
shims individually. Press center stem assembly with side bear-
ing to install gear carrier to center stem assembly. I

A : Drift (SST: KV38109820)

B : Drift (SST: KV38109810) J
CAUTION:
• The drift shall be placed on the center of the adjusting
shims. K
• The pressure shall be as low as possible to install differ-
ential assembly into gear carrier assembly. The maximum JSDIA2247ZZ

pressure shall be 10 kN (1 ton, 1.0 Imp ton). L

• If the adjusting shims are installed by tapping, the gear carrier may be damaged. Avoid tapping.
5. Install dummy cover set, check and adjust drive gear runout, tooth contact, backlash, and total preload
torque. Refer to DLN-154, "Adjustment". M
6. Remove dummy cover set.
7. Apply liquid gasket (1) to mating surface of rear cover. Overlap
both ends of the bead for at least 3 mm (0.12 in). N
CAUTION:
Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering
to the mounting surfaces. O

JSDIA2252ZZ

DLN-153
 CENTER STEM ASSEMBLY
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
8. Set the drifts (A and B) to the right and left side bearing adjusting
shims individually. Compress center stem assembly and side
bearing to install rear cover.

A : Drift (SST: KV38109820)

B : Drift (SST: KV38109810)
CAUTION:
• The drift shall be placed on the center of the adjusting
shims.
• The pressure shall be as low as possible to install the rear
cover. The maximum pressure shall be 10 kN (1 ton, 1.0 JSDIA2247ZZ

Imp ton).
• If rear cover is forced in by tapping, rear cover may be damaged by adjusting shims. Avoid tap-
ping.
9. Tighten rear cover mounting bolts to the specified torque.
10. Install side oil seal. Refer to DLN-148, "Assembly".
11. Check total preload torque. Refer to DLN-154, "Adjustment".
Adjustment INFOID:0000000006698787

TOTAL PRELOAD TORQUE

1. Remove electric controlled coupling assembly. Refer to DLN-147, "Disassembly".
2. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
4. Measure the total preload, using the preload gauge (A) (SST:
3127S000).

Total preload torque : Refer to DLN-167, "Pre-

load Torque".
NOTE:
Total preload torque = Pinion bearing torque + Side bearing
torque
JSDIA2253ZZ
• If measured value is out of the specification, disassemble it to
check and adjust each part. Adjust the pinion bearing preload and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.

When the preload torque is large

On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting shims.

When the preload is small

On pinion bearings: Tighten the drive pinion nut.
On side bearings: Use thicker side bearing adjusting shims.

DRIVE GEAR RUNOUT

1. Remove rear cover. Refer to DLN-152, "Disassembly".
2. Following the procedure below, install a dummy cover set (SST: KV381096S0) to gear carrier.
a. Temporarily tighten bearing guides (SST: KV38109610, KV38109620) to gear carrier.
b. Position dummy cap spacers (SST: KV38109630, KV38109640) and angle (SST:KV38109650) to bearing
guide.
c. Tighten rear cover mounting bolts to the specified torque. Refer to DLN-151, "Exploded View".
d. Tighten dummy cap spacer mounting bolts evenly to the specified torque.

DLN-154
 CENTER STEM ASSEMBLY
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]

Tightening torque : 5.9 N·m (0.6 kg-m, 52 in-lb) A

3. Fit a dial indicator to the drive gear back face.
4. Rotate the drive gear to measure runout.
B
Drive gear back face : Refer to DLN-167, "Drive
runout Gear Runout".
C
• If the runout is outside of the repair limit, check drive gear
assembly condition; foreign material may be caught between
drive gear and differential case, or differential case or drive
gear may be deformed, etc. DLN
CAUTION:
JSDIA2254ZZ
Replace drive gear and drive pinion as a set.
E
TOOTH CONTACT
1. Remove rear cover. Refer to DLN-152, "Disassembly".
2. Following the procedure below, install a dummy cover set (SST: KV381096S0) to gear carrier. F
a. Temporarily tighten bearing guides (SST: KV38109610, KV38109620) to gear carrier.
b. Position dummy cap spacers (SST: KV38109630, KV38109640) and angle (SST:KV38109650) to bearing
guide. G
c. Tighten rear cover mounting bolts to the specified torque. Refer to DLN-151, "Exploded View".
d. Tighten dummy cap spacer mounting bolts evenly to the specified torque.
H
Tightening torque : 5.9 N·m (0.6 kg-m, 52 in-lb)
3. Apply red lead to drive gear.
CAUTION: I
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.
J

