Page 2665 of 3833

TROUBLE DIAGNOSIS
TF-55
C
E
F
G
H
I
J
K
L
MA
B
TF
Trouble Diagnoses for SymptomsEDS000IS
4WD INDICATOR LAMP DOSE NOT COME ON FOR APPROXIMATELY 1 SECOND WHEN THE
IGNITION SWITCH IS TURNED TO ON
Inspection Procedure
1.CHECK BLOWN FUSES BETWEEN IGN AND COMBINATION METER
Check that there are no blown fuses between IGN and combination meter.
OK or NG
OK >> GO TO 2.
NG >> Replace fuse and check again.
2.CHECK CONTINUITY BETWEEN COMBINATION METER AND 4WD CONTROL UNIT
1. Disconnect combination meter connector and 4WD control unit connector.
2. Check continuity between combination meter harness connector M46 terminal No.18 (LHD models: PU/
W, RHD models: Y/G) and 4WD control unit harness control unit connector E122 terminal No.16 (Y/G).
OK or NG
OK >> GO TO 3.
NG >> Check harness between combination meter and 4WD control unit.
3.CHECK COMBINATION METER POWER CIRCUIT
1. Disconnect combination meter connector.
2. With ignition ON, check the voltage between the combination meter harness connector M44 terminal
No.46 (W/L) (LHD models) or No.59 (W/L) (RHD models) and body ground.
OK or NG
OK >> GO TO 4.
NG >> Check combination meter circuits.
4.CHECK 4WD AUTO LAMP (ON COMBINATION METER) CIRCUIT
Check continuity between combination meter terminal 46 (LHD models) or 59 (RHD models) and terminal 18.
OK or NG
OK >> Using CONSULT-II perform self-diagnosis.
NG >> Check for burned-out bulb in 4WD AUTO lamp.
4WD WARNING LAMP DOES NOT ILLUMINATE WITH IGNITION ON
1.INSPECTION OF BLOWN FUSE BETWEEN IGNITION SWITCH AND COMBINATION METER
Check blown fuse between ignition switch and combination meter.
OK or NG
OK >> GO TO 2 (No blown fuse).
NG >> Replace the fuse and perform the inspection again.18 (LHD models: PU/W, RHD models: YG) - 16 (Y/G)
: Continuity should exist.
LHD models:46 (W/L), RHD models: 59(W/L) 1(W)
- Body ground
: Battery voltage
46 (LHD models) or 59 (RHD models) - 18
: Continuity should exist.
Page 2666 of 3833

TF-56
TROUBLE DIAGNOSIS
2. COMBINATION METER POWER SUPPLY CIRCUIT INSPECTION
1. Disconnect combination meter connector.
2. Check voltage between the combination meter harness connector M46 terminal No. LHD models: 46 (W/
L) RHD models: 59 (W/L) and body ground.
OK or NG
OK >> Malfunctioning combination meter.
NG >> Check fuse 10A [#11] to combination meter harness and connector.
4WD WARNING LAMP DOES NOT GO OUT SEVERAL SECONDS AFTER ENGINE
STARTED.(4WD MODE INDICATOR LAMP GOES OUT)
1. PERFORM SELF-DIAGNOSIS
Using CONSULT-II perform self-diagnosis.
OK or NG
OK >> No malfunction detected. Perform inspection again.
NG >>
●Determine the location of the malfunction according to the result of Self-diagnosis using CON-
SULT-II. (Malfunction is present in the 4WD system.)
●CONSULT-II does not display 4WD system-related trouble codes. GO TO 2.
2. 4WD CONTROL UNIT CONNECTOR CONNECTION INSPECTION
●Check 4WD control unit connector for proper connection.
OK or NG
OK >> Reconnect the 4WD control unit connector properly and perform inspection again.
NG >> Repair or replace the connector.
HEAVY TIGHT-CORNER BRAKING SYMPTOM OCCURS WHEN THE VEHICLE IS DRIVEN IN
AUTO MODE AND THE STEERING WHEEL IS TURNED FULLY TO EITHER SIDE AFTER THE
ENGINE IS STARTED
1. PERFORM SELF-DIAGNOSIS.
Using CONSULT-II perform self-diagnosis.
OK or NG
OK >> GO TO 2. (No self-diagnosis malfunction indicated.)
