Page 2891 of 3061

TROUBLE DIAGNOSIS FOR SYSTEM
TF-69
< SERVICE INFORMATION >
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Perform the self-diagnosis, after driving a vehicle for a while.
OK or NG
OK >> Inspection End.
NG >> Replace transfer control unit. Refer to TF-115, "
Removal and Installation".
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-121, "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-121, "
Removal and Installation".
Actuator Position SwitchINFOID:0000000003532538
CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE
Terminal Condition Continuity
3 - 412V direct current supply between terminals 1 and 2 No
OFF Yes
3 - 512V direct current supply between terminals 1 and 2 Yes
OFF No
WIIA0291E
Terminal Actuator motor
21 (Battery voltage) - 24 (Ground) Clockwise rotate
24 (Battery voltage) - 21 (Ground) Counterclockwise rotate
WDIA0224E
21 - 24 : Approx. 0.2 Ω
SDIA2726E
Page 2925 of 3061

TROUBLE DIAGNOSIS FOR SYMPTOMS
TF-103
< SERVICE INFORMATION >
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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-3
.
• Harness for short or open between battery and combination meter harness connector M24 ter-
minal 24.
• Ignition switch. Refer to PG-3
.
4.CHECK HARNESS BETWEEN TRANSFER CONTROL UNIT AND COMBINATION METER
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connector and combination meter harness connector.Continuity should exist.
SDIA2691E
Connector Terminal Voltage (Approx.)
M24 24 - Ground 0V
WDIA0151E
Connector Terminal Voltage (Approx.)
M24 24 - Ground Battery voltage
WDIA0152E
Page 2928 of 3061

TF-106
< SERVICE INFORMATION >
TROUBLE DIAGNOSIS FOR SYMPTOMS
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-3
.
• Harness for short or open between battery and combination meter harness connector M24 ter-
minal 24.
• Ignition switch. Refer to PG-3
.
4.CHECK HARNESS BETWEEN TRANSFER CONTROL UNIT AND COMBINATION METER
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connector and combination meter harness connector.
3. Check continuity between the following terminals.
- Transfer control unit harness connector E142 terminal 5 and
combination meter harness connector M24 terminal 34.
Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 5.
NG >> Repair or replace damaged parts.Continuity should exist.
SDIA2691E
Connector Terminal Voltage (Approx.)
M24 24 - Ground 0V
WDIA0151E
Connector Terminal Voltage (Approx.)
M24 24 - Ground Battery voltage
WDIA0152E
Continuity should exist.
WDIA0154E
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
Page 2939 of 3061
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 2951 of 3061

TRANSFER ASSEMBLY
TF-129
< SERVICE INFORMATION >
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1. 2-4 sleeve 2. 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
49. 2-4 fork 50. Shift fork spring 51. Fork guide
52. Retainer pin 53. Shift rod
WDIA0194E
Page 2953 of 3061
TRANSFER ASSEMBLY
TF-131
< SERVICE INFORMATION >
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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.
Front Case
1. Remove the rear case assembly. Refer to TF-128, "Disassembly and Assembly".
2. Remove the lock pin nut.
SDIA2092E
SDIA2093E
SDIA2094E
SDIA2095E
Page 2954 of 3061
TF-132
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
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.
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.
SDIA2150E
SDIA3381E
WDIA0196E
Tool number : KV40104000 ( — )
SDIA2841E
SDIA2779E