JSDIA2255ZZ
L
4. Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION: M
Check tooth contact on drive side and reverse side.

O
SDIA0570E

DLN-155
 CENTER STEM ASSEMBLY
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
Tooth Contact Judgment Guide

SDIA2549E

5. If tooth contact is improperly adjusted, follow the procedure

below to adjust the pinion height (dimension X).

SDIA0517E

• If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken drive pinion gear adjusting shim to
move drive pinion closer to drive gear.

PDIA0440E

DLN-156
 CENTER STEM ASSEMBLY
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
• If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin drive pinion gear adjusting shim to move A
drive pinion farther from drive gear.

PDIA0441E

DLN
BACKLASH
1. Remove rear cover. Refer to DLN-152, "Disassembly".
2. Following the procedure below, install a dummy cover set (SST: KV381096S0) to gear carrier. E
a. Temporarily tighten bearing guides (SST: KV38109610, KV38109620) to gear carrier.
b. Position dummy cap spacers (SST: KV38109630, KV38109640) and angle (SST:KV38109650) to bearing
guide. F
c. Tighten rear cover mounting bolts to the specified torque. Refer to DLN-151, "Exploded View".
d. Tighten dummy cap spacer mounting bolts evenly to the specified torque.
G
Tightening torque : 5.9 N·m (0.6 kg-m, 52 in-lb)
3. Fit a dial indicator to the drive gear face to measure the back-
lash. H

Backlash : Refer to DLN-167, "Back-

lash". I
• If the backlash is outside of the specified value, change the
thickness of side bearing adjusting shims.
J
When the backlash is large:
Make drive gear back adjusting shims thicker, and drive JSDIA2256ZZ
K
gear front adjusting shims thinner.
When the backlash is small:
Make drive gear back adjusting shims thinner, and L
drive gear front adjusting shims thicker.

Inspection INFOID:0000000006363658
M
INSPECTION AFTER DISASSEMBLY
Drive Gear and Drive Pinion N
• Clean up the disassembled parts.
• If the gear teeth never mesh or line-up correctly, determine the cause and adjust or replace as necessary.
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive
O
gear and drive pinion as a set.
Bearing
• Clean up the disassembled parts. P
• If any chipped (by friction), pitted, worn, rusted or scratched marks, or unusual noise from the bearing is
observed, replace as a bearing assembly (as a new set).
Oil Seal
• Whenever disassembled, replace.
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace them.
Companion Flange
• Clean up the disassembled parts.
DLN-157
 CENTER STEM ASSEMBLY
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
• If any chipped mark [about 0.1 mm, (0.004 in)] or other damage on the contact sides of the lips of the com-
panion flange is found, replace.

DLN-158
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
DRIVE PINION
A
Exploded View INFOID:0000000006363822

DLN

J
JSDIA2246GB

1. Filler plug 2. Gasket 3. Drain plug K

4. Breather tube 5. Clip 6. Breather hose
7. Breather 8. sub-harness clip 9. sub-harness
10. Rear cover 11. Center stem 12. Side bearing (right) L
13. Side bearing adjusting shim (right) 14. Side oil seal (right) 15. Connector clip
16. Electric controlled coupling (right) 17. Electric controlled coupling oil seal 18. Reamer bolt
19. Drive pinion 20. Drive pinion adjusting shim 21. Pinion rear bearing M
22. Collapsible spacer 23. Breather 24. Gear carrier
25. Carrier bracket (right) 26. Pinion front bearing 27. Front oil seal
28. Companion flange 29. Drive pinion lock nut 30. Carrier bracket (left) N
31. Drive gear 32. Side bearing (left) 33. Side bearing adjusting shim (left)
34. Electric controlled coupling (left) 35. Side oil seal (left)
A. Oil seal lip B. Gear carrier mounting face O

: Always replace after every disassembly.

