COLLISION DIAGNOSISSRS-61
C
DE
F
G
I
J
K L
M A
B
SRS
Revision: November 2009 2006 QX56
For Side and Rollover CollisionEHS001N4
Check the SRS components using the following table.
After the work is completed, perform self-diagnosis to check that no malfunction is detected. Refer to
SRS-20, "
SRS Operation Check" .
WHEN SRS IS ACTIVATED IN THE SIDE OR ROLLOVER COLLISION
1. Replace the following components:
–Front seat back assembly (on the side on which side air bag is activated)
–Diagnosis sensor unit
–(LH or RH) side air bag (satellite) sensor (on the side on which side air bag is activated)
2. Check the SRS components and the related parts using the following table.
–Replace any SRS components and the related parts showing visible signs of damage (dents, cracks,
deformation).
3. Conduct self-diagnosis using CONSULT-II and “AIR BAG” warning lamp. Refer to SRS-20, "
SRS Opera-
tion Check" for details. Ensure entire SRS operates properly.
WHEN SRS IS NOT ACTIVATED IN THE SIDE OR ROLLOVER COLLISION
1. Check the SRS components and the related parts using the following table.
–If the front seat back assembly is damaged, the front seat back assembly must be replaced.
2. Conduct self-diagnosis using CONSULT-II and “AIR BAG” warning lamp. Refer to SRS-20, "
SRS Opera-
tion Check" for details. Ensure entire SRS operates properly.
Steering wheel 1. Visually check steering wheel for deformities.
2. Check harness (built into steering wheel) and connectors for damage, and terminals for deformities.
3. Install driver air bag module into the steering wheel to check fit and alignment with the wheel.
4. Check steering wheel for excessive free play.
5. If no damage is found, reinstall.
6. If damaged—REPLACE.
Spiral cable If the driver front air
bag has deployed:
REPLACE the spiral
cable. If the driver front air bag has not deployed:
1. Visually check spiral cable and combination switch for damage.
2. Check connectors and protective tape for damage.
3. Check steering wheel for noise, binding or heavy operation.
4. If no damage is found, reinstall.
5. If damaged
—REPLACE.
Occupant classifica-
tion system (Passen-
ger seat) 1. Remove passenger seat.
2. Check control unit case for dents, cracks of deformities.
3. Check connectors and pressure sensor tube for damage, and terminals for deformities.
4. Check seat frame and cushion pan for dents or deformities.
5. If no damage is found, reinstall seat with new fasteners.
6. If damaged
— REPLACE seat cushion assembly with new fasteners.
Harness and connec-
tors 1. Check connectors for poor connection, damage, and terminals for deformities.
2. Check harness for binding, chafing, cuts, or deformities.
3. If no damage is found, reinstall the harness and connectors.
4. If damaged—
REPLACE the damaged harness. Do not attempt to repair, splice or modify any SRS harness.
Instrument panel If the passenger front air bag has deployed:
REPLACE the instru-
ment panel assembly.If the passenger front air bag has NOT deployed:
1. Visually check instrument panel for damage.
2. If no damage is found, reinstall the instrument panel.
3. If damaged—
REPLACE the instrument panel.
Part
SRS is activated SRS is NOT activated
SRS-62
COLLISION DIAGNOSIS
Revision: November 20092006 QX56
SRS INSPECTION (FOR SIDE AND ROLLOVER COLLISION)
PartSRS is activated SRS is NOT activated
LH side curtain air
bag module If the LH side curtain
air bag has deployed:
REPLACE the LH
side curtain air bag
module. (Repair the
center pillar inner, etc.
before installing new
one if damaged.)If the LH side curtain air bag has NOT deployed:
1. Check for visible signs of damage (dents, tears, deformation) of the center pillar on
the collision side.
2. If damaged—Remove the LH side curtain air bag module.
3. Check for visible signs of damaged (tears etc.) of the LH side curtain air bag mod- ule.
4. Check harness and connectors for damage, and terminals for deformities.
5. If no damage is found, reinstall the LH side curtain air bag module with new fasten- ers.
6. If damaged—REPLACE the LH side curtain air bag module with new fasteners.
RH side curtain air
bag module If the RH side curtain
air bag has deployed:
REPLACE the RH
side curtain air bag
module. (Repair the
center pillar inner, etc.
before installing new
one if damaged.)If the RH side curtain air bag has NOT deployed:
1. Check for visible signs of damage (dents, tears, deformation) of the center pillar on
the collision side.
