Page 4305 of 4449
TF-4
PRECAUTIONS
Revision: 2004 November 2004 FX35/FX45
Service NoticeADS000RJ
After overhaul refill the transfer with new transfer fluid.
Check the fluid level or replace the fluid only with the vehicle parked on level ground.
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.
Fitting improper size and unusual wear tires applies excessive force to vehicle mechanism and can cause
longitudinal 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 ones if necessary.
Gaskets, seals and O-rings 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
tightening sequence is specified, use it.
Observe the specified torque when assembling.
Clean and flush the parts sufficiently and blow-dry them.
Be careful not to 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.
Wiring Diagrams and Trouble DiagnosisADS000RK
When you read wiring diagrams, refer to the following:
GI-15, "How to Read Wiring Diagrams".
PG-3, "POWER SUPPLY ROUTING CIRCUIT".
When you perform trouble diagnosis, refer to the following:
GI-11, "How to Follow Trouble Diagnoses".
GI-27, "How to Perform Efficient Diagnosis for an Electrical Incident".
Page 4306 of 4449
PREPARATION
TF-5
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: 2004 November 2004 FX35/FX45
PREPARATIONPFP:00002
Special Service ToolsADS000RL
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool nameDescription
ST27862000
(—)
Drift
a: 62.5 mm (2.461 in) dia.
b: 42 mm (1.654 in) dia.
Installing front oil seal into front case
KV38108300
(J44195)
Flange wrench
Removing and installing companion flange
lock nut
KV381054S0
(J34286)
Puller
Removing rear oil seal
ST30720000
(J25405)
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
Installing rear oil seal
KV40104830
(—)
Drift
a: 76.3 mm (3.004 in) dia.
b: 67.9 mm (2.673 in) dia.
Installing rear oil seal
ST33061000
(J8107-2)
Drift
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
Removing front drive shaft front bearing
ST35322000
(—)
Drift
a: 39 mm (1.54 in) dia.
b: 31 mm (1.22 in) dia.
Removing front drive shaft rear bearing
ZZA0194D
NT771
ZZA0601D
ZZA0811D
ZZA1003D
ZZA0810D
ZZA1000D
Page 4307 of 4449
TF-6
PREPARATION
Revision: 2004 November 2004 FX35/FX45
Commercial Service ToolsADS000SA
ST30022000
(—)
Drift
a: 110 mm (4.33 in) dia.
b: 56 mm (2.20 in) dia.
c: 46 mm (1.81 in) dia.Installing front drive shaft front bearing
Installing main shaft into rear case
ST30914000
(—)
Drift
a: 98 mm (3.86 in) dia.
b: 51 mm (2.01 in) dia.
c: 40 mm (1.57 in) dia.
Installing front drive shaft rear bearing
ST30613000
(—)
Drift
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
Installing main shaft oil seal into front case Tool number
(Kent-Moore No.)
Tool nameDescription
ZZA0978D
ZZA0978D
ZZA1000D
Tool nameDescription
Power tool
Loosening nuts and bolts
PBIC0190E
Page 4308 of 4449
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
TF-7
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: 2004 November 2004 FX35/FX45
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartADS000RM
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageTF-8TF-44TF-44TF-49TF-49
SUSPECTED PARTS
(Possible cause)
TRANSFER FLUID (Level low)
TRANSFER FLUID (Wrong)
TRANSFER 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
Transfer fluid leakage 3122
Page 4309 of 4449
TF-8
TRANSFER FLUID
Revision: 2004 November 2004 FX35/FX45
TRANSFER FLUIDPFP:31001
ReplacementADS000RN
DRAINING
1. Run the vehicle to warm up the transfer unit sufficiently.
2. Stop the engine, and remove the drain plug to drain the transfer
fluid.
3. Apply sealant to drain plug. Install drain plug on transfer and
tighten to the specified torque. Refer to TF-44, "
Components" .
Use Genuine Silicone RTV or equivalent. Refer to GI-48,
"Recommended Chemical Products and Sealants" .
FILLING
1. Remove filler plug and add transfer fluid until fluid level reaches
the specified limit near filler plug mounting hole.
CAUTION:
Carefully fill the fluid. (Fill up for approx. 3 minutes.)