: Select with proper thickness. P

: N·m (kg-m, ft-lb)

: Apply gear oil.

: Apply anti-corrosive oil.

DLN-159
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]

: Apply multi purpose grease

: Apply Genuine Liquid Gasket 1217 or equivalent.

Disassembly INFOID:0000000006363823

1. Remove electric controlled coupling. Refer to DLN-147, "Disassembly".

2. Remove center stem assembly. Refer to DLN-152, "Disassembly".
3. Remove drive pinion lock nut with the flange wrench (A) (com-
mercial service tool).

JSDIA2266ZZ

4. Put matching mark (B) on the end of drive pinion. The matching
mark should be in line with the matching mark (A) on companion
flange (1).
CAUTION:
For matching mark, use paint. Never damage companion
flange and drive pinion.
NOTE:
The matching mark on the final drive companion flange indicates
the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary.
JSDIA2118ZZ

5. Remove companion flange using the pullers (A) (commercial

service tool).

JSDIA2267ZZ

6. Press drive pinion assembly out of gear carrier.

CAUTION:
Never drop drive pinion assembly.
7. Remove front oil seal.
8. Remove pinion front bearing inner race.
9. Remove collapsible spacer.

JSDIA2268ZZ

DLN-160
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
10. Remove pinion rear bearing inner race and pinion height adjust-
ing washer with the replacer (A) (commercial service tool). A
11. Remove pinion height adjusting washer.

PDIA0801J

DLN
12. Tap pinion front/rear bearing outer races uniformly using a brass
rod or equivalent to remove them.
CAUTION:
E
Never damage gear carrier.
13. Perform inspection after disassembly. Refer to DLN-165,
"Inspection".
F

G
JSDIA2269ZZ

Assembly INFOID:0000000006363824
H
1. Install pinion front bearing outer race to the gear carrier with drift
(A) (SST: ST17130000).
CAUTION: I
• At first, using a hammer, tap bearing outer race until it
becomes flat to gear carrier.
• Never reuse pinion front and rear bearing outer race. J

K
JSDIA2270ZZ

2. Install pinion rear bearing outer race to the gear carrier with drift L
(A) (SST: KV38100300).
CAUTION:
• At first, using a hammer, tap bearing outer race until it M
becomes flat to gear carrier.
• Never reuse pinion front and rear bearing outer race.

JSDIA2296ZZ O

DLN-161
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
3. Temporarily install pinion height adjusting washer (1).
When hypoid gear set has been replaced
• Select pinion height adjusting washer. Refer to DLN-164,
"Adjustment".
When hypoid gear set has been reused
• Temporarily install the removed pinion height adjusting washer
or same thickness washer to drive pinion.
CAUTION:
Pay attention to the direction of pinion height adjusting
washer. (Assemble as shown in the figure.) JSDIA0760ZZ

4. Install pinion rear bearing inner race (1) to drive pinion with the
drift (A) (SST: ST30032000).
CAUTION:
Never reuse pinion rear bearing inner race.
5. Check and adjust the tooth contact and back lash of drive gear
and drive pinion following the procedure below.
a. Assemble drive pinion into gear carrier.
CAUTION:
• Never assemble a collapsible spacer.
• Apply gear oil to pinion rear bearing.
b. Assemble pinion front bearing inner race to drive pinion assem- JSDIA0761ZZ

bly.
CAUTION:
• Never reuse pinion front bearing inner race.
• Apply gear oil to pinion front bearing.
c. Using drift (A) (SST: ST37710000), press the pinion front bear-
ing inner race to drive pinion as far as drive pinion nut can be
tightened.

