Page 2857 of 4555

TROUBLE DIAGNOSIS FOR SYMPTOMS
TF-53
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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-30, "
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 2858 of 4555
TF-54
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
Page 2859 of 4555

SIDE OIL SEAL
TF-55
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SIDE OIL SEALPFP:33142
Removal and InstallationEDS0004S
NOTE:
Transaxle side oil seal is attached to transaxle assembly. Replace it when transfer assembly is
removed from vehicle.
REMOVAL
1. Remove RH drive shaft. Refer to FAX-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 suitable 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 RH drive shaft. Refer to FAX-11, "
Removal and Installa-
tion" .
4. Check oil level. Refer to TF-10, "
Inspection" .
TFB0202D
PDIA0928E
Page 2860 of 4555
TF-56
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 hose till the paint mark.
1. Air breather hose 2. Transfer assembly 3. Breather tube
SDIA1859J
SCIA2663J
SDIA1824J
Page 2861 of 4555

TRANSFER ASSEMBLY
TF-57
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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-56, "
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-81, "
ENGINE ASSEMBLY" (QR engine models), EM-222,
"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-81, "
ENGINE ASSEMBLY" (QR engine models),
EM-222, "
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
PDIA0927E
Page 2862 of 4555
TF-58
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-57, "COM-
PONENTS" . (YD engine models only)
After the installation, check the oil level and oil leakage. Refer to TF-10, "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
Page 2863 of 4555
TRANSFER ASSEMBLY
TF-59
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Disassembly and AssemblyEDS001YQ
COMPONENTS
1. Pinion lock nut 2. Companion flange 3. Pinion sleeve oil seal
4. Pinion rear bearing 5. Dust cover 6. Pinion sleeve
7. O-ring 8. Collapsible spacer 9. Pinion front bearing
10. Drive pinion 11. Pinion sleeve shim 12. Adapter case oil seal
13. Drain plug 14. Adapter case 15. Oil gutter
16. O-ring 17. Gear ring bearing adjusting shim
(Adapter case side)18. Gear ring bearing (Adapter case
side)
19. Gear ring oil seal 20. Gear ring 21. Drive gear
22. Gear ring bearing (Transfer case
side)23. Gear ring bearing adjusting shim
(Transfer case side)24. Oil defense
25. Filler plug 26. Transfer case oil seal 27. Transfer case
28. Breather tube 29. Plug
SDIA3122E
Page 2864 of 4555

TF-60
TRANSFER ASSEMBLY
ASSEMBLY INSPECTION
Backlash
1. Install a bolt to the companion flange.
2. Fit a dial indicator onto the bolt.
3. Measure the circumference backlash of the companion flange,
and make sure it satisfies the standard below.
If measured value is out of the specification, disassemble it to
check and adjust each part.
Tooth Contact
1. Remove the pinion sleeve assembly. Refer to TF-64, "Pinion Sleeve Assembly" .
2. Apply red lead to the drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on the drive gear.
3. Install the pinion sleeve shims and pinion sleeve assembly.
Refer to TF-74, "
Pinion Sleeve Assembly" .
4. Remove the plug on the upper side of the transfer case.
When installing plug, apply recommended sealant on screw
part, and tighten it at the specified torque. Refer to TF-59,
"COMPONENTS" .
5. Rotate the companion flange back and forth several times, and
check the drive pinion gear to drive gear tooth contact by view-
ing from the plug hole.Backlash : 0.13 - 0.19 mm (0.0051 - 0.0075 in)
SDIA1937J
TFB0212D
SDIA1938E