NG >> Determine the location of the malfunction according to the result of self-diagnosis using CON-
SULT-II. (Malfunction is present in the 4WD system.)
2. CHECK USING THE DATA MONITOR FUNCTION OF THE CONSULT- II.
●Perform inspection by the data monitor function of the CONSULT-II.
●Check that the operation is in AUTO mode.
●Measure voltage when the accelerator pedal is not depressed. (Accelerator pedal not depressed: approx.
0.5V or lower)
●Measure the current supplied to the 4WD solenoid valve. (Accelerator pedal not depressed: approx. 0A)
OK or NG
OK >> GO TO 3. (No self-diagnosis malfunction indicated.)
NG >>
●Not in AUTO mode. GO TO 3.
●Voltage when accelerator pedal is not depressed is higher than approximately 0.5V.
●4WD solenoid valve current when the accelerator pedal is not depressed is other than 0A.
●Countermeasure: Keep the vehicle idling for approximately 15 minutes before checking again.
(Voltage when accelerator pedal is not depressed will be automatically reset to zero during this
period.)
Page 2667 of 3833

TROUBLE DIAGNOSIS
TF-57
C
E
F
G
H
I
J
K
L
MA
B
TF
3.INSPECTION USING 4WD MODE CHANGE-OVER SWITCH
●On data monitor screen of the CONSULT-II, check 4WD mode switch.
●Check if the display changes from ## to 2WD mode when the 2WD switch is pressed.
●Check if the display changes from ## to AUTO mode when the AUTO switch is pressed.
●Check if the display changes from ## to LOCK mode when the LOCK switch is pressed.
OK or NG
OK >> No malfunction detected.
NG >>
●Not in AUTO mode. (In 2WD or LOCK mode)
Countermeasure: Slightly depress the accelerator pedal and check that the operation mode
changes to LOCK mode.
●Check circuit between 4WD mode switch harness connector M39 terminal No.1 (BR) and
4WD control unit harness connector E122 terminal No. 27 (BR).
(AUTO mode is not available because a malfunction is present in the 2WD mode harness.)
NOTICE:
Mechanism of 4WD mode change-over.
●2WD mode: Operation changes to 2WD mode when 4WD control unit harness connector E122
terminal No. 27 (BR) is shorted to ground.
●AUTO mode: Operation changes to AUTO mode when 4WD control unit harness connector
E122 terminals No. 27 (BR) and No. 26 (L) is shorted to ground.
●LOCK mode: Operation changes to LOCK mode when 4WD control unit harness connector
E122 terminal No. 26 (L) is shorted to ground.
4WD MODES CANNOT BE SWITCHED AFTER ENGINE IS STARTED
1.INSPECTION USING 4WD MODE CHANGE-OVER SWITCH
●Drive modes cannot be switched after the engine is started.
●On data monitor screen of the CONSULT-II, check 4WD mode switch.
●Check if the display changes from ## to 2WD mode when the 2WD switch is pressed.
●Check if the display changes from ## to AUTO mode when the AUTO switch is pressed.
●Check if the display changes from ## to LOCK mode when the LOCK switch is pressed.
OK or NG
OK >> No malfunction detected.
NG >>
●CONSULT-II display does not change from ## when the 2WD switch is pressed. Check harness
of the 2WD switch.
●CONSULT-II display does not change from ## when the AUTO switch is pressed. Check har-
ness of the 2WD switch and LOCK switch.
●CONSULT-II display does not change from ## when the LOCK switch is pressed. Check har-
ness of the LOCK switch.
●Perform 4WD mode change-over switch inspection.
WHILE DRIVING, 4WD WARNING LAMP FLASHES RAPIDLY. (WHEN IT FLASHERS FOR
APPROX. ONE MINUTE, THEN DOES NOT ILLUMINATE.)
●While driving, 4WD warning lamp flashes rapidly. (when it flashes for approx. one minute, then does not
illuminate.)
Rapid flashing: 2 times/second
This phenomenon protects drivetrain parts when a heavy load is applied to the electronically controlled
coupling and multiple disc clutch temperature increases. It is not a malfunction.
When the difference of diameters by or with the front and rear wheel with AUTO mode the shift switch
occasionally changes to LOCK mode automatically. This is not a malfunction.
