Page 2969 of 3066

COLLISION DIAGNOSIS
SRS-47
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SRS
For Side CollisionEHS000DG
WHENTHESIDEAIRBAGISACTIVATEDINTHESIDECOLLISION:
1. Replace the following component:
–All parts of front seat back (including front seat back frame) with front side air bag module (on the side on
which front side air bag is activated)
–Diagnosis sensor unit
–Side air bag (satellite) sensor
2. Check the SRS components and the related parts using the table shown below.
–Replace any SRS components and the related parts showing visible signs of damage (dents, cracks,
deformation).
3. Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer toSRS-15, "
SRS Operation
Check". Ensure entire SRS operation properly.
WHEN SRS IS NOT ACTIVATED IN THE SIDE COLLISION:
1. Check the SRS components and the related parts using the table shown below.
–Replace any SRS components and the related parts showing visible signs of damage (dents, cracks,
deformation).
2. Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer toSRS-15, "
SRS Operation
Check". Ensure entire SRS operation properly.
Spiral cable 1. Visually check spiral cable and combination switch for damage.
2. Check connectors and protective tape for damage.
3. Check steering wheel for noise, binding or heavy operation.
4. If no damage is found, reinstall with bolts.
5. If damaged—REPLACE.
Harness and Connec-
tors1. Check connectors for poor connection, damage, and terminals for deformities.
2. Check harness for binding, chafing, cuts, or deformities.
3. If no damage is found, reinstall the harness and connectors.
4. Damaged—REPLACE damaged section of harness. Do not attempt to repair, splice or modify any SRS
harness.
Instrument panel 1. Visually check instrumental panel for damage.
2. If no damage is found, reinstall the instrument panel.
3. If damaged—REPLACE the instrument panel with bolts. Part SRS is activated SRS is NOT activated
Page 2970 of 3066

SRS-48
COLLISION DIAGNOSIS
SRS INSPCTION (FOR SIDE COLLISION)
PartFront side air bag and
side curtain air bag is
activatedFront side air bag and side curtain air bag is NOT activated
Front (LH or RH) side
air bag moduleREPLACE all parts of
seat back with
deployed front side
air bag module.1. Check for visible signs of damage (dents, tears, deformation) of the seat back on
the collision side.
2. If damaged—REPLACE the damaged seat parts with new bolts and remove the
front side air bag module.
3. Check for visible signs of damaged (tears etc.) of the front side air bag module.
4. Check harness and connectors for damage, and terminals for deformities.
5. If no damaged is found, reinstall the front side air bag module with new nuts.
6. If damaged—REPLACE the front side air bag module with new nut.
Air bag must be deployed before disposing of it.
(LH or RH) side air
bag (satellite) sensorREPLACE the side
air bag (satellite)
sensor on the colli-
sion side with new
nuts.
(Repair the center pil-
lar inner, etc. before
installing new one if
damaged.)1. Remove the side air bag (satellite) sensor on the collision side. Check harness
connectors for damage, terminals for deformities, and harness for binding.
2. Check for visible signs of damage (dents, cracks, deformation) of the side air bag
(satellite) sensor.
3. Install the side air bag (satellite) sensor to check fit.
4. If no damage is found, reinstall the side sir bag (satellite) sensor with new nuts.
5. If damaged—REPLACE the side air bag (satellite) sensor with new nuts.
Diagnosis sensor unit REPLACE the diag-
nosis sensor unit with
the new bolts.1. Check case and bracket for dents, cracks or deformities.
2. Check connectors for damage, and terminals for deformities.
3. If no damage is found, reinstall the diagnosis sensor unit with new bolts and
ground bolt.
4. If damaged—REPLACE the diagnosis sensor unit with new bolts and ground bolt.
Seat belt pre-ten-
sioner assembly1. Check if the seat belt can be extended smoothly.
If the seat belt cannot be extended smoothly,
–Check for deformities of the center pillar inner.
–If the center pillar inner has no damage, REPLACE the seat belt pre-tensioner assembly.
2. Remove the seat belt pre-tensioner assembly on the collision side. Check harness cover and connectors
for damage, terminals for deformities, and harness for binding.
3. Check for visible signs of damage (dents, cracks, deformation) of the seat belt pre-tensioner assembly.
4. If no damage is found, reinstall the seat belt pre-tensioner assembly.
5. If damaged—REPLACE the seat belt pre-tensioner assembly with new bolts.
The seat belt pre-tensioner assembly must be deployed before disposing of it.
Seat with front side
air bagREPLACE all parts of
front seat back
(including front seat
back frame)1. Visually check the seat on the collision side.
2. Remove the seat on the collision side and check the following for damage and
deformities.
–Harness, connectors and terminals
–Frame and recliner (for front and rear seat), and also adjuster and slides (for front
seat)
3. If no damage is found, reinstall the seat.
4. If damaged—REPLACE the damaged seat parts with new bolts.
Center pillar inner 1. Check the center pillar inner on the collision side for damage (dents, cracks, deformation).
2. If damaged—REPAIR the center pillar inner.
Trim 1. Check for visible signs of damage (dents, cracks, deformation) of the interior trim on the collision side.
2. If damaged—REPLACE the damaged trim parts.
Page 2971 of 3066

