Page 2809 of 4555
PREPARATION
TF-5
C
E
F
G
H
I
J
K
L
MA
B
TF
PREPARATIONPFP:00002
Special Service ToolsEDS002V6
Tool number
Tool nameDescription
ST3127S000
Preload gaugeMeasuring preload torque
ST33220000
Drift
a: 37 mm (1.46 in) dia.
b: 31 mm (1.22 in) dia.
c: 22 mm (0.87 in) dia.Removing drive pinion
KV381054S0
Puller
Removing pinion rear bearing outer race
Removing pinion front bearing outer race
Removing gear ring oil seal
ST30031000
ReplacerRemoving pinion front bearing inner race
ST33200000
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
Removing gear ring bearing inner race
(adapter case side)
Installing companion flange
ST33061000
Drift
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.Removing gear ring bearing inner race
(transfer case side)
ZZA0503D
ZZA1046D
ZZA0601D
ZZA0700D
ZZA1002D
ZZA0810D
Page 2810 of 4555

TF-6
PREPARATION
ST30720000
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.Installing gear ring bearing outer race
(transfer case side)
Installing gear ring bearing inner race
(transfer case side)
Installing gear ring bearing inner race
(adapter case side)
Installing gear ring bearing outer race
(adapter case side)
Installing transfer case oil seal
ST33230000
Drift
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 seal
ST27863000
Drift
a: 74.5 mm (2.933 in) dia.
b: 62.5 mm (2.461 in) dia.Installing gear ring bearing inner race
(transfer case side)
KV40101630
Drift
a: 68 mm (2.68 in) dia.
b: 60 mm (2.36 in) dia.Installing gear ring bearing inner race
(transfer case side)
KV38102510
Drift
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.Installing gear ring bearing inner race
(adapter case side)
KV38100300
Drift
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 Tool number
Tool nameDescription
ZZA0811D
ZZA1046D
ZZA1003D
ZZA1003D
ZZA1003D
ZZA1046D
Page 2811 of 4555
PREPARATION
TF-7
C
E
F
G
H
I
J
K
L
MA
B
TF
ST33400001
Drift
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.Installing pinion front bearing outer race
Installing pinion sleeve oil seal
ST30901000
Drift
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
Installing pinion front bearing outer race
Installing pinion front bearing inner race Tool number
Tool nameDescription
ZZA0814D
ZZA0978D
Page 2812 of 4555
TF-8
PREPARATION
Commercial Service ToolsEDS002V7
Tool nameDescription
Drift
a: 80 mm (3.15 in) dia.
b: 73 mm (2.87 in) dia.Installing side oil seal (installing adapter case
oil seal)
Drift
a: 85 mm (3.35 in) dia.Installing gear ring bearing outer race
(transfer case side)
Drift
a: 90 mm (3.54 in) dia.Installing gear ring bearing outer race
(adapter case side)
NT115
PDIA0893E
PDIA0893E
Page 2813 of 4555
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
TF-9
C
E
F
G
H
I
J
K
L
MA
B
TF
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGPFP:00003
NVH Troubleshooting ChartEDS001V9
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-10TF-59TF-59TF-59TF-68TF-68
SUSPECTED PARTS
(Possible cause)
TRANSFER OIL (Level low)
TRANSFER OIL (Wrong)
TRANSFER OIL (Level too high)
LIQUID GASKET (Damaged)
O-RING (Worn or damaged)
OIL SEAL (Worn or damaged)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
SymptomNoise 1 2 3 3
Transfer oil leakage 31222
Page 2814 of 4555