When the difference of revolution speed between the front and rear wheel with AUTO mode, the shift
switch occasionally changes to LOCK mode automatically. This is not a malfunction.
WHILE DRIVING, 4WD WARNING LAMP FLASHES SLOWLY. (WHEN IT CONTINUES TO ILLU-
MINATE UNTIL ENGINE TURNS OFF.)
1. Check using the data monitor function of the CONSULT-II.
Page 2668 of 3833

TF-58
TROUBLE DIAGNOSIS
●Perform inspection with the data monitor function of the CONSULT- I I .
●Check if the value of IMPROPER SIZE TIRE MONITOR is 8 mm (0.31 in) or more.
●Stop the engine. Restart the engine and drive the vehicle at 20 km/h (12 MPH) or faster for approxi-
mately 200 seconds. Confirm the 4WD warning lamp flashes slowly.
(Check if the value of IMPROPER SIZE TIRE MONITOR is 8 mm (0.31 in) or more.)
When the tire size is normal, the value of IMPROPER SIZE TIRE MONITOR will change from 8 mm
(0.31 in) or more to 0 to 4 mm (0 to 0.16 in) (normal condition) after the vehicle is driven 20 km/h (12
MPH) or faster for approximately 5 seconds.
2. Tire inspection
●Inspection of tire pressure.
●Wear condition.
●Check size of the front and rear tires. (No excessive difference should be observed.)
VEHICLE DOES NOT ENTER 4WD MODE EVEN THOUGH 4WD WARNING LAMP IS OFF.
1. Check using the data monitor function of the CONSULT-II.
Perform inspection by the data monitor function of the CONSULT-II.
–Check if the vehicle operation changes to 2WD, AUTO, and LOCK modes.
–Check current supplied to the 4WD solenoid valve in AUTO mode.
2. Check using the active test function of the CONSULT-II.
Using active test mode of CONSULT-II, supply current to the 4WD solenoid valve and check that the mon-
itor current becomes close to this supply current.
●The 4WDcontrol unit is normal when the difference between 4WD solenoid valve current and the monitor
current is within ±10%.
It is necessary to inspect the electronically controlled coupling assembly.
TIGHT-CONER BRAKING SYMPTOM OCCURS WHEN THE VEHICLE IS STARTED IN AUTO
WARNING LAMP REMAIN OFF).
1. THROTTLE POSITION SENSOR AND HARNESS INSPECTION
Check accelerator pedal stroke.
OK or NG
OK >> Perform self-diagnosis again.
NG >> Malfunctioning throttle position sensor harness.
4WD ACTUATOR RELAY (4WD SOLENOID ACTUATOR RELAY) TURNS ON/OFF FREQUENTLY
1. SELF-DIAGNOSIS RESULT IS 4WD ACTUATOR RELAY (4WD SOLENOID ACTUATOR RELAY) ON
ERROR AND OFF ERROR.
Is self-diagnosis result [ON error and OFF error]?
OK or NG
OK >> GO TO 2.
NG >> Repair or replace as necessary.
2. 4WD ACTUATOR RELAY (4WD SOLENOID ACTUATOR RELAY) AND HARNESS INSPECTION
Is self-diagnosis result [ON error and OFF error]?
OK or NG
OK >> Perform self-diagnosis again.
NG >> Malfunctioning 4WD actuator relay (4WD solenoid actuator relay) harness. Accelerator pedal not
depressed:Approx. 0A
Accelerator pedal
depressed:Approx. 2.8A
Example) Monitor value becomes approx. 1A for 4WD solenoid current 1A setting.
