Page 2625 of 4179

TROUBLE DIAGNOSIS FOR SYMPTOMS
TF-49
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4. CHECK SYSTEM FOR 4WD SOLENOID
Perform trouble diagnosis for 4WD solenoid system. Refer to TF-36, "
4WD Solenoid" .
OK or NG
OK >> GO TO 5.
NG >> Repair or replace damaged parts.
5. CHECK ELECTRIC CONTROLLED COUPLING
1. Turn ignition switch “OFF”.
2. Set the selector lever (shift lever) to “N” (neutral) position and disengage the parking brake.
3. Lift up the vehicle.
4. Rotate the propeller shaft by hand.
5. Hold rear wheel of right and left lightly.
Does rear wheel rotate?
YES >> Replace electric controlled coupling for mechanical malfunction (clutch sticking etc.). Refer to
RFD-22, "
Disassembly and Assembly" .
NO >> GO TO 6.
6. SYMPTOM CHECK
Check again.
OK or NG
OK >>INSPECTION END
NG >> GO TO 7.
7. CHECK 4WD CONTROL UNIT
Check 4WD control unit input/output signal. Refer to TF-28, "
4WD Control Unit Input/Output Signal Reference
Va l u e s" .
OK or NG
OK >>INSPECTION END
NG >> Check 4WD control unit pin terminals for damage or loose connection with harness connector. If
any items are damaged, repair or replace damaged parts.
Vehicle Does Not Enter 4WD Mode Even Though 4WD Warning Lamp Turned to
OFF
EDS001VY
CAUTION:
Make sure that parking brake is securely released if the symptom has occurred at vehicle speed of 10
km/h (6 MPH) or more.
Page 2626 of 4179

TF-50
TROUBLE DIAGNOSIS FOR SYMPTOMS
DIAGNOSTIC PROCEDURE
1. CHECK PARKING BRAKE SWITCH SIGNAL
With CONSULT-II
1. Turn ignition switch “ON”.
2. Select “DATA MONITOR” mode for “ALL MODE AWD/4WD” with CONSULT-II.
3. Operate parking brake and read out monitor “P BRAKE SW”.
OK or NG
OK >> GO TO 2.
NG >> Check the following. If any items are damaged, repair or
replace damaged parts.
Parking brake switch
Brake warning lamp circuit. Refer to DI-34, "Wiring
Diagram — WARN —/LHD Models" or DI-42, "Wiring Diagram — WARN —/RHD Models" .
2. CHECK 4WD SOLENOID
Check 4WD solenoid. Refer to TF-38, "
COMPONENT INSPECTION" .
OK or NG
OK >> GO TO 3.
NG >> Replace electric controlled coupling for malfunction of 4WD solenoid. Refer to RFD-22, "
Disas-
sembly and Assembly" .
3. CHECK 4WD CONTROL UNIT
Check 4WD control unit input/output signal. Refer to TF-28, "
4WD Control Unit Input/Output Signal Reference
Va l u e s" .
OK or NG
OK >> GO TO 4.
NG >> Check 4WD control unit pin terminals for damage or loose connection with harness connector. If
any items are damaged, repair or replace damaged parts.
4. SYMPTOM CHECK
Check again.
OK or NG
OK >>INSPECTION END
NG >> Replace electric controlled coupling for mechanical malfunction (mechanical engagement of
clutch is not possible.). Refer to RFD-22, "
Disassembly and Assembly" .
While Driving, 4WD Warning Lamp Flashes Rapidly (When Flashing in Approx.
1 Minute and Then Turning OFF)
EDS001VZ
NOTE:
Rapid flashing: 2 times/second
This symptom protects drivetrain parts when a heavy load is applied to the electric controlled coupling and
multiple disc clutch temperature increases. It is not a malfunction.
When this symptom occurs, stop vehicle and allow it to idle for some times. Flashing will stop and system will
be restored.
Monitor item Condition Display value
P BRAKE SWParking brake operated ON
Parking brake not operated OFF
SDIA1933E
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TROUBLE DIAGNOSIS FOR SYMPTOMS
TF-51
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While Driving, 4WD Warning Lamp Flashes Slowly (When Continuing to Flash
until Turning Ignition Switch OFF)
EDS001W0
NOTE:
Slow flashing: 1 time/2 seconds
DIAGNOSTIC PROCEDURE
1. CHECK TIRE
Check the following.
Tire pressure
Wear condition
Longitudinal tire size (There shall be no difference of tire size between front and rear tires.)
OK or NG
OK >> GO TO 2.
NG >> Drive at vehicle speed of 20 km/h (12 MPH) or more for 5 seconds or more after repairing or
replacing damaged parts. (Initialize improper size tire information.)
2. CHECK INPUT SIGNAL OF TIRE DIAMETER
With CONSULT-II
1. Start engine.
2. Drive at 20 km/h (12 MPH) or more for approx. 200 seconds.
3. Select “DATA MONITOR” mode for “ALL MODE AWD/4WD” with CONSULT-II.
4. Check monitor “DIS-TIRE MONI”.
Display of
“DIS-TIRE MONI”
“0-4mm”>>INSPECTION END
Except for “0-4mm”>>GO TO 3.