TF-1
TRANSFER
D DRIVELINE/AXLE
CONTENTS
C
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SECTION
A
B
TF
TRANSFER
PRECAUTIONS .......................................................... 3
Caution ..................................................................... 3
PREPARATION ........................................................... 4
Special Service Tools ............................................... 4
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ................................................ 7
NVH Troubleshooting Chart ..................................... 7
TRANSFER FLUID ..................................................... 8
Replacement ............................................................ 8
DRAINING ............................................................. 8
FILLING ................................................................. 8
Inspection ................................................................. 8
OIL LEAKAGE AND OIL LEVEL ........................... 8
SIDE OIL SEAL .......................................................... 9
Removal and Installation .......................................... 9
REMOVAL ............................................................. 9
INSTALLATION ..................................................... 9
AIR BREATHER HOSE ............................................ 10
Removal and Installation ........................................ 10
TRANSFER ASSEMBLY .......................................... 12
Removal and Installation from Vehicle ................... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 12
Component Parts Drawing ..................................... 14
Assembly Inspection .............................................. 15
BACKLASH ......................................................... 15
TOOTH CONTACT .............................................. 15
PRELOAD TORQUE ........................................... 17
COMPANION FLANGE RUNOUT ...................... 18
Disassembly and Assembly ................................... 19
DISASSEMBLY ................................................... 19
INSPECTION AFTER DISASSEMBLY ............... 23
SELECTIONG ADJUSTING SHIMS ................... 24
ASSMBLY ........................................................... 26
ALL MODE 4X4 SYSTEM ........................................ 31
Precautions ............................................................ 31
System Component ................................................ 31
System Description ................................................ 31
ERECTRONIC COUPLING ................................. 31
4WD CONTROL UNIT ........................................ 314WD MODE SWITCT .......................................... 32
4WD WARNING LAMP ....................................... 32
FAIL- SAFE FUNCTION ...................................... 33
System Diagram ..................................................... 33
CAN Communication .............................................. 33
SYSTEM DESCRIPTION .................................... 33
SYSTEM DIAGRAM ............................................ 33
INPUT/OUTPUT SIGNAL .................................... 34
Circuit Diagram ....................................................... 35
Wiring Diagram ....................................................... 36
TROUBLE DIAGNOSIS ............................................ 40
Fail-safe function .................................................... 40
How to proceed with trouble diagnosis ................... 40
BASIC CONCEPT ............................................... 40
Trouble diagnosis chart by symptom ...................... 41
4WD control unit input/output signal standard ........ 42
4WD CONTROL UNIT CONNECTOR TERMI-
NAL ARRANGEMENT ........................................ 42
REFERENCE STANDARD TABLE ...................... 43
CONSULT-II functions ............................................ 45
CONSULT-II FUNCTION APPLICATION TABLE... 45
SELF-DIAGNOSIS .............................................. 45
DATA MONITOR ................................................. 46
ACTIVE TEST ..................................................... 48
ECU PART NUMBER .......................................... 49
Component Inspection ............................................ 49
4WD SOLENOID VALVE ..................................... 49
System Inspection .................................................. 49
CONTROL UNIT POWER SUPPLY SYSTEM .... 49
G-SENSOR SYSTEM ......................................... 50
4WD SOLENOID, ACTUATOR RELAY SYSTEM... 51
CAN COMMUNICATION SYSTEM ..................... 53
4WD MODE SWITCH SYSTEM .......................... 53
Trouble Diagnoses for Symptoms .......................... 54
4WD INDICATOR LAMP DOSE NOT COME ON
FORAPPROXIMATELY1SECONDWHENTHE
IGNITION SWITCH IS TURNED TO ON ............. 54
4WD WARNING LAMP DOES NOT ILLUMINATE
WITH IGNITION ON ............................................ 55
4WD WARNING LAMP DOES NOT GO OUT
Page 2972 of 3066

