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NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
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NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS000I4
Use the chart below to help you find the cause of the problem.The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference page
Refer to MA section("Checking Transfer Fluid"
("CHASSIS AND BODY MAINTENANCE").
TF-13
TF-13TF-22TF-22
Possible cause and Suspected parts
FLUID (Level low)
FLUID (Wrong)
FLUID (Level too high)
LIQUID GASKET (Damaged)
OIL SEAL (Worn or damaged)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
SymptomNoise 1 2 3 3
Fluid leakage 3 1 2 2
jumps out of gear 1
Page 2618 of 3833

TF-8
TRANSFER FLUID
TRANSFER FLUID
PFP:KLD30
ReplacementEDS0004Q
DRAINING
1. Run the vehicle to warm up the transfer body sufficiently.
2. Stop the engine, and remove the drain plug to drain the transfer
oil.
3. Apply recommended sealant to drain plug. Position drain plug
on transfer and tighten to the specified torque.
FILLING
1. Remove filler plug and add gear oil until oil level reaches the
specified limit near filler plug mounting hole.
CAUTION:
Carefully fill the oil. (Fill up for approx. 3 minutes.)
2. Leave the vehicle for 3 minutes, and check the oil level again.
3. Apply recommended sealant to filler plug. Position filler plug on
transfer and tighten to the specified torque.
InspectionEDS0004R
OIL LEAKAGE AND OIL LEVEL
1. Check oil level from filler plug mounting hole as shown in the fig-
ure.
2. Before installing filler plug, apply recommended sealant. Posi-
tion filler plug on transfer and tighten to the specified torque. Drain plug tightening torque
: 9.8 - 19.6 N·m (1.0 - 1.9 kg-m, 87 -173 in-lb)
SDIA0512E
Oil capacity
: Approx. 0.31 (1/2 lmp pt)
Drain plug tightening torque
: 9.8 - 19.6 N·m (1.0 - 1.9 kg-m, 87 -173 in-lb)
SDIA0513E
Filler plug tightening torque
: 9.8 - 19.6 N·m (1.0 - 1.9 kg-m, 87 -173 in-lb)
SDIA0513E
Page 2619 of 3833
SIDE OIL SEAL
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SIDE OIL SEALPFP:33142
Removal and InstallationEDS0004S
REMOVAL
1. Remove the drive shaft.
2. Remove the side shaft.
3. Remove oil seal with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage the adapter case.
INSTALLATION
1. Apply multi-purpose grease to oil seal lips. As shown in the fig-
ure, using a drift, install the oil seal so that it becomes flush with
the case end surface.
CAUTION:
●Discard old oil seals; replace with new ones.
●When installing, do not incline the oil seal.
2. Install the side shaft.
CAUTION:
Be careful not to damage the oil seal lips.
3. Install the drive shaft.
4. Check oil level.
TFB0202D
SDIA0515E
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TF-10
AIR BREATHER HOSE
AIR BREATHER HOSE
PFP:31098
Removal and InstallationEDS0004T
● Refer to the figure for air breather hose removal and installation information.
CAUTION:
●Be sure to insert air breather hose into transfer tube (metal connector) until hose end reaches the
tube's base.
●Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
PDIA0015E
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TRANSFER ASSEMBLY
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TRANSFER ASSEMBLYPFP:33100
Removal and Installation from VehicleEDS0004U
REMOVAL
1. Remove the exhaust front tube, propeller shaft, and RH drive shaft.
2. Remove the side shaft.
3. Remove the air breather hose.
4. Remove transfer gusset (vehicle with YD22ET engine only).
5. Place a transmission jack onto the transaxle.
6. Remove the center member.
7. Remove suspension members.
●Refer to FSU-12, "Removal and Installation" in FUS Front Suspension.
8. Remove rear engine mounting bracket.
9. Place a transmission jack onto the transfer unit.
10. Remove the mounting bolts fastening the transaxle and transfer unit.
11. Remove the transfer unit from the vehicle.
INSTALLATION
Paying attention to the following items, install in the reverse order of removal.
SDIA1177E
Page 2622 of 3833
TF-12
TRANSFER ASSEMBLY
●When installing the transfer to the transaxle, install the mounting
bolts following the standard below.
CAUTION:
When installing the transfer to the transaxle, be careful not
to damage the oil seals.
●When installing transfer gusset, tighten mounting bolts to the following torque (vehicles with YD22ET
engine only):
●After the installation, check the oil level and oil leakage.
Bolt No. 1 2
Quantity 4 2
Nominal length mm (in) 65 (2.56) 40 (1.57)
Tightening torque [N·m
(kg·mfg.-lb.)]30 - 39 (3.0 - 4.0,22-28)
SDIA1178E
Tightening torque : 31 - 40 N·m (3.1 - 4.1 kg-m, 23 - 29 ft.-lb.)
Page 2623 of 3833
TRANSFER ASSEMBLY
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Component Parts DrawingEDS0004V
SDIA1149E
Page 2624 of 3833
TF-14
TRANSFER ASSEMBLY
Assembly Inspection
EDS0004W
BACKLASH
1. Install a bolt to the companion flange.
2. Fit a dial gauge onto the bolt.
3. Measure the circumference backlash of the companion flange,
and check that it satisfies the standard below.
●If outside the standard, disassemble it to check and adjust
each part.
TOOTH CONTACT
1. Remove the pinion sleeve assembly, and apply red lead to the
drive gear.
CAUTION:
Apply red lead to the both faces of 3 to 4 gears at 4 loca-
tions evenly spaced on the drive gear.
2. Install the pinion sleeve shims and pinion sleeve assembly.
3. Remove the plug on the upper side of the transfer case.
4. Rotate the companion flange back and forth several times, and
check the drive pinion gear to drive gear tooth contact by view-
ing from the plug hole.Backlash : 0.13 - 0.19 mm (0.0051 - 0.0075 in)
TFB0280D
TFB0212D
SDIA0516E