TF-10
TRANSFER OIL
TRANSFER OILPFP:KLD30
ReplacementEDS001W2
DRAINING
CAUTION:
When draining oil, protect exhaust tube with cover.
1. Run the vehicle to warm up the transfer body sufficiently.
2. Stop engine, and remove drain plug to drain the transfer oil.
3. Apply recommended sealant to drain plug. Install drain plug on
transfer and tighten to the specified torque. Refer to TF-59,
"COMPONENTS" .
FILLING
1. Remove filler plug and add gear oil until oil level reaches the
specified limit near filler plug mounting hole.
CAUTION:
Carefully fill the oil. (Fill up for approx. 3 minutes)
2. Leave the vehicle for 3 minutes, and check the oil level again.
3. Apply recommended sealant to filler plug. Install filler plug on
transfer and tighten to the specified torque. Refer to TF-59, "
COMPONENTS" .
InspectionEDS001W3
OIL LEAKAGE AND OIL LEVEL
1. Check oil level from filler plug mounting hole as shown in the fig-
ure.
CAUTION:
Do not start engine while checking oil level.
2. Before installing filler plug, apply recommended sealant. Install
filler plug on transfer and tighten to the specified torque. Refer to
TF-59, "
COMPONENTS" .
SDIA0512E
Oil grade and Viscosity
: Refer to MA-17, "
Fluids and Lubricants" .
Oil capacity
: Approx. 0.31 (1/2 lmp pt)
SDIA0513E
SDIA0513E
Page 2815 of 4555
ALL MODE 4X4 SYSTEM
TF-11
C
E
F
G
H
I
J
K
L
MA
B
TF
ALL MODE 4X4 SYSTEMPFP:47850
Power Transfer DiagramEDS001VA
System DescriptionEDS001VB
ELECTRIC CONTROLLED COUPLING
Operation Principle
1. The 4WD control unit supplies command current to electric con-
trolled coupling (4WD solenoid).
2. The 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. The main clutch transmits torque to front wheels according to
pressing power.
Transmission torque to the rear wheels is determined accord-
ing to command current.
4WD CONTROL UNIT
4WD controls distribution of drive power between front-wheel
drive (100:0) and 4WD (50:50) conditions according to signals
from sensors.
Self-diagnosis can be done with CONSULT-II.
SDIA1607E
SFIA0284E
SDIA1844E
SDIA2285E
Page 2816 of 4555

TF-12
ALL MODE 4X4 SYSTEM
4WD MODE SWITCH
AUTO Mode
Electronic control allows optimal distribution of torque to front/rear wheels to match road conditions.
4WD mode makes possible stable driving, with no wheel spin, on snowy roads or other slippery surfaces.
On roads which do not require 4WD, AUTO mode contributes to improved fuel economy by driving in con-
ditions close to front-wheel drive.
Sensor inputs determine the vehicle's turning condition, and tight cornering/braking are controlled by dis-
tributing optimum torque to rear wheels.
LOCK Mode
Front/rear wheel torque distribution is fixed, ensuring stable driving when climbing slopes.
Vehicle will switch automatically to AUTO mode if vehicle speed increases. If vehicle speed then
decreases, the vehicle automatically returns to direct 4-wheel driving conditions.
LOCK mode will change to AUTO mode automatically, when the vehicle speed exceeds approx. 30 km/h
(19 MPH). The LOCK indicator light keeps illuminating.
NOTE:
If there is a significant difference in pressure or wear between tires, full vehicle performance is not available.
LOCK mode may be prohibited, or speeds at which LOCK mode is enabled may be restricted detecting tire
conditions.
2WD Mode
Vehicle is in front-wheel drive.
NOTE:
If front wheels are slipping in 2WD mode, do not switch to AUTO or LOCK. This can cause difficulties for
the system.
Even if the 4WD mode switch is in 2WD mode, the 4WD control unit occasionally automatically change to
AUTO mode depending on the driving condition (For example; Depressing the acceleration firmly). This is
not malfunction. However, 4WD indicator lamp dose not illuminate.
4WD INDICATOR LAMP AND LOCK INDICATOR LAMP
The following is the indications of indicator lamp.
4WD WARNING LAMP
Turns ON when there is a malfunction in 4WD system. It indicates that the vehicle is in fail-safe mode and
change to front-wheel drive or shifting driving force-4WD (Rear-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.
4WD Warning Lamp Indication
Condition 4WD indicator lamp LOCK indicator lamp
AUTO mode ON OFF
LOCK mode ON ON
2WD mode OFF OFF
Lamp check Turns ON for approx. 1 second when ignition switch is turned ON.
SDIA2298E
Condition 4WD warning lamp
Lamp checkTurns ON when ignition switch is turned ON. Turns OFF
approx. 1 seconds after engine start.
4WD system malfunctionON
Protection function is activated due to heavy load to electric con-
trolled coupling. (4WD system is not malfunctioning and 4WD system
changes to 2WD mode.)Rapid flashing: 2 times/second
(Flashing in approx. 1 minute and then turning OFF.)