DLK-220
< PRECAUTION >[WITH INTELLIGENT KEY SYSTEM]
PRECAUTIONS
5. When the repair work is completed, return the ignition switch to the
″LOCK ″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of a ll control units using CONSULT-III.
Precaution for workINFOID:0000000001539080
• After removing and installing the opening/closing parts, be sure to carry out fitting adjustments to check their
operation.
• Check the lubrication level, damage, and wear of each part. If necessary, grease or replace it.
Revision: March 2010 2008 QX56
DLN-3
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PRECAUTIONS .............................................. ..118
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ..
118
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect ............................... ..
118
Precaution for Transfer Assembly and Transfer
Control Unit Replacement .....................................
119
Precaution .............................................................119
Service Notice .......................................................120
PREPARATION .........................................121
PREPARATION .............................................. ..121
Special Service Tool ........................................... ..121
Commercial Service Tool ......................................124
ON-VEHICLE MAINTENANCE ..................125
TRANSFER OIL FILTER ................................ ..125
Removal and Installation .......................................125
TRANSFER FLUID ......................................... ..127
Replacement ....................................................... ..127
Inspection ..............................................................127
ON-VEHICLE REPAIR ...............................128
TRANSFER CONTROL UNIT ........................ ..128
Removal and Installation .......................................128
FRONT OIL SEAL ............................................129
Removal and Installation .......................................129
REAR OIL SEAL ..............................................131
Removal and Installation .......................................131
SIDE OIL SEAL .............................................. ..133
Removal and Installation .......................................133
TRANSFER CONTROL DEVICE ................... ..134
Removal and Installation .......................................134
AIR BREATHER HOSE .................................. ..135
Removal and Installation .......................................135
TRANSFER MOTOR ...................................... ..138
Removal and Installation .......................................138
REMOVAL AND INSTALLA TION .............139
TRANSFER ASSEMBLY ............................... ..139
Removal and Installation .......................................139
DISASSEMBLY AND ASSEMBLY ........... .140
TRANSFER ASSEMBLY ............................... ..140
Disassembly and Assembly ................................ ..140
SERVICE DATA AND SPECIFICATIONS
(SDS) ......... ................................. ................
177
SERVICE DATA AND SPECIFICATIONS
(SDS) ...............................................................
177
General Specification .......................................... ..177
Inspection and Adjustment ....................................177
PROPELLER SHAFT: 2F1310
PRECAUTION ...... ......................................
179
PRECAUTIONS ...............................................179
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ..
179
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect .................................
179
PREPARATION .........................................181
PREPARATION ...............................................181
Commercial Service Tool .................................... ..181
SYMPTOM DIAGNOSIS ............................182
NOISE, VIBRATION, AND HARSHNESS
(NVH) TROUBLESHOOTING .........................
182
NVH Troubleshooting Chart ................................ ..182
ON-VEHICLE REPAIR ...............................183
PROPELLER SHAFT ......................................183
On-Vehicle Service .............................................. ..183
REMOVAL AND INSTALLATION .............184
PROPELLER SHAFT ......................................184
Removal and Installation ..................................... ..184
DISASSEMBLY AND ASSEMBLY ............186
PROPELLER SHAFT ......................................186
Disassembly and Assembly ................................. ..186
SERVICE DATA AND SPECIFICATIONS
(SDS) ............... .......................................... .
188
SERVICE DATA AND SPECIFICATIONS
(SDS) ...............................................................
188
General Specification .......................................... ..188
Snap Ring ..............................................................188
PROPELLER SHAFT: 2S1410
PRECAUTION ...... ......................................
189
PRECAUTIONS ...............................................189
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................. ..
189
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect .................................
189
PREPARATION .........................................191
PREPARATION ...............................................191
Revision: March 2010 2008 QX56
DLN-4
Commercial Service Tool ......................................191
SYMPTOM DIAGNOSIS ............................192
NOISE, VIBRATION, AND HARSHNESS
(NVH) TROUBLESHOOTING ......................... .
192
NVH Troubleshooting Chart ................................ ..192
ON-VEHICLE REPAIR ...............................193
PROPELLER SHAFT ..................................... .193
On-Vehicle Service .............................................. ..193
REMOVAL AND INSTALLATION ..............194
PROPELLER SHAFT ..................................... .194
Removal and Installation ..................................... ..194
DISASSEMBLY AND ASSEMBLY ............197
PROPELLER SHAFT ..................................... .197
Disassembly and Assembly ................................. ..197
SERVICE DATA AND SPECIFICATIONS
(SDS) ........................................................ ..