2. Leave the vehicle for 3 minutes, and check the fluid level again.
3. Set a new seal washer onto filler plug and install it on transfer
and tighten to the specified torque. Refer to TF-44, "
Compo-
nents" .
CAUTION:
Do not reuse seal washer.
InspectionADS000RO
FLUID LEAKAGE AND FLUID LEVEL
1. Check fluid level from filler plug mounting hole as shown in the
figure.
2. Before installing filler plug, set a new seal washer. Install filler
plug on transfer and tighten to the specified torque. Refer to TF-
44, "Components" .
CAUTION:
Do not reuse seal washer.
SDIA2087E
Fluid capacity
: Approx. 1.25 (2-5/8 US pt, 2-1/4 lmp pt)
SDIA2028E
SDIA2028E
Page 4310 of 4449
AWD SYSTEM
TF-9
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: 2004 November 2004 FX35/FX45
AWD SYSTEMPFP:41650
Power Transfer DiagramADS000RV
System DescriptionADS000RW
DESCRIPTION
Electronic control allows optimal distribution of torque to front/rear wheels to match road conditions.
Makes possible stable driving, with no wheel spin, on snowy roads or other slippery surfaces.
On roads which do not require AWD, it contributes to improved fuel economy by driving in conditions close
to rear-wheel drive.
Sensor inputs determine the vehicle's turning condition, and in response tight cornering/braking are con-
trolled by distributing optimum torque to front wheels.
NOTE:
When driving, if there is a large difference between front and rear wheel speed which continues for a long
time, fluid temperature of drive system parts becomes too high and AWD warning lamp flashes rapidly.
(When AWD warning lamp flashes, vehicle changes to rear-wheel drive conditions.) Also, optional distri-
bution of torque sometimes becomes rigid before lamp flashes rapidly, but it is not malfunction.
If AWD warning lamp is flashing rapidly, stop vehicle and allow it to idle for some time. Flashing will stop
and AWD system will be restored.
When driving, AWD warning lamp may flash slowly if there is a significant difference in diameter of the
tires. At this time, vehicle performance is not fully available and cautious driving is required. (Continues
until engine is turned OFF.)
If the warning lamp flashes slowly during driving but remains OFF after engine is restarted, the system is
normal. If it again flashes slowly after driving for some time, vehicle must be inspected.
When the difference of revolution speed between the front and rear wheel with AUTO mode the shift occa-
sionally changes to direct 4-wheel driving conditions automatically. This is not malfunction.
SDIA1611E
Page 4311 of 4449
TF-10
AWD SYSTEM
Revision: 2004 November 2004 FX35/FX45
ELECTRIC CONTROLLED COUPLING
Operation principle
1. AWD control unit supplies command current to electric controlled coupling (AWD solenoid).
2. 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. Main clutch transmits torque to front wheels according to pressing power.
Transmission torque to front wheels is determined according
to command current.
AWD CONTROL UNIT
Controls distribution of drive power between rear-wheel drive
(0:100) and AWD (50:50) conditions according to signals from
sensors.
Self-diagnosis can be done with CONSULT-II.
SDIA2270E
SDIA1844E
SDIA2273E
Page 4312 of 4449
AWD SYSTEM
TF-11
C
E
F
G
H
I
J
K
L
MA
B
TF
Revision: 2004 November 2004 FX35/FX45
AWD WARNING LAMP
Turns ON when there is a malfunction in AWD system. It indicates that fail-safe mode is engaged and vehicle
change to rear-wheel drive or shifting driving force-AWD (Front-wheels still have some driving torque).
Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately for 1
seconds after the engine starts if system is normal.
AWD Warning Lamp Indication
System DiagramADS000RX
Condition AWD warning lamp
Lamp checkTurns ON when ignition switch is turned ON. Turns OFF
approx. 1 second after engine start.
AWD system malfunctionON
Protection function is activated due to heavy load to electric con-
trolled coupling. (AWD system is not malfunctioning and AWD system
changes to 2WD mode.)Rapid flashing: 2 times/second
(Flashing in approx. 1 minute and then turning OFF.)
Large difference in diameter of front/rear tiresSlow flashing: 1 time/2 seconds
(Continuing to flash until turning ignition switch OFF)
Other than above (system normal) OFF
SDIA2160E