Page 2977 of 3171
TF-10
PREPARATION
Commercial Service Tools
EDS0031F
Tool nameDescription
Puller
lRemoving companion flange
lRemoving mainshaft rear bearing
Drift
a: 81 mm (3.19 in) dia.Installing dust cover
PullerRemoving mainshaft rear bearing
Pin punch
a: 6 mm (0.24 in) dia.Removing retaining pin
NT077
ZZA1236D
ZZB0823D
NT410
Page 2978 of 3171
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
TF-11
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B
TF
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS0031G
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 page
TF-12TF-112TF-136TF-120TF-120
SUSPECTED PARTS
(Possible cause)
TRANSFER FLUID (Level low)
TRANSFER FLUID (Wrong)
TRANSFER FLUID (Level too high)
LIQUID GASKET (Damaged)
O-RING (Worn or damaged)
OIL SEAL (Worn or damaged)
SHIFT FORK (Worn or damaged)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
SymptomNoise 1 2 3 3
Transfer fluid leakage 3 1 2 2 2
Hard to shift or will not shift 1 1 2
Page 2979 of 3171

TF-12
TRANSFER FLUID
TRANSFER FLUID
PFP:31001
ReplacementEDS0031H
DRAINING
1. Stop engine.
2. Remove the drain plug and gasket. Drain the fluid.
3. Install the drain plug with a new gasket to the transfer. Tighten to
the specified torque. Refer toTF-112, "
COMPONENTS".
CAUTION:
Do not reuse gasket.
FILLING
1. Remove the filler plug and gasket.
2. Fill the transfer with new fluid until the fluid level reaches the
specified limit near the filler plug hole.
CAUTION:
Carefully fill fluid. (Fill up for approx. 3 minutes.)
3. Leave the vehicle for 3 minutes, and check fluid level again.
4. Install the filler plug with a new gasket to the transfer. Tighten to
the specified torque. Refer toTF-112, "
COMPONENTS".
CAUTION:
Do not reuse gasket.
InspectionEDS0031I
FLUID LEAKAGE AND FLUID LEVEL
1. Make sure that fluid is not leaking from the transfer assembly or around it.
2. Check fluid level from the filler plug hole as shown.
CAUTION:
Do not start engine while checking fluid level.
3. Install the filler plug with a new gasket to the transfer. Tighten to
the specified torque. Refer toTF-112, "
COMPONENTS".
CAUTION:
Do not reuse gasket.
SDIA3286E
Fluid grade:
Refer toMA-14, "
Fluids and Lubricants".
Fluid capacity:
Approx. 2.0 (1-3/4 Imp qt)
SDIA3287E
SDIA3287E
Page 2980 of 3171
4WD SYSTEM
TF-13
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TF
4WD SYSTEMPFP:33084
Cross-Section ViewEDS0031J
1. Mainshaft 2. Rear case 3. Oil pump assembly
4. Clutch gear 5. 2-4 shift fork 6. 2-4 sleeve
7. Drive chain 8. Sprocket 9. L-H shift fork
10. L-H sleeve 11. Internal gear 12. Front case
13. Planetary carrier assembly 14. Sun gear assembly 15. L-H shift rod
16. Control shift rod
(A/T models)17. Companion flange 18. Front drive shaft
19. Control shift rod assembly
(M/T models)20. Transfer control device
SDIA3418E
Page 2981 of 3171
TF-14
4WD SYSTEM
Power Transfer
EDS0031K
POWER TRANSFER DIAGRAM
1. Mainshaft 2. Clutch gear 3. 2-4 sleeve
4. Drive chain 5. Sprocket 6. L-H sleeve
7. Planetary carrier assembly 8. Sun gear assembly 9. Front drive shaft
WDIA0223E
Page 2982 of 3171

4WD SYSTEM
TF-15
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TF
POWER TRANSFER FLOW
System DescriptionEDS0031L
TRANSFER CONTROL DEVICE
Actuator motor and actuator position switch are integrated. Transfer control device shifts from 4HÛ4LO and
between 2WDÛ4WD.
Actuator Motor
Actuator motor is operated by signal from transfer control unit and it operates control shift rod so as to shift
from 4HÛ4LO and between 2WDÛ4WD.
Actuator Position Switch
Actuator position switch detects actuator motor position and sends it to transfer control unit.
WAIT DETECTION SWITCH
Wait detection switch detects if transfer gear is in 4WD by 2-4 shift fork position.
NOTE:
If 4WD shift switch is switched to 4H or 4LO, transfer is not in 4WD completely when gear does not engage.
(Wait detection system is operating.)
4LO SWITCH
4LO switch detects if transfer gear is under 4LO condition by L-H shift fork position.
AT P S W I T C H
ATP switch detects if transfer gear is under neutral condition by L-H shift fork position.
NOTE:
Transfer gear may be under neutral condition when shifting between 4HÛ4LO.
TRANSFER CONTROL UNIT
lTransfer control unit controls transfer control device by input signals of each sensor and each switch, and
itdirectsshiftsfrom4HÛ4LO and 2WDÛ4WD.
lSelf-diagnosis can be done.
TRANSFER SHIFT RELAY
Transfer shift high relay and transfer shift low relay apply power supply to transfer control device (actuator
motor).
TRANSFER SHUT OFF RELAY
Transfer shut off relay 1 and transfer shut off relay 2 apply power supply to transfer control unit.
SDIA2213E
Page 2983 of 3171
TF-16
4WD SYSTEM
4WD SHIFT SWITCH AND INDICATOR LAMP
4WD Shift Switch
4WD shift switch is able to select from 2WD, 4H or 4LO.
4WD Shift Indicator Lamp
lDisplays driving conditions selected by 4WD shift switch with front, rear and center indicators, while
engine is running. (When shifting from 4H to 4LO, 4LO indicator lamp also turns on. And when 4WD warn-
ing lamp is turned on, all 4WD shift indicator lamps are turned off.)
lTurns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately 1 sec-
ondaftertheenginestartsifsystemisnormal.
4LO Indicator Lamp
lDisplays 4LO condition while engine is running. 4LO indicator lamp flashes if transfer gear does not shift
completely under 4HÛ4LO. In this condition, transfer may be under neutral condition and A/T parking
mechanism may not operate.
lTurns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately 1 sec-
ondaftertheenginestartsifsystemisnormal.
SDIA3290E
Page 2984 of 3171

4WD SYSTEM
TF-17
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4WD WARNING LAMP
Turns ON or flashes when there is a malfunction in 4WD system.
Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately 1 sec-
ond after the engine starts if system is normal.
4WD Warning Lamp Indication
NOTE:
4WD warning lamp is turned on when the following one or more parts are malfunctioning.
lVehicle speed signal
[from ABS actuator and electric unit (control unit)]
lCAN communication line
lAD converter
lEngine speed signal
l4WD shift switch
lWait detection switch
lActuator motor
lTransfer control device
lTransfer shut off relay
lTransfer shift relay
lPNP switch signal
ATP WARNING LAMP (A/T MODELS)
When A/T selector lever is in “P” position, vehicle may move because A/T parking mechanism does not oper-
ate when transfer is under neutral condition. ATP warning lamp is turned on to indicate this condition to the
driver.
Condition 4WD warning lamp
Lamp checkTurns ON when ignition switch is turned ON.
Turns OFF after engine start.
4WD system malfunctionON
(For indicated malfunction items, see the “NOTE”)
During self-diagnosis Flashes at malfunction mode.
Large difference in diameter of front/
rear tiresSlow flashing: 1 time/2 seconds
(Continues to flash until ignition switch is turned OFF)
Other than above (system normal) OFF