199
SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................... .
199
General Specification .......................................... ..199
Snap Ring ..............................................................200
FRONT FINAL DRIVE: M205
PRECAUTION .............. ..............................
201
PRECAUTIONS .............................................. .201
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .............................................................. ..
201
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect .................................
201
Precaution for Servicing Front Final Drive .............202
PREPARATION ..........................................203
PREPARATION .............................................. .203
Special Service Tool ............................................ ..203
Commercial Service Tool ......................................205
SYMPTOM DIAGNOSIS ............................206
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ......................... .
206
NVH Troubleshooting Chart ................................ ..206
ON-VEHICLE MAINTENANCE ..................207
DIFFERENTIAL GEAR OIL ............................ .207
Changing Differential Gear Oil ...............................207
Checking Differential Gear Oil ............................. ..207
ON-VEHICLE REPAIR ...............................208
SIDE OIL SEAL .............................................. ..208
Removal and Installation .......................................208
FRONT OIL SEAL ............................................209
Removal and Installation .......................................209
CARRIER COVER .......................................... ..211
Removal and Installation .......................................211
REMOVAL AND INSTALLA TION .............212
FRONT FINAL DRIVE .................................... ..212
Removal and Installation .......................................212
DISASSEMBLY AND ASSEMBLY ...........214
FRONT FINAL DRIVE .................................... ..214
Disassembly and Assembly ................................. .214
SERVICE DATA AND SPECIFICATIONS
(SDS) ........ .................................................
231
SERVICE DATA AND SPECIFICATIONS
(SDS) .............................................................. ..
231
General Specification ........................................... .231
Inspection and Adjustment ....................................231
REAR FINAL DRIVE: R230
PRECAUTION ............... ............................
233
PRECAUTIONS .............................................. ..233
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .............................................................. .
233
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect ................................
233
Precaution for Servicing Rear Final Drive .............234
PREPARATION .........................................235
PREPARATION .............................................. ..235
Special Service Tool ............................................ .235
Commercial Service Tool ......................................239
SYMPTOM DIAGNOSIS ...........................240
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ......................... ..
240
NVH Troubleshooting Chart ..................................240
DESCRIPTION ................................................ ..241
Cross-Sectional View ........................................... .241
ON-VEHICLE MAINTENANCE .................242
DIFFERENTIAL GEAR OIL ..............................242
Changing Differential Gear Oil ............................. .242
Checking Differential Gear Oil ..............................242
ON-VEHICLE REPAIR ..............................243
FRONT OIL SEAL ............................................243
Revision: March 2010 2008 QX56
4WD SYSTEMDLN-17
< FUNCTION DIAGNOSIS > [ATX14B]
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CAN CommunicationINFOID:0000000001737099
Refer to LAN-51, "DTC Index".
1. A: Transfer shut off relay E69
B: Transfer shift low relay E47
C: Transfer shift high relay E46 2. A: Actuator
B: Transfer control device F58
C: Actuator lever
D: Transfer case 3. Wait detection switch F59
(View with transfer case removed)
4. A: Clutch pressure switch B: Line pressure switch
C: Transfer fluid temperature sensor
D: 2-4WD shift solenoid valve
E: Clutch pressure solenoid valve
(View with contro l valve removed
from transfer case) 5. A: Neutral 4LO switch F60
B: ATP switch F55
C: Transfer motor F57
D: Transfer terminal cord assembly F56
E: Oil filter 6. Combination meter M23, M24
A: 4WD warning lamp
B: ATP warning lamp
C: 4LO indicator lamp (located in in-
formation display)
D: 4WD shift indicator lamp
7. 4WD shift switch M141 8. Transfer control unit E142, E143 9. Transfer dropping resistor E135
Transfer motor relay E153, E154
(View with battery removed)
Revision: March 2010 2008 QX56
DIAGNOSIS SYSTEM (TRANSFER CONTROL UNIT)DLN-19
< FUNCTION DIAGNOSIS > [ATX14B]
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12. Move A/T selector lever to N position.