JSDIA2271ZZ

d. Install companion flange (1).

CAUTION:
Never assemble front oil seal.
NOTE:
When reusing drive pinion, align the matching mark (B) of drive
pinion with the matching mark (A) of companion flange, and then
install companion flange.

JSDIA2118ZZ

DLN-162
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
e. Temporarily tighten removed drive pinion nut to drive pinion
using flange wrench (commercial service tool). A
NOTE:
Use removed drive pinion nut only for the preload measurement.
f. Rotate drive pinion more than 20 times to adjust bearing. B
g. Tighten to drive pinion lock nut using flange wrench (commercial
service tool), while adjusting pinion bearing preload torque using
preload gauge (A) (SST: ST3127S000).
C
Pinion bearing preload : 1.0 - 1.3 N·m (0.11 – 0.13
(without oil seal) kg-m, 9 – 11 in-lb)
DLN
CAUTION:
Drive pinion lock nut is tightened with no collapsible
spacer. Be careful not to overtighten it. While measuring the
preload, tighten it by 5° to 10°. E
h. Assemble removed drive side bearing adjusting washer or same
thickness of it and install center stem assembly. Refer to DLN-
153, "Assembly". F
CAUTION:
Apply differential gear oil to the side bearings.
i. Check and adjust tooth contact, drive gear to drive pinion back- G
lash. Refer to DLN-154, "Adjustment". JSDIA2273ZZ

j. Remove center stem assembly.

k. Remove companion flange. H
l. Remove drive pinion assembly from gear carrier.
m. Remove pinion front bearing inner race.
6. Assemble collapsible spacer. I
CAUTION:
Never reuse collapsible spacer.
7. Assemble drive pinion into gear carrier. J
CAUTION:
Apply gear oil to pinion rear bearing.
8. Assemble pinion front bearing inner race to drive pinion assembly. K
CAUTION:
• Never reuse pinion front bearing inner race.
• Apply gear oil to pinion front bearing. L
9. Using drift (A) (SST: ST37710000), press the pinion front bear-
ing inner race to drive pinion as far as drive pinion nut can be
tightened.
M

O
JSDIA2271ZZ

DLN-163
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
10. Install front oil seal as shown in figure with the drift (A) (commer-
cial service tool).
CAUTION:
• Never reuse oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal.

JSDIA2272ZZ

11. Install companion flange (1).

NOTE:
When reusing drive pinion, align the matching mark (B) of drive
pinion with the matching mark (A) of companion flange, and then
install companion flange.

JSDIA2118ZZ

12. Apply anti-corrosion oil to the thread and seat of drive pinion
lock nut, and temporarily tighten drive pinion lock nut to drive
pinion, using flange wrench (commercial service tool).
CAUTION:
Never reuse drive pinion lock nut.
13. Adjust to the drive pinion lock nut tightening torque and pinion
bearing preload torque, using preload gauge (A) (SST:
ST3127S000).

Pinion bearing preload : Refer to DLN-167, "Pre-

load Torque".
CAUTION:
• Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
• If the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Never
loosen drive pinion lock nut to adjust the preload torque.
• After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions.
14. Install center stem assembly. Refer to DLN-153, "Assembly".
CAUTION: JSDIA2273ZZ
Never install rear cover at this timing.
15. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion
flange runout. Refer to DLN-154, "Adjustment" and DLN-164, "Adjustment".
16. Check total preload torque. Refer to DLN-154, "Adjustment".
17. Install rear cover. Refer to DLN-153, "Assembly".
Adjustment INFOID:0000000006363825

PINION GEAR HEIGHT

If the hypoid gear set has been replaced, select the pinion height adjusting washer.