Page 2669 of 3833

SERVICE DATA AND SPECIFICATIONS (SDS)
TF-59
C
E
F
G
H
I
J
K
L
MA
B
TF
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
General SpecificationsEDS000I6
Inspection and AdjustmentEDS0004Y
PRELOAD TORQUE BEFORE DISASSEMBLY
PRELOAD TORQUE AFTER DISASSEMBLY AND REASSEMBLY
BACKLSH
Unit: mm (in)
COMPANION FLANGE RUNOUT
Unit: mm (in)
SELECTIVE PARTS
Gear ring bearing adjusting shim
Unit: mm (in) Applied model QR20DE YD22ET
Transfer model TY20A
Oil capacity (Approx) (lmp p t)0.310(1/2)
Gear ratio2.470
Number of teeth Drive pinion 17
Drive gear 42
Item Specification [N·m (kg-m, in-lb)]
Pinion bearing (P
1 )0.10 - 0.39 (0.01 - 0.04, 1 - 3)
Gear ring bearing to pinion bearing
(Overall preload)When all oil seals are installed: P
1 +0.16 - 0.22 (0.016 - 0.023, 1.4 - 1.9)
Without transfer case oil seal and gear ring oil
sealP
1 +0.06 - 0.12 (0.006 - 0.013, 0.6 - 1.1)
Item Specification [N·m (kg-m, in-lb)]
Pinion bearing (P’
1 )0.40 - 0.78 (0.04 - 0.08, 4 - 6)
Gear ring bearing to pinion bearing
(Overall preload)When all oil seals are installed: P’
1 +0.45 - 0.47 (0.045 - 0.048, 3.9 - 4.1)
Without transfer case oil seal and gear ring oil
sealP’
1 +0.35 - 0.37 (0.035 - 0.038, 1 - 3)
Item Standard
Drive gear to drive pinion gear 0.13 - 0.19 (0.0051 - 0.0075 in)
Runout limit 0.08 (0.0031)
Selection parts Transfer case side
Thickness Part No. Thickness Part No. Thickness Part No.
0.80 (0.0315)
0.83 (0.0327)
0.86 (0.0339)
0.89 (0.0350)
0.92 (0.0362)
0.95 (0.0374)
0.98 (0.0386)
1.01 (0.0398)
1.04 (0.0409)
1.07 (0.0421)
1.10 (0.0433)
1.13 (0.0445)
1.16 (0.0457)
1.19 (0.0469)33147 AD300
33147 AD301
33147 AD302
33147 AD303
33147 AD304
33147 AD305
33147 AD306
33147 AD307
33147 AD308
33147 AD309
33147 AD310
33147 AD311
33147 AD312
33147 AD3131.22 (0.0480)
1.25 (0.0492)
1.28 (0.0504)
1.31 (0.0516)
1.34 (0.0528)
1.37 (0.0539)
1.40 (0.0551)
1.43 (0.0563)
1.46 (0.0575)
1.49 (0.0587)
1.52 (0.0598)
1.55 (0.0610)
1.58 (0.0622)
1.61 (0.0634)33147 AD314
33147 AD315
33147 AD316
33147 AD317
33147 AD318
33147 AD319
33147 AD320
33147 AD321
33147 AD322
33147 AD323
33147 AD324
33147 AD360
33147 AD361
33147 AD3621.64 (0.0646)
1.67 (0.0657)
1.70 (0.0669)
1.73 (0.0681)
1.76 (0.0693)
1.79 (0.0705)
1.82 (0.0717)
1.85 (0.0728)
1.88 (0.0740)
1.91 (0.0752)
1.94 (0.0764)
1.97 (0.0776)
2.00 (0.0787)
2.03 (0.0799)33147 AD363
33147 AD364
33147 AD365
33147 AD366
33147 AD367
33147 AD368
33147 AD369
33147 AD370
33147 AD371
33147 AD372
33147 AD373
33147 AD374
33147 AD375
33147 AD376
Page 2670 of 3833

TF-60
SERVICE DATA AND SPECIFICATIONS (SDS)
Unit: mm (in)
PINION SLEEVE SHIM
Unit: mm (in) Selection parts Adapter case side
Thickness Part No. Thickness Part No. Thickness Part No.