TF-2
SEVERAL SECONDS AFTER ENGINE
STARTED.(4WD MODE INDICATOR LAMP
GOES OUT) ........................................................ 55
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 ......................................... 56
4WD MODES CANNOT BE SWITCHED AFTER
ENGINE IS STARTED ......................................... 57
WHILE DRIVING, 4WD WARNING LAMP
FLASHES RAPIDLY.(WHEN IT FLASHERSFOR
APPROX. ONE MINUTE, THEN DOES NOT
ILLUMINATE.) ..................................................... 57
WHILE DRIVING, 4WD WARNING LAMP
FLASHES SLOWLY. (WHEN IT CONTINUES TO
ILLUMINATE UNTIL ENGINE TURNS OFF.) ...... 58
VEHICLE DOES NOT ENTER 4WD MODEEVEN THOUGH 4WD WARNING LAMP IS OFF.... 58
TIGHT-CONER BRAKING SYMPTOM OCCURS
WHEN THE VEHICLE IS STARTED IN AUTO
WARNING LAMP REMAIN OFF). .......................58
4WD ACTUATOR RELAY (4WD SOLENOID
ACTUATOR RELAY) TURNS ON/OFF FRE-
QUENTLY ............................................................58
SERVICE DATA AND SPECIFICATIONS (SDS) ......60
General Specifications ............................................60
Inspection and Adjustment ......................................60
PRELOAD TORQUE BEFORE DISASSEMBLY...60
PRELOAD TORQUE AFTER DISASSEMBLY
AND REASSEMBLY ............................................60
BACKLSH ............................................................60
SELECTIVE PARTS ............................................60
PINION SLEEVE SHIM ........................................61
Page 2973 of 3066

PRECAUTIONS
TF-3
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TF
PRECAUTIONSPFP:00001
CautionEDS0004O
lDo not reuse the drained transfer oil.
lCheck the oil level with the vehicle on the level ground.
lDuring removal and installation, be careful not to allow foreign material such as dust or dirt to enter into
the transfer unit.
lBefore starting diagnosis of the vehicle, understand trouble symptoms well. Perform correct and system-
atic operations.
lCheck for the correct installation status prior to removal or disassembly. If mating marks are required, be
certain they do not interfere with the function of the parts they are applied to.
lCarry out the work in a clean work place. Using a dustproof room is recommended.
lBefore 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.
lCheck appearance of the disassembled parts for damage, deformation, and abnormal wear. If a malfunc-
tion is detected, replace it with a new one.
lNormally replace O-rings, oil seals, bearings, and lock nuts with new ones every time they are removed.
lIn principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If
tightening sequence is specified, observe it.
lClean and flush the parts sufficiently and blow them dry.
lBe careful not to damage sliding surfaces and mating surfaces.
lAlways use shop paper for cleaning the inside of components.
lDo not use cotton gloves or a shop cloth. Using them may leave lint on the surface of the parts.
lDuring assembly always tighten bolts and screws to specified torque. new transfer oil a petroleum jelly
such as "Vaseline", or multi-purpose grease as appropriate.
lDiscard waste oil after oil changes or part treatment in accordance with local laws and regulations.
Page 2974 of 3066