DLN-164
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
1. Use the formula below to calculate pinion height adjusting
washer thickness. A

Washer selection equation:

T = T0 + (t1− t2) B
T: Correct washer thickness
T0: Removed washer thickness
C
t1: Old drive pinion head letter “H × 0.01”
(“H”: machined tolerance 1/100 mm × 100)
New drive pinion head letter “H × 0.01”
SDIA0249J
t2:
DLN
(“H”: machined tolerance 1/100 mm × 100)

Example: E
T = 3.21 + [(2 × 0.01) − (−1 × 0.01)] = 3.24
T0: 3.21
t1: +2 F

t2: −1
2. Select the proper pinion height adjusting washer. For selecting adjusting washer, refer to the latest parts G
information.
CAUTION:
If unable to find a washer of desired thickness, use a washer with thickness closest to the calcu-
H
lated value.

Example:
I
Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm
J
COMPANION FLANGE RUNOUT
1. Fit a dial indicator onto the companion flange face (inner side of
the rear propeller shaft mounting bolt holes).
K
2. Rotate companion flange to check for runout.

Companion flange runout : Refer to DLN-167, "Com- L

panion Flange Runout".
3. Fit a test indicator to the inner side of companion flange (socket
diameter). M
4. Rotate companion flange to check for runout.
PDIA0439E

Companion flange runout : Refer to DLN-167, "Com- N

panion Flange Runout".
5. If the runout value is outside the runout limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90° step, and O
search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, replace companion flange.
c. If the runout value is still outside of the limit after companion flange has been replaced, possible cause will P
be an assembly malfunction of drive pinion and electric controlled coupling, malfunctioning coupling bear-
ing, or malfunctioning of electric controlled coupling.
Inspection INFOID:0000000006363826

INSPECTION AFTER DISASSEMBLY

DLN-165
 DRIVE PINION
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: RTVS]
Drive Gear and Drive Pinion
• Clean up the disassembled parts.
• If the gear teeth never mesh or line-up correctly, determine the cause and adjust or replace as necessary.
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive
gear and drive pinion as a set.
Bearing
• Clean up the disassembled parts.
• If any chipped (by friction), pitted, worn, rusted or scratched marks, or unusual noise from the bearing is
observed, replace as a bearing assembly (as a new set).
Oil Seal
• Whenever disassembled, replace.
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace them.
Companion Flange
• Clean up the disassembled parts.
• If any chipped mark [about 0.1 mm, (0.004 in)] or other damage on the contact sides of the lips of the com-
panion flange is found, replace.

DLN-166
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR FINAL DRIVE: RTVS]

SERVICE DATA AND SPECIFICATIONS (SDS) A

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000006363828
B

Applied model 4WD

C
Final drive model RTVS
Gear ratio 2.416
Number of teeth (Drive gear/Drive pinion) 29/12 DLN
Oil capacity (Approx.) (lmp pt) 0.40 (3/4)
Drive pinion adjustment spacer type Collapsible
E
Drive Gear Runout INFOID:0000000006359860

Unit: mm (in)
F
Item Limit
Drive gear back face runout 0.05 (0.0020)
G
Preload Torque INFOID:0000000006359862

Unit: N·m (kg-m, in-lb)

H
Item Standard
Pinion bearing (P1) 1.06 – 1.76 N·m (0.11 – 0.18 kg-m)
Side bearing (P2) 0.33 – 0.70 N·m (0.03 – 0.07 kg-m) I
Side bearing to pinion bearing (Total preload)
1.39 – 2.46 N·m (0.14 – 0.25 kg-m)
(Total preload = P1 + P2)

J
Backlash INFOID:0000000006359863

Unit: mm (in)
Item Standard K
Drive gear to drive pinion gear 0.13 – 0.18 (0.0051 – 0.0071)

Companion Flange Runout INFOID:0000000006359864 L

Unit: mm (in)

Item Limit M
Companion flange face 0.13 (0.0051)
Inner side of the companion flange 0.19 (0.0075)
N

DLN-167