13. Turn 4WD shift switch to AUTO position.
14. Move A/T selector lever to P position.
15. Read the flickering of 4WD warning lamp.
Self-diagnosis example
ERASE SELF-DIAGNOSIS
• In order to make it easier to find the cause of hard-to-duplicate malfunctions, malfunction information is
stored into the control unit as necessary during use by the user. This memory is not erased no matter how
many times the ignition switch is turned ON and OFF.
• However, this information is erased by turning igni tion switch OFF after performing self-diagnostics or by
erasing the memory using the CONSULT-III.
DATA MONITOR MODE
Operation Procedure
1. Connect CONSULT-III.
2. Touch DATA MONITOR.
3. Select from SELECT MONITOR ITEM, screen of data monitor mode is displayed.
NOTE:
When malfunction is detected, CONSUL T-III performs REAL-TIME DIAGNOSIS.
Also, any malfunction detected while in th is mode will be displayed at real time.
Display Item List
×: Standard –: Not applicable
PDIA0227E
Monitored item (Unit) Monitor item selection
Remarks
ECU INPUT
SIGNALS MAIN
SIGNALS SELEC-
TION FROM MENU
VHCL/S SEN·FR [km/h] or [mph] ×–×Wheel speed calculated by ABS actuator and
electric unit (control unit).
Signal input with CAN communication line.
VHCL/S SEN·RR [km/h] or [mph] ×–×Wheel speed calculated by TCM.
Signal input with CAN communication line.
ENGINE SPEED [rpm] ×–×Engine speed calculated by ECM.
Signal input with CAN communication line.
THRTL POS SEN [V] ×–×Accelerator peda
l position (APP) sensor sig-
nal voltage is displayed.
Signal input with CAN communication line.
FLUID TEMP SE [V] ×–×Transfer fluid temperature sensor signal volt-
age is displayed.
BATTERY VOLT [V] ×–×Power supply voltage for transfer control unit.
2WD SWITCH [ON/OFF] ×–×4WD shift switch status is displayed.
AUTO SWITCH [ON/OFF] ×–×4WD shift switch status is displayed.
LOCK SWITCH [ON/OFF] ×–×4WD shift switch status is displayed.
(LOCK means 4H of 4WD shift switch.)
Revision: March 2010
2008 QX56
DLN-22
< COMPONENT DIAGNOSIS >[ATX14B]
P1811 POWER SUPPLY CIRCUIT
FOR TRANSFER CONTROL UNIT
COMPONENT DIAGNOSIS
P1811 POWER SUPPLY CIRCUIT FOR TRANSFER CONTROL UNIT
DescriptionINFOID:0000000001737101
Power supply to transfer control unit is abnormally low while driving.
DTC LogicINFOID:0000000001737102
DTC DETECTION LOGIC
DTC CONFIRMATION PROCEDURE
1.DTC CONFIRMATION PROCEDURE
1. Turn ignition switch ON.
2. Perform self-diagnosis.
Is DTC P1811 detected?
YES >> Perform diagnosis procedure. Refer to DLN-22, "Diagnosis Procedure".
NO >> Inspection End.
Diagnosis ProcedureINFOID:0000000001737103
1.CHECK POWER SUPPLY
1. Turn ignition switch OFF. (Stay for at least 5 seconds.)
2. Connect transfer control unit harness connector.
3. Check voltage between transfer control unit harness connector terminals and ground.
4. Turn ignition switch ON. (Do not start engine.)
5. Check voltage between transfer control unit harness connector terminals and ground.
Are the inspection results normal?
YES >> GO TO 2.
NO >> Check the following. If any items are damaged, repair or replace damaged parts.
DTC CONSULT-III Diagnostic item is detected when... Reference
[ P 1 8 11 ] B AT T E R Y V O LTA G E Power supply voltage for transfer control
unit is abnormally low while driving.Refer to
DLN-22
.
Connector Terminal Voltage (Approx.)
E142 16 - Ground
0V
22 - Ground
E143 29 - Ground
30 - Ground
Battery voltage
47 - Ground
WDIA0165E
Connector Terminal Voltage (Approx.)