3. CHECK 4WD CONTROL UNIT
Check 4WD control unit input/output signal. Refer to TF-28, "
4WD Control Unit Input/Output Signal Reference
Va l u e s" .
OK or NG
OK >> GO TO 4.
NG >> Check 4WD control unit pin terminals for damage or loose connection with harness connector. If
any items are damaged, repair or replace damaged parts.
4. SYMPTOM CHECK
Check again.
OK or NG
OK >>INSPECTION END
NG >> Replace 4WD control unit.
SDIA1900E
Page 2628 of 4179
TF-52
4WD CONTROL UNIT
4WD CONTROL UNITPFP:41650
Removal and InstallationEDS001W4
REMOVAL
1. Remove cluster lid “A”. Refer to IP-11, "Removal and Installation" .
2. Remove front speaker grille. Refer to IP-11, "
Removal and Installation" .
3. Remove driver box. Refer to IP-11, "
Removal and Installation" .
4. Disconnect 4WD control unit connector.
5. Remove 4WD control unit.
INSTALLATION
Install in the reverse order of removal.
SDIA1881E
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SIDE OIL SEAL
TF-53
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SIDE OIL SEALPFP:33142
Removal and InstallationEDS0004S
NOTE:
Transaxle side oil seal is attached to transaxle assembly. Replace it when transaxle assembly is
removed from vehicle.
REMOVAL
1. Remove drive shaft. Refer to FA X - 11 , "Removal and Installation" .
2. Remove side shaft. Refer to FA X - 11 , "
Removal and Installation" .
CAUTION:
Be careful not to damage gear ring oil seal inside of transfer.
3. Remove oil seal with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage adapter case.
INSTALLATION
1. Apply multi-purpose grease to oil seal lips. As shown in the fig-
ure, install oil seal so that it becomes flush with the case end
surface, using a drift.
CAUTION:
Do not reuse oil seal.
When installing, do not incline oil seal.
2. Install side shaft. Refer to FA X - 11 , "
Removal and Installation" .
CAUTION:
Be careful not to damage gear ring oil seal inside of trans-
fer.
3. Install drive shaft. Refer to FA X - 11 , "
Removal and Installation" .
4. Check oil level. Refer to TF-9, "
Inspection" .
TFB0202D
SDIA0515E
Page 2630 of 4179
TF-54
AIR BREATHER HOSE
AIR BREATHER HOSEPFP:31098
ComponentsEDS001YM
Removal and InstallationEDS0004T
Note the following, when removal and installation.
CAUTION:
Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it.
Be sure to insert air breather hose into breather tube (metal con-
nector) until hose end reaches the tube's base.
Be sure to insert the paint mark of hose.
1. Air breather hose 2. Transfer assembly 3. Breather tube
SDIA1859J
SCIA2663J
SDIA1824J
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TRANSFER ASSEMBLY
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TRANSFER ASSEMBLYPFP:33100
Removal and InstallationEDS0004U
COMPONENTS
REMOVAL
1. Remove exhaust front tube. Refer to EX-2, "Removal and Installation" .
2. Remove propeller shaft. Refer to PR-4, "
Removal and Installation" .
3. Remove RH drive shaft. Refer to FAX-11, "
Removal and Installation" .
4. Remove side shaft. Refer to FA X - 11 , "
Removal and Installation" .
CAUTION:
Be careful not to damage oil seal.
5. Remove air breather hose. Refer to TF-54, "
AIR BREATHER HOSE" .
6. Remove transfer gusset (YD engine models only).
7. Support transaxle assembly with a jack.
8. Remove center member. Refer to EM-78, "
ENGINE ASSEMBLY" (QR engine models), EM-208,
"ENGINE ASSEMBLY" (YD engine models).
9. Remove suspension member. Refer to FSU-12, "
FRONT SUSPENSION MEMBER" .
10. Remove rear engine mounting bracket. Refer to EM-78, "
ENGINE ASSEMBLY" (QR engine models),
EM-208, "
ENGINE ASSEMBLY" (YD engine models).
11. Support transfer assembly with a jack.
12. Remove bolts fixing transaxle assembly and transfer assembly.
13. Remove the transfer assembly from vehicle.
CAUTION:
Be careful not to damage oil seal of transaxle.
1. Transaxle assembly 2. Transfer assembly 3. Side shaft
4. Transfer gusset
(YD engine models only)5. Grommet 6. Insulator
7. Center member
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TF-56
TRANSFER ASSEMBLY
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.
CAUTION:
When installing transfer to transaxle, be careful not to dam-
age oil seal of transaxle.
When installing transfer gusset, tighten mounting bolts with the specified torque. Refer to TF-55, "COM-
PONENTS" . (YD engine models only)
After the installation, check the oil level and oil leakage. Refer to TF-9, "Inspection" .
Bolt No. 1 2
Quantity 4 2
Bolt length “ ” mm (in)65 (2.56) 40 (1.57)
Tightening torque
N·m (kg-m, ft-lb)34.3 (3.5, 25)
SDIA1178E