0.80 (0.0315)
0.83 (0.0327)
0.86 (0.0339)
0.89 (0.0350)
0.92 (0.0362)
0.95 (0.0374)
0.98 (0.0386)
1.01 (0.0398)
1.04 (0.0409)
1.07 (0.0421)
1.10 (0.0433)
1.13 (0.0445)
1.16 (0.0457)
1.19 (0.0469)
1.22 (0.0480)33147 5V200
33147 5V201
33147 5V202
33147 5V203
33147 5V204
33147 5V205
33147 5V206
33147 5V207
33147 5V208
33147 5V209
33147 5V210
33147 5V211
33147 5V212
33147 5V213
33147 5V2141.25 (0.0492)
1.28 (0.0504)
1.31 (0.0516)
1.34 (0.0528)
1.37 (0.0539)
1.40 (0.0551)
1.43 (0.0563)
1.46 (0.0575)
1.49 (0.0587)
1.52 (0.0598)
1.55 (0.0610)
1.58 (0.0622)
1.61 (0.0634)
1.64 (0.0646)
1.67 (0.0657)33147 5V215
33147 5V216
33147 5V217
33123 5V218
33123 5V219
33123 5V220
33123 5V221
33123 5V222
33123 5V223
33123 5V224
33123 5V260
33123 5V261
33123 5V262
33123 5V263
33123 5V2641.70 (0.0669)
1.73 (0.0681)
1.76 (0.0693)
1.79 (0.0705)
1.82 (0.0717)
1.85 (0.0728)
1.88 (0.0740)
1.91 (0.0752)
1.94 (0.0764)
1.97 (0.0776)
2.00 (0.0787)
2.03 (0.0799)
2.06 (0.0811)
2.09 (0.0811)33123 5V265
33123 5V266
33123 5V267
33123 5V268
33123 5V269
33123 5V270
33123 5V271
33123 5V272
33123 5V273
33123 5V274
33123 5V275
33123 5V276
33123 5V277
33123 5V278
Thickness Part No. Thickness Part No. Thickness Part No.
0.77 (0.0303)
0.80 (0.0315)
0.83 (0.0327)
0.86 (0.0339)
0.89 (0.0350)
0.92 (0.0362)
0.95 (0.0374)33155 5V214
33155 5V200
33155 5V201
33155 5V202
33155 5V203
33155 5V204
33155 5V2050.98 (0.0386)
1.01 (0.0398)
1.04 (0.0409)
1.07 (0.0421)
1.10 (0.0433)
1.13 (0.0445)
1.16 (0.0457)33155 5V206
33155 5V207
33155 5V208
33155 5V209
33155 5V210
33155 5V211
33155 5V2121.19 (0.0469)
1.22 (0.0480)
1.25 (0.0492)
1.28 (0.0504)
1.31 (0.0516)
1.34 (0.0528)33155 5V213
33155 5V215
33155 5V216
33155 5V217
33155 5V218
33155 5V219
Page 2671 of 3833
PR-1
PROPELLER SHAFT
D DRIVELINE/AXLE
CONTENTS
C
E
F
G
H
I
J
K
L
M
SECTION
A
B
PR
PROPELLER SHAFT
REAR PROPELLER SHAFT ...................................... 2
On-Vehicle Inspection .............................................. 2
PROPELLER SHAFT RUNOUT INSPECTION ..... 2
APPEARANCE AND NOISE INSPECTION .......... 2
Removal and Installation .......................................... 3
REMOVAL ............................................................. 3
INSPECTION AFTER REMOVAL ......................... 3
INSTALLATION ..................................................... 4SERVICE DATA AND SPECIFICATIONS (SDS) ........ 5
General Specifications ......................................... ..... 5
Propeller Shaft Axial Play ......................................... 5
Propeller Shaft Vibration ........................................... 5
Page 2672 of 3833

PR-2
REAR PROPELLER SHAFT
REAR PROPELLER SHAFT
PFP:37000
On-Vehicle InspectionEDS000ZW
PROPELLER SHAFT RUNOUT INSPECTION
If vibration occurs during driving at high speed, check for propeller shaft runout first.
1. Lift vehicle.
2. While rotating final drive companion flange by hand, measure
propeller shaft runout at 4 to 5 points.
Propeller Shaft Runout Measuring Points
Propeller Shaft Runout Adjustment
1. Reinstall companion flange after rotating it by 90°, 180°, and 270°. Then perform driving test and check
propeller shaft runout again at each point.
2. If it still exceeds the limit, replace propeller shaft assembly.
3. Perform driving test to check.
APPEARANCE AND NOISE INSPECTION
●Check propeller shaft tube for dent and cracks on the surface. If necessary, replace propeller shaft
assembly.
●If center bearing has abnormal noise or damage, replace propeller shaft assembly. Runout repair limit : 0.6 mm (0.024 in) or less
SPD356A
Distance A B
3F63A-DOJ87 469.5 mm (18.48 in) 414.5 mm (16.32 in)
SDIA0560E