Page 3778 of 3924

SIDE CURTAIN AIR BAG MODULESRS-41
< SERVICE INFORMATION >
C
DE
F
G
I
J
K L
M A
B
SRS
N
O P
Replace side curtain air bag modu le if it has been dropped or
sustained an impact.
Do not expose the air bag mo dule to temperatures exceeding
90 °C (194 °F).
Do not allow oil, grease or water to come in contact with the
side curtain air bag module.
INSTALLATION
Install in the reverse order of removal.
CAUTION:
Be careful not to damage the air bag harness.
After the work is completed, make sure no system malfunction is detected by air bag warning lamp.
In case that malfunction is detected by the air ba g warning lamp, reset by the self-diagnosis function
and delete the memory by CONSULT-III.
In case that malfunction is still detected after the avove operation, perform self-diagnosis to repair
malfunctions. Refer to Refer to SRS-23, "
SRS Operation Check".
SBF814E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3787 of 3924

TF-1
DRIVELINE/AXLE
CEF
G H
I
J
K L
M
SECTION TF
A
B
TF
N
O P
CONTENTS
TRANSFER
SERVICE INFORMATION .. ..........................3
DTC INDEX ..................................................... .....3
C1201-C1210, U1000 ......................................... ......3
PRECAUTIONS ...................................................4
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ......
4
Precaution .................................................................4
Service Notice or Precaution .....................................5
PREPARATION ...................................................6
Special Service Tool ........................................... ......6
Commercial Service Tool ..........................................7
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING .............................
9
NVH Troubleshooting Chart ................................ ......9
TRANSFER FLUID .............................................10
Replacement ....................................................... ....10
Inspection ................................................................10
AWD SYSTEM ................................................ ....11
Power Transfer Diagram ..................................... ....11
System Description .................................................11
Schematic ...............................................................13
CAN Communication ...............................................13
TROUBLE DIAGNOSIS .....................................14
Fail-Safe Function ............................................... ....14
How to Perform Trouble Diagnosis .........................14
Location of Electrical Parts ......................................15
Circuit Diagram .......................................................16
Wiring Diagram - AWD - ..........................................17
Trouble Diagnosis Chart by Symptom ....................20
AWD Control Unit Input/Output Signal Reference
Value ................................................................... ....
20
CONSULT-III Function (ALL MODE AWD/4WD) ....21
TROUBLE DIAGNOSIS FOR SYSTEM .............24
DTC C1201 CONTROLLER FAILURE ................ ....24
DTC C1203 ABS SYSTEM ......................................24
DTC C1204 4WD SOLENOID ............................. ....25
DTC C1205 4WD ACTUATOR RLY ........................27
DTC C1210 ENGINE SIGNAL 1 ..............................28
DTC U1000 CAN COMM CIRCUIT .........................28
Power Supply Circuit for AWD Control Unit .............28
TROUBLE DIAGNOSIS FOR SYMPTOMS ......30
AWD Warning Lamp Does Not Turn ON When the
Ignition Switch Is Turned to ON ...............................
30
AWD Warning Lamp Does Not Turn OFF Several
Seconds after Engine Started ..................................
30
Heavy Tight-Corner Braking Symptom Occurs
When the Vehicle Is Driven and the Steering
Wheel Is Turned Fully to Either Side after the En-
gine Is Started .........................................................
32
Vehicle Does Not Enter AWD Mode Even Though
AWD Warning Lamp Turned to OFF .......................
33
While Driving, AWD Warning Lamp Flashes Rap-
idly (When Flashing in Approx. 1 Minute and Then
Turning OFF) ....................................................... ....
33
While Driving, AWD Warning Lamp Flashes Slow-
ly (When Continuing to Flash until Turning Ignition
Switch OFF) .............................................................
33
AWD CONTROL UNIT ......................................35
Removal and Installation .........................................35
FRONT OIL SEAL .............................................36
Removal and Installation .........................................36
REAR OIL SEAL ...............................................37
Removal and Installation .........................................37
AIR BREATHER HOSE ....................................39
Removal and Installation .........................................39
TRANSFER ASSEMBLY ..................................40
Removal and Installation .........................................40
Disassembly and Assembly .....................................40
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3792 of 3924

