Page 3181 of 3383

TF-76
TROUBLE DIAGNOSIS FOR SYSTEM
Revision: November 20092006 QX56
COMPONENT INSPECTION
Transfer Shift Relay
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Remove transfer shift high relay and transfer shift low relay. Refer to TF-22, "
Location of Electrical Parts" .
3. Apply 12V direct current between transfer shift relay terminals 1 and 2.
4. Check continuity between relay terminals 3 and 4, 3 and 5.
5. If NG, replace transfer shift relay.
Transfer Control Device
1. Remove transfer control device. Refer to TF-138, "Removal and Installation" .
2. Check operation by applying battery voltage to transfer control device (actuator motor) terminals 21 and 24.
CAUTION:
Do not operate actuator motor for more than 1 second.
Change the actuator motor position to “HIGH” when
installing.
Be careful not to overheat the harness.
3. Check continuity between transfer control device (actuator motor) terminals 21 and 24.
4. If NG, replace transfer control device (actuator motor). Refer to TF-138, "
Removal and Installation" .
Terminal ConditionContinuity
3 - 4 12V direct current supply between terminals 1 and 2 No
OFF
Yes
3 - 5 12V direct current supply between terminals 1 and 2 Yes
OFF
No
WIIA0291E
TerminalActuator motor
21 (Battery voltage) - 24 (Ground) Clockwise rotate
24 (Battery voltage) - 21 (Ground) Counterclockwise rotate
21 - 24 : Approx. 0.2 \b
WDIA0224E
SDIA2726E
Page 3223 of 3383

TF-118
TROUBLE DIAGNOSIS FOR SYMPTOMS
Revision: November 20092006 QX56
2. CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT
1. Turn ignition switch “ OFF”. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connector.
3. Check continuity between transfer control unit harness connec- tor E142 terminals 3, 6, E143 terminal 45 and ground.
Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 3.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.
3. CHECK COMBINATION METER POWER SUPPLY CIRCUIT
1. Turn ignition switch “ OFF”. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connector.
3. Check voltage between combination meter harness connector terminal and ground.
4. Turn ignition switch “ ON”. (Do not start engine.)
5. Check voltage between combination meter harness connector terminal and ground.
OK or NG
OK >> GO TO 4.
NG >> Check the following. If any items are damaged, repair or replace damaged parts.
10A fuse No. 14 located in the fuse block (J/B). Refer
to PG-4, "
POWER SUPPLY ROUTING CIRCUIT" .
Harness for short or open between battery and combination meter harness connector M24 ter-
minal 24.
Ignition switch. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" .
Continuity should exist.
SDIA2691E
Connector
Terminal Voltage (Approx.)
M24 24 - Ground 0V
WDIA0151E
ConnectorTerminal Voltage (Approx.)
M24 24 - Ground Battery voltage
WDIA0152E
Page 3227 of 3383