E142 16 - Ground
Battery voltage
22 - Ground
E143 29 - Ground
30 - Ground
0V
47 - Ground Battery voltage
WDIA0166E
Revision: March 2010 2008 QX56
P1811 POWER SUPPLY CIRCUIT FOR TRANSFER CONTROL UNIT
DLN-23
< COMPONENT DIAGNOSIS > [ATX14B]
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• 10A fuses No. 26 located in fuse and fusible link box and No. 59 located in the fuse and relay box.
• 20A fuse No. 53 located in the IPDM E/R.
• Harness for short or open between battery and transfer control unit harness connector terminals
47.
• Harness for short or open between battery and transfer control unit harness connector terminal
29.
• Harness for short or open between battery and transfer shut off relay harness connector E69 terminal 1, and 3.
• Harness for short or open between transfer shut off relay harness connector E69 terminal 2 and transfer control unit harness connector terminal 30.
• Harness for short or open between transfer shut off relay harness connector E69 terminal 5 and transfer control unit harness connector terminals 16 and 22.
• Battery and ignition switch.
• Transfer shut off relay. Refer to DLN-23, "
Component Inspection".
2.CHECK 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.
Are the inspection results normal?
YES >> GO TO 3.
NO >> Repair open circuit or short to ground or short to power in harness or connectors.
3.CHECK TRANSFER CONTROL UNIT
Check transfer control unit input/output signal. Refer to DLN-80, "
Reference Value".
Are the inspection results normal?
YES >> GO TO 4.
NO >> Check transfer control unit pin terminals for damage or loose connection with harness connector. If any items are damaged, repair or replace damaged parts.
4.CHECK DTC
Perform the self-diagnosis, after driving a vehicle for a while.
Are the inspection results normal?
YES >> Inspection End.
NO >> Replace transfer control unit. Refer to DLN-128, "
Removal and Installation".
Component InspectionINFOID:0000000001737104
1. Turn ignition switch OFF. (Stay for at least 5 seconds.)
2. Remove transfer shut off relay. Refer to DLN-16, "
Component Parts Location".
3. Apply 12V direct current between transfer shut off relay termi- nals 1 and 2.
4. Check continuity between relay terminals 3 and 5.
5. If inspection results are abnormal replace the transfer shut off relay.Continuity should exist.
SDIA2691E
Condition
Continuity
12V direct current supply between terminals 1 and 2 Yes
OFF No
SCIA1245E
Revision: March 2010 2008 QX56
P1810 NEUTRAL-4LO SWITCHDLN-29
< COMPONENT DIAGNOSIS > [ATX14B]
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Are inspection results normal?
YES >> GO TO 5.
NO >> GO TO 2.
2.CHECK HARNESS BETWEEN TR ANSFER CONTROL UNIT AND NEUTRAL-4LO SWITCH
1. Turn ignition switch OFF. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connecto r and the neutral-4LO switch harness connector.
3. Check continuity between transfer control unit harness connec- tor E143 terminal 25 and neutral-4LO switch harness connector
F60 terminal 13.
Also check harness for short to ground and short to power.
Are inspection results normal?
YES >> GO TO 3.
NO >> Repair or replace damaged parts.
3.CHECK GROUND CIRCUIT
1. Turn ignition switch OFF. (Stay for at least 5 seconds.)
2. Disconnect neutral-4LO switch harness connector.
3. Check continuity between neutral-4LO switch harness connec- tor F60 terminal 12 and ground.
Also check harness for short to ground and short to power.
Are inspection results normal?
YES >> GO TO 4.
NO >> Repair open circuit or short to ground or short to power in harness or connectors.
4.CHECK 4LO SWITCH
1. Turn ignition switch OFF.
2. Disconnect neutral-4LO switch harness connector.
3. Remove neutral-4LO switch.
Connector Te r m i n a l
(Wire col-
or) Condition
Voltage
(Approx.)
E143 25 -
Ground • Vehicle stopped
• Engine running
• A/T selector lever
N position
• Brake pedal de- pressed 4WD shift switch:
2WD, AUTO or 4H
Battery
voltage
4WD shift switch: 4H to
4LO (While actuator
motor is operating.) Battery
voltage
→ 0V
4WD shift switch: 4LO
to 4H (While actuator
motor is operating.) 0V
→
Battery
voltage
4WD shift switch: 4LO 0V
Continuity should exist.
SDIA2694E
Continuity should exist.
SDIA2695E
Revision: March 2010 2008 QX56