2. If damaged—Remove the RH side curtain air bag module.
3. Check for visible signs of damaged (tears etc.) of the RH side curtain air bag mod- ule.
4. Check harness and connectors for damage, and terminals for deformities.
5. If no damage is found, reinstall the RH side curtain air bag module with new fasten- ers.
6. If damaged —REPLACE the RH side curtain air bag module with new fasteners.
Front LH side air bag
module If the front LH side air
bag has deployed:
REPLACE front LH
seatback assembly.If the front LH side air bag has NOT deployed:
1. Check for visible signs of damage (dents, tears, deformation) of the seat back on
the collision side.
2. Check harness and connectors for damage, and terminals for deformities.
3. If damaged—REPLACE the front LH seatback assembly.
Front RH side air bag
module If the front RH side air
bag has deployed:
REPLACE front RH
seatback assembly.If the front RH side air bag has NOT deployed:
1. Check for visible signs of damage (dents, tears, deformation) of the seat back on
the collision side.
2. Check harness and connectors for damage, and terminals for deformities.
3. If damaged—REPLACE the front RH seatback assembly.
(LH or RH) side air
bag (satellite) sensor If any of the SRS
components have
deployed:
REPLACE the side
air bag (satellite) sen-
sor on the collision
side with new fasten-
ers. (Repair the cen-
ter pillar inner, etc.
before installing new
one if damaged.)If none of the SRS components have been activated:
1. Remove the side air bag (satellite) sensor on the collision side. Check harness
connectors for damage, terminals for deformities, and harness for binding.
2. Check for visible signs of damage (dents, cracks, deformation) of the side air bag (satellite) sensor.
3. Install the side air bag (satellite) sensor to check fit.
4. If no damage is found, reinstall the side sir bag (satellite) sensor with new fasten- ers.
5. If damaged—REPLACE the side air bag (satellite) sensor with new fasteners.
Diagnosis sensor unit If any of the SRS components have
deployed:
REPLACE the diag-
nosis sensor unit with
new fasteners.If none of the SRS components have been activated:
1. Check case and bracket for dents, cracks or deformities.
2. Check connectors for damage, and terminals for deformities.
3. If no damage is found, reinstall the diagnosis sensor unit with new fasteners.
4. If damaged—REPLACE the diagnosis sensor unit with new fasteners.
COLLISION DIAGNOSISSRS-63
C
DE
F
G
I
J
K L
M A
B
SRS
Revision: November 2009 2006 QX56
Seat belt pre-ten-
sioner assemblies
(All applicable loca-
tions: buckle, reel, lap
outer)If either the driver or
passenger seat belt
pre-tensioner* has
been activated:
REPLACE all seat
belt pre-tensioner
assemblies with new
fasteners.
*: Confirm seat belt
pre-tensioner activa-
tion using CONSULT-
II only.If the pre-tensioners have NOT been activated:
1. Remove seat belt pre-tensioners.
Check harness cover and connectors for damage, terminals for deformities, and
harness for binding.
2. Check belts for damage and anchors for loose mounting.
3. Check retractor for smooth operation.
4. Check seat belt adjuster for damage.
5. Check for deformities of the center pillar inner.
6. If the center pillar inner has no damage, REPLACE the seat belt pre-tensioner assembly.
7. If no damage is found, reinstall seat belt pre-tensioner assembly.
8. If damaged— REPLACE. Install the seat belt pre-tensioners with new fasteners.
Seat (with front side
air bag) If either the front LH
or front RH side air
bag modules has
been deployed:
REPLACE front seat-
back assembly on the
deployed side.If the front LH or front RH side air bag modules have NOT deployed:
1. Visually check the seat on the collision side.
2. Remove the seat on the collision side and check the following for damage and
deformities.
–Harness, connectors and terminals
–Frame and recliner (for front and rear seat), and also adjuster and slides (for front
seat)
3. If no damage is found, reinstall the seat.
4. If damaged —REPLACE the damaged seat parts using new fasteners. If the front
seat back is damaged, the front seat back assembly must be replaced.
Center inner pillar 1. Check the center inner pillar on the collision side for damage (dents, cracks, deformation). 2. If damaged—REPAIR the center inner pillar.
Trim/headlining 1. Check for visible signs of damage (dents, cracks, deformation) of the interior trim on the collision side. 2. If damaged—REPLACE the damaged trim parts.
Part
SRS is activated SRS is NOT activated
TF-142
TRANSFER MOTOR
Revision: November 20092006 QX56
TRANSFER MOTORPFP:00000
Removal and InstallationEDS003BD
REMOVAL
1. Disconnect the transfer motor connector.
2. Remove the air breather hose from the transfer motor. Refer to
TF-139, "
Removal and Installation" .
3. Remove the transfer motor bolts.
4. Remove the transfer motor.
INSTALLATION
1. Apply ATF to the new O-ring and install it to the transfer motor.
CAUTION:
Do not reuse O-rings.