TF-122
TROUBLE DIAGNOSIS FOR SYMPTOMS
Revision: November 20092006 QX56
2. CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT
1. Turn ignition switch “ OFF”. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connector.
3. Check continuity between transfer control unit harness connec- tor E142 terminals 3, 6, E143 terminal 45 and ground.
Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 3.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.
3. CHECK COMBINATION METER POWER SUPPLY CIRCUIT
1. Turn ignition switch “ OFF”. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connector.
3. Check voltage between combination meter harness connector terminal and ground.
4. Turn ignition switch “ ON”. (Do not start engine.)
5. Check voltage between combination meter harness connector terminal and ground.
OK or NG
OK >> GO TO 4.
NG >> Check the following. If any items are damaged, repair or replace damaged parts.
10A fuse No. 14 located in the fuse block (J/B). Refer
to PG-4, "
POWER SUPPLY ROUTING CIRCUIT" .
Harness for short or open between battery and combination meter harness connector M24 ter-
minal 24.
Ignition switch. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" .
Continuity should exist.
SDIA2691E
Connector
Terminal Voltage (Approx.)
M24 24 - Ground 0V
WDIA0151E
ConnectorTerminal Voltage (Approx.)
M24 24 - Ground Battery voltage
WDIA0152E
Page 3238 of 3383
FRONT OIL SEALTF-133
CE F
G H
I
J
K L
M A
B
TF
Revision: November 2009 2006 QX56
FRONT OIL SEALPFP:38189
Removal and InstallationEDS003B8
REMOVAL
1. Partially drain the transfer fluid. Refer to TF-11, "DRAINING" .
2. Remove the front propeller shaft. Refer to PR-5, "
REMOVAL" .
3. Remove the companion flange self-lock nut using Tool.
4. Put a matching mark on top of the front drive shaft in line with the mark on the companion flange.
CAUTION:
Use paint to make the matching mark on the front drive
shaft. Do not damage the front drive shaft.
5. Remove the companion flange using suitable tool.
6. Remove the oil seal from the front case using Tool. CAUTION:
Do not damage front case.Tool number : KV40104000 ( — )
SDIA2657E
SDIA2658E
WDIA0193E
Tool number : KV381054S0 (J-34286)
LDIA0144E
Page 3239 of 3383
TF-134
FRONT OIL SEAL
Revision: November 20092006 QX56
INSTALLATION
1. Install the new oil seal until it is flush with the end face of the
front case using Tool.
CAUTION:
Do not reuse oil seal.
Apply petroleum jelly to oil seal.
2. Align the matching mark of the front drive shaft with the match- ing mark of the companion flange, then install the companion
flange.
3. Install the new self-lock nut. Tighten to the specified torque using Tool. Refer to TF-146, "
COMPONENTS" .
CAUTION:
Do not reuse self-lock nut.
4. Install the front propeller shaft. Refer to PR-5, "
INSTALLATION"
.
5. Refill the transfer with fluid and check fluid level. Refer to TF-11,
"TRANSFER FLUID" .
6. Check the transfer for fluid leakage. Refer to TF-11, "
FLUID
LEAKAGE AND FLUID LEVEL" .
Tool number : KV38100500 ( — )
SDIA2662E
SDIA2658E
Tool number : KV40104000 ( — )
LDIA0147E
Page 3251 of 3383
TF-146
TRANSFER ASSEMBLY
Revision: November 20092006 QX56
Disassembly and AssemblyEDS003BG
COMPONENTS
1. 2-4 sleeve2. L-H sleeve 3. Snap ring
4. Internal gear 5. Planetary carrier assembly 6. Metal bushing
7. Needle bearing 8. Sun gear 9. Carrier bearing
10. Snap ring 11. Snap ring 12. Input bearing
13. Wait detection switch 14. Check plug 15. Check spring
16. Check ball 17. Front case 18. Snap ring
19. Input oil seal 20. Shift cross 21. Side oil seal
22. Lock pin 23. Shift lever 24. Gasket
25. Drain plug 26. Front oil seal 27. Companion flange
28. Self-lock nut 29. Mainshaft 30. Needle bearing
31. Front bearing 32. Front drive shaft 33. Rear bearing
34. Spacer 35. Drive chain 36. Clutch drum
37. Snap ring 38. Clutch hub 39. Snap ring
40. Retaining plate 41. Driven plate (10 sheet) 42. Drive plate (10 sheet)
43. Return spring assembly 44. Press flange 45. Thrust needle bearing
46. Snap ring 47. Retaining pin 48. L-H fork
WDIA0194E
Page 3254 of 3383
TRANSFER ASSEMBLYTF-149
CE F
G H
I
J
K L
M A
B
TF
Revision: November 2009 2006 QX56
Front Case
1. Remove the rear case assembly. Refer to TF-148, "Rear Case" .
2. Remove the lock pin nut.
3. Remove the lock pin using suitable tool.
4. Remove the shift lever.
5. Remove the side oil seal from the front case using suitable tool. CAUTION:
Do not damage front case or shift cross.
6. Remove the check plug, check spring and check ball.
7. Remove the wait detection switch.
8. Remove the self-lock nut from the companion flange using Tool.
SDIA2150E
SDIA3381E
WDIA0196E
Tool number : KV40104000 ( — )
SDIA2841E
Page 3286 of 3383

TRANSFER ASSEMBLYTF-181
CE F
G H
I
J
K L
M A
B
TF
Revision: November 2009 2006 QX56
24. Install the new companion flange self-lock nut. Tighten to the
specified torque using Tool. Refer to TF-146, "
COMPONENTS" .
CAUTION:
Do not reuse self-lock nut.
25. Remove all the sealant from the check plug, switch mating sur- face and front case.
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
26. Install the check ball and check spring to the front case. Apply silicone gasket, to the check plug and wait detection switch and
install them to the front case. Tighten to the specified torque.
Refer to TF-146, "
COMPONENTS" .
Use Genuine Silicone RTV or equivalent. Refer to GI-46,
"RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS" .
NOTE:
Wait detection switch harness connector is black.
27. Install the new oil seal in the front case using Tool.
CAUTION:
Do not reuse oil seal.
Apply petroleum jelly to seal lip before installing.
28. Install the shift lever to the shift cross.
29. Install the lock pin and lock pin nut. Tighten to the specified torque. Refer to TF-146, "
COMPONENTS" .
Rear Case
1. Apply petroleum jelly to the circumference of the new rear oil
seal. Install the new rear oil seal so that it is flush with the case
tip face using Tool.
CAUTION:
Do not reuse oil seal.
Apply petroleum jelly to seal lip before installing.Tool number : KV40104000 ( — )
WDIA0219E
Tool number : ST22360002 (J-25679-01)
WDIA0158E
SDIA2182E
Tool number : ST30720000 (J-25405)
SDIA2204E