Page 2937 of 3061

TRANSFER CONTROL UNIT
TF-115
< SERVICE INFORMATION >
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TRANSFER CONTROL UNIT
Removal and InstallationINFOID:0000000003532562
REMOVAL
1. Set transfer state as 2WD when 4WD shift switch is at 2WD, or as AUTO when 4WD shift switch is at
AUTO.
CAUTION:
When removing transfer control unit, transfer state must be at 2WD or AUTO.
2. Turn the ignition switch OFF and disconnect negative battery terminal.
3. Remove the glove box assembly. Refer to IP-10, "
Removal and Installation".
4. Disconnect the two transfer control unit connectors.
5. Remove the transfer control unit bolts.
6. Remove the transfer control unit.
INSTALLATION
Installation is in the reverse order of removal.
• When installing the transfer control unit, tighten bolts to the specified torque.
CAUTION:
• Do not connect harness connector to transfer control unit when 4WD shift switch is at 4LO.
• After the installation, check perform self-diagnosis. Refer to TF-48, "
Self-Diagnosis Procedure". If NG, adjust
position between transfer assembly and transfer control unit. Refer to TF-3, "
Precaution for Transfer Assem-
bly and Transfer Control Unit Replacement".
BDIA0014E
Transfer control unit bolts : 5.1 N·m (0.52 kg-m, 45 in-lb)
Page 2938 of 3061
TF-116
< SERVICE INFORMATION >
FRONT OIL SEAL
FRONT OIL SEAL
Removal and InstallationINFOID:0000000003532563
REMOVAL
1. Partially drain the transfer fluid. Refer to TF-11, "Replacement".
2. Remove the front propeller shaft. Refer to PR-4, "
Removal and Installation".
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.
INSTALLATION
Tool number : KV40104000 ( — )
SDIA2657E
SDIA2658E
WDIA0193E
Tool number : KV381054S0 (J-34286)
LDIA0144E
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FRONT OIL SEAL
TF-117
< SERVICE INFORMATION >
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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-128, "
Disassembly and Assembly".
CAUTION:
Do not reuse self-lock nut.
4. Install the front propeller shaft. Refer to PR-4, "
Removal and
Installation".
5. Refill the transfer with fluid and check fluid level. Refer to TF-11
.
6. Check the transfer for fluid leakage. Refer to TF-11, "
Inspec-
tion". Tool number : KV38100500 ( — )
SDIA2662E
SDIA2658E
Tool number : KV40104000 ( — )
LDIA0147E
Page 2940 of 3061
TF-118
< SERVICE INFORMATION >
REAR OIL SEAL
REAR OIL SEAL
Removal and InstallationINFOID:0000000003532564
REMOVAL
1. Partially drain the transfer fluid. Refer to TF-11, "Replacement".
2. Remove the rear propeller shaft. Refer to PR-8, "
Removal and Installation".
3. Remove the dust cover from the rear case.
CAUTION:
Do not damage the rear case.
4. Remove the rear oil seal from the rear case using Tool.
CAUTION:
Do not damage the rear case.
INSTALLATION
1. Install the new oil seal until it is flush with the end face of the rear
case using Tool.
CAUTION:
• Do not reuse oil seal.
• Apply petroleum jelly to oil seal.
2. Apply petroleum jelly to the circumference of the new dust cover.
Position the new dust cover using the identification mark as
shown.
CAUTION:
• Do not reuse dust cover.
• Position the identification mark at the position shown.
WDIA0127E
Tool number : KV381054S0 (J-34286)
LDIA0139E
Tool number : ST30720000 (J-25405)
LDIA0140E
SDIA3436E
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REAR OIL SEAL
TF-119
< SERVICE INFORMATION >
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3. Install the new dust cover to the rear case using Tool.
CAUTION:
• Do not reuse dust cover.
• Apply petroleum jelly to dust cover.
4. Install the rear propeller shaft. Refer to PR-8, "
Removal and
Installation".
5. Refill the transfer with fluid and check fluid level. Refer to TF-11,
"Replacement".
6. Check the transfer for fluid leakage. Refer to TF-11, "
Inspec-
tion". Tool number : KV40105310 ( — )
PDIA0116E
Page 2942 of 3061
TF-120
< SERVICE INFORMATION >
SIDE OIL SEAL
SIDE OIL SEAL
Removal and InstallationINFOID:0000000003532565
REMOVAL
1. Remove the front propeller shaft. Refer to PR-4, "Removal and Installation".
2. Remove the companion flange. Refer to TF-116, "
Removal and Installation".
3. Remove the transfer control device from the transfer assembly. Refer to TF-121, "
Removal and Installa-
tion".
4. Remove the side oil seal using suitable tool.
CAUTION:
Do not damage shift cross.
INSTALLATION
1. Install the new side oil seal until it is flush with the end face of
case using Tool.
CAUTION:
• Do not reuse oil seal.
• Apply petroleum jelly to oil seal.
2. Install the transfer control device to the transfer assembly. Refer
to TF-121, "
Removal and Installation".
3. Install the companion flange. Refer to TF-116, "
Removal and
Installation".
4. Install the front propeller shaft. Refer to PR-4, "
Removal and Installation".
SDIA2666E
Tool number : ST22360002 (J-25679-01)
SDIA2665E
Page 2943 of 3061
TRANSFER CONTROL DEVICE
TF-121
< SERVICE INFORMATION >
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TRANSFER CONTROL DEVICE
Removal and InstallationINFOID:0000000003532566
CAUTION:
• Change vehicle state to 2WD, and then remove and install transfer control device.
• Check 4WD shift indicator after installation. Refer to TF-3, "
Precaution for Transfer Assembly and
Transfer Control Unit Replacement".
1. Shift lever 2. Transfer control device
SDIA2654E
Page 2944 of 3061
TF-122
< SERVICE INFORMATION >
AIR BREATHER HOSE
AIR BREATHER HOSE
Removal and InstallationINFOID:0000000003532567
CAUTION:
• Make sure there are no pinched or restricted areas on each air breather hose caused by bending or
winding when installing it.
• Install each air breather hose into the breather tube (metal
connector) until the hose end reaches the end of the curve
section. Set each air breather hose with paint mark facing
upward.
• Install actuator/transfer motor air breather hose and transfer
air breather hose on clip A and clip B with the paint mark fac-
ing upward.
1. Breather tube 2. Clip A 3. Clip B
4. Clip C 5. Clip D 6. Clip E
7. Actuator 8. Air breather hose clamp 9. Clip F
10. Transfer motor 11. Breather tube (transfer)
SDIA3339E
SDIA3341E
SDIA3342E