2. Fit the double-flat end of the transfer motor shaft into the slot of the sub-oil pump assembly. Then tighten to the specified torque.
Refer to TF-146, "
COMPONENTS" .
CAUTION:
Be sure to install connector bracket.
3. Install the air breather hose to the transfer motor. Refer to TF-
139, "Removal and Installation" .
4. Connect the transfer motor connector.
5. Check the transfer fluid. Refer to TF-11, "
FILLING" .
6. Start the engine for one minute. Then stop the engine and recheck the transfer fluid. Refer to TF-11,
"FLUID LEAKAGE AND FLUID LEVEL" .
SDIA2133E
SDIA2787E
TRANSFER ASSEMBLYTF-147
CE F
G H
I
J
K L
M A
B
TF
Revision: November 2009 2006 QX56
49. 2-4 fork50. Shift fork spring 51. Fork guide
52. Retainer pin 53. Shift rod
1. Dust cover 2. Rear oil seal 3. Rear case
4. Breather tube 5. Seal ring 6. Main oil pump cover
7. Inner gear 8. Outer gear 9. Main oil pump housing
10. D-ring 11. D-ring 12. Clutch piston
13. Thrust needle bearing race 14. Oil strainer 15. O-ring
16. Snap ring 17. Control valve assembly 18. Lip seal (large 5 pieces)
19. Lip seal (small 2 pieces) 20. Gasket 21. Filler plug
22. Oil filter stud 23. O-ring 24. Oil filter
25 ATP switch 26. Neutral-4LO switch 27. Oil pressure check plug
28. Harness bracket 29. Air breather hose clamp 30. Stem bleeder
31. Harness bracket 32. Center case 33. Mainshaft rear bearing
34. C-ring 35. Washer holder 36. Snap ring
37. Sub oil pump housing 38. Outer gear 39. Inner gear
WDIA0302E
TF-148
TRANSFER ASSEMBLY
Revision: November 20092006 QX56
DISASSEMBLY
Rear Case
1. Remove the rear case bolts.
2. Remove the rear case from the center case.
3. Remove the dust cover using suitable tool.
4. Remove the rear oil seal using suitable tool.
CAUTION:
Do not damage rear case.
5. Remove the breather tube.
40. Sub oil pump cover 41. O-ring 42. Transfer motor
43. Connector bracket A. Apply Genuine Anaerobic Liquid
Gasket, Three Bond TB1133C or
equivalent. B. Apply Genuine Liquid Gasket,
Three Bond TB1215 or equivalent.
SDIA2092E
SDIA2093E
SDIA2094E
SDIA2095E
TF-150
TRANSFER ASSEMBLY
Revision: November 20092006 QX56
9. Put a matching mark on top of the front drive shaft thread in line
with the mark on the companion flange.
CAUTION:
Use paint to make the matching mark on the front drive
shaft thread. Never damage the front drive shaft.
10. Remove the companion flange using suitable tool.
11. Remove the center case bolts, harness bracket and air breather hose clamp.
12. Remove the filler plug and gasket.
13. Separate the center case from the front case. Then remove the center case from the front case by prying it up using suitable
tools.
CAUTION:
Do not damage the mating surfaces.
14. Remove the shift rod components together with the 2-4 sleeve and L-H sleeve.
15. Remove the shift cross from the front case.
SDIA2779E
WDIA0133E
SDIA2100E
SDIA2101E
SDIA2140E
TF-164
TRANSFER ASSEMBLY
Revision: November 20092006 QX56
Planetary Carrier
Measure the end play of each pinion gear. If it is out of specifica-
tion, replace the planetary carrier assembly with a new one.
Check the working face of each gear and bearing for damage,
burrs, partial wear, dents and other abnormality. If any is found,
replace the planetary carrier assembly with a new one.
Sun Gear
Check if the oil passage of the sun gear assembly is clogged.
For this, try to pass a 3.6 mm (0.142 in) dia. pin through the oil
passage as shown.
Check the sliding and contact surface of each gear and bearing
for damage, burrs, partial wear, dents, and other abnormality. If
any is found, replace the sun gear assembly with a new one.
Internal Gear
Check the internal gear teeth for damage, partial wear, dents
and other abnormality. If any is found, replace the internal gear
with a new one.
Gears and Drive Chain
Check the gear faces and shaft for wear, cracks, damage, and
seizure.
Check the surfaces which contact the sun gear, clutch drum,
clutch hub, press flange, clutch piston and each bearing for
damage, peel, partial wear, dents, bending, or other abnormal
damage. If any is found, replace with a new one.Pinion gear end play : 0.1 - 0.7 mm (0.004 - 0.028 in)
PDIA0185E
PDIA0186E
SMT008D
SMT944C