TF-6
< SERVICE INFORMATION >
PREPARATION
PREPARATION
Special Service ToolINFOID:0000000001327426
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name Description
ST27862000
(—)
Drift
a: 62.5 mm (2.461 in) dia.
b: 42 mm (1.65 in) dia. Installing front oil seal
KV381054S0
(J-34286)
Puller Removing rear oil seal
ST30720000
(J-25405)
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia. Installing rear oil seal
Installing mainshaft oil seal
KV40104830
(—)
Drift
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.500 in) dia. Installing rear oil seal
KV38100300
(J-25523)
Drift
a: 54 mm (2.13 in) dia.
b: 46 mm (1.81 in) dia.
c: 32 mm (1.26 in) dia. Removing mainshaft bearing
ST33052000
(—)
Drift
a: 28 mm (1.10 in) dia.
b: 22 mm (0.87 in) dia. Removing mainshaft assembly
ZZA0194D
ZZA0601D
ZZA0811D
ZZA1003D
ZZA1046D
ZZA1000D
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3795 of 3924
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTINGTF-9
< SERVICE INFORMATION >
CEF
G H
I
J
K L
M A
B
TF
N
O P
NOISE, VIBRATION AND HARSHN ESS (NVH) TROUBLESHOOTING
NVH Troubleshooting ChartINFOID:0000000001327428
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
Reference pageTF-10TF-40TF-40TF-40TF-40TF-40
SUSPECTED PARTS
(Possible cause)
TRANSFER FLUID (Level low)
TRANSFER FLUID (Wrong)
TRANSFER FLUID (Level too high)
LIQUID GASKET (Damaged)
OIL SEAL (Worn or damaged)
GEAR (Worn or damaged)
BEARING (Worn or damaged)
TRANSFER CASE (Damaged)
Symptom Noise 1 2 3 3 3
Transfer fluid leakage 4 1 2 2 3
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3822 of 3924
TF-36
< SERVICE INFORMATION >
FRONT OIL SEAL
FRONT OIL SEAL
Removal and InstallationINFOID:0000000001327457
REMOVAL
1. Remove the drain plug to drain the transfer fluid. Refer to TF-10, "Replacement".
2. Remove the front propeller shaft. Refer to PR-4
.
3. Remove front oil seal using a flat-bladed screwdriver. CAUTION:
Be careful not to damage the front case and front drive
shaft.
INSTALLATION
1. Apply ATF to front oil seal, install it with a drift until the end faceof front case.
CAUTION:
Do not reuse front oil seal.
When installing, do no t incline front oil seal.
2. Install front propeller shaft. Refer to PR-4
.
3. Install transfer fluid, check fluid level and for fluid leakage. Refer to TF-10, "
Inspection".
SDIA1782E
Tool number : ST27862000 ( — )
SDIA1783E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3823 of 3924
REAR OIL SEALTF-37
< SERVICE INFORMATION >
CEF
G H
I
J
K L
M A
B
TF
N
O P
REAR OIL SEAL
Removal and InstallationINFOID:0000000001327458
REMOVAL
1. Remove the rear propeller shaft. Refer to PR-7.
2. Remove self-lock nut of companion flange using the flange wrench.
3. Put matching mark on the end of the mainshaft. The mark should be in line with the mark on the companion flange.
CAUTION:
For matching mark, use paint. Do not damage mainshaft.
4. Remove the companion flange using a puller. CAUTION:
Be careful not to damage the companion flange.
5. Remove the rear oil seal using a puller. CAUTION:
Be careful not to damage the rear case.
INSTALLATION
SDIA2454E
SDIA2378E
SDIA1785E
Tool number : KV381054S0 (J-34286)
SDIA1786E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3824 of 3924
TF-38
< SERVICE INFORMATION >
REAR OIL SEAL
1. Apply ATF to rear oil seal, install it with a drift.CAUTION:
Do not reuse rear oil seal.
When installing, do not incline rear oil seal.
2. Align the matching mark of mainshaft with the mark of compan- ion flange, then install the companion flange.
3. Using flange wrench, install the self-lock nut of companion flange and tighten to the specified torque. Refer to TF-40, "
Dis-
assembly and Assembly".
CAUTION:
Do not reuse self-lock nut.
4. Install the rear propeller shaft. Refer to PR-7
.
5. Check fluid level. Refer to TF-10, "
Inspection".
Dimension A : 6.7 - 7.3 mm (0.264 - 0.287 in)
Tool number A: ST30720000 (J-25405)
B: KV40104830 ( — )
PDIA0292E
SDIA2378E
PDIA0245E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
Page 3827 of 3924

TRANSFER ASSEMBLYTF-41
< SERVICE INFORMATION >
CEF
G H
I
J
K L
M A
B
TF
N
O P
DISASSEMBLY
Front Case and Rear Case
1. Remove drain plug and filler plug.
1. Drive chain 2. Front drive shaft rear bearing 3. Front drive shaft
4. Front drive shaft front bearing 5. Sprocket 6. Mainshaft
7. Needle bearing 8. Snap ring 9. Mainshaft bearing
10. Front case 11. Front oil seal 12. Mainshaft oil seal
13. Oil cover 14. Electric controlled coupling 15. Spacer
16. Snap ring 17. O-ring 18. Oil gutter
19. Drain plug 20. Baffle plate 21. Rear bearing
22. Snap ring 23. Spacer 24. Rear oil seal
25. Companion flange 26. Self-lock nut 27. Breather tube
28. Rear case 29. Harness bracket 30. Retainer
31. Filler plug 32. Gasket 1: Apply Genuine Anaerobic Liquid Gasket or equivalent. Refer to GI-44, "
Recommended Chemical Product and Sealant".
2: Apply Genuine Silicone RTV or equivalent. Refer to GI-44, "
Recommended Chemical Product and Sealant".
Refer to GI-8, "
Component" for symbols not described on the above.
SDIA3608E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C