TF-4
PREPARATION
PREPARATION
PFP:00002
Special Service ToolsEDS0004P
Tool name
Tool numberDescription
Drift
KV38101700
a: 82 mm (3.23 in) dia.
b: 78 mm (3.07 in) dia.Side oil seal installation (adapter case oil
seal installation)
Preload gauge
ST3127S000Measuring preload torque
Puller
KV381054S0
lRemoving pinion bearing outer race
lRemoving gear ring oil seals
Drift
ST33220000
a: 37 mm (1.46 in) dia.
b: 31 mm (1.22 in) dia.
c: 22 mm (0.87 in) dia.Removing drive pinion gear assembly
Removing bearing replacer
ST30031000Removing pinion bearing inner race
Drift
ST30720000
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
lRemoving gear ring bearing outer race
on adapter case
lInstalling gear ring bearing outer race on
transfer case
lInstalling gear bearing inner race on
transfer case
lInstalling gear ring bearing inner race on
adapter case
lInstalling gear ring bearing outer race on
adapter case
lInstalling transfer case oil seals
ZZA1149D
ZZA0503D
ZZA0601D
ZZA1046D
ZZA0700D
ZZA0811D
Page 2975 of 3066

PREPARATION
TF-5
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TF
Drift
ST33200000
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.75 in) dia.lRemoving gear ring bearing inner race
on adapter case
lInstalling companion flange
Drift
ST33061000
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
lRemoving gear ring bearing inner race
on transfer case
lRemoving speedometer drive gear
Drift
KV38100500
a: 80 mm (3.15 in) dia.
b: 60 mm (2.36 in) dia.Installing speedometer drive gear
Drift
KV40101840
a: 77 mm (3.03 in) dia.
b: 85 mm (3.35 in) dia.Installing gear ring bearing outer race on
transfer case
Drift
ST33230000
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.Installing gear ring oil seals
Drift
KV40104710
a: 76.3 mm (3.004 in) dia.
b: 67.9 mm (2.673 in) dia.Installing speedometer drive gear
Drift
ST27863000
a: 74.5 mm (2.933 in) dia.
b: 62.5 mm (2.461 in) dia.Installing gear bearing inner race on
transfer case To o l n a m e
Tool numberDescription
ZZA1002D
ZZA0810D
ZZA0811D
ZZA0881D
ZZA1046D
ZZA1003D
ZZA1003D
Page 2976 of 3066
TF-6
PREPARATION
Drift
KV40101630
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.Installing gear bearing inner race on
transfer case
Drift
KV38100300
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia.Installing pinion rear bearing outer race
Drift
ST33400001
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
lInstalling pinion front bearing outer race
lInstalling pinion sleeve oil seals
Drift
ST30901000
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
lInstalling pinion front bearing outer race
lInstalling pinion front bearing inner race
Drift
KV40105230
a: 92 mm (3.62 in) dia.
b: 86 mm (3.39 in) dia.Installing gear ring bearing outer race on
adapter case
Drift
KV38102510
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.Installing gear ring bearing inner race on
adapter case Tool name
Tool numberDescription
ZZA1003D
ZZA1046D
ZZA0814D
ZZA0978D
ZZA1141D
ZZA1003D