DLN-106
< PERIODIC MAINTENANCE >[TRANSFER: ATX90A]
TRANSFER FLUID
PERIODIC MAINTENANCE
TRANSFER FLUID
InspectionINFOID:0000000006222324
FLUID LEAKAGE
Check transfer surrounding area (oil seal, drain plug, and filler plug etc.) for fluid leakage.
FLUID LEVEL
1. Remove filler plug (1) and gasket. Then check that fluid is filled
up from mounting hole for the filler plug.
CAUTION:
Never start engine whil e checking fluid level.
2. Set a new gasket onto filler plug (1), and install it on transfer and then tighten to the specified torque.
CAUTION:
Never reuse gasket.
DrainingINFOID:0000000006222325
1. Run the vehicle to warm up the transfer unit sufficiently.
2. Stop the engine.
3. Remove the drain plug (1) and drain transfer fluid.
4. Set a new gasket onto drain plug (1), and install it to transfer andtighten to the specified torque.
CAUTION:
Never reuse gasket.
RefillingINFOID:0000000006222326
1. Remove filler plug (1). Fill up with new transfer fluid up to mount-ing hole for the filler plug.
CAUTION:
Carefully fill the fluid. (Fill up for approximately 3 minutes.)
2. Leave the vehicle for 3 minutes, and check the fluid level again.
3. Set a new gasket onto filler plug, and install it on transfer and tighten to the specified torque.
CAUTION:
Never reuse gasket.
4. Perform learning of transfer fluid viscosity. Refer to DLN-47, "
Work Procedure".
Specified torque : 33 N·m (3.4 kg-m, 24 ft-lb)
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Specified torque : 33 N-m (3.4 kg-m, 24 ft-lb)
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Fluid grade and Viscosity : Refer to
MA-10, "Fluids
and Lubricants".
Fluid capacity : Refer to DLN-124, "
Gen-
eral Specifications".
Specified torque : 33 N-m (3.4 kg-m, 24 ft-lb)
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Revision: 2010 May2011 QX56
DLN-110
< REMOVAL AND INSTALLATION >[TRANSFER: ATX90A]
FRONT OIL SEAL
1. Install front oil seal with a drift (A) (commercial service tool)
within the dimension (L) shown as follows.
CAUTION:
Never reuse front oil seal.
Apply transfer fluid onto circumference of oil seal.
2. Install the dust shield to the front shaft flange.
3. Install the front shaft flange.
4. Install the snap ring. CAUTION:
Never reuse the snap ring.
5. Install the O-ring to plug. CAUTION:
Never reuse the O-ring.
Never damage the O-ring.
6. Tighten the plug to specified torque.
7. Install front propeller shaft. Refer to DLN-129, "
Removal and Installation".
8. Fill with new transfer fluid, check fluid level and for fluid leakage. Refer to DLN-106, "
Inspection".
L : 5.3 – 5.7 mm
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Revision: 2010 May2011 QX56
DLN-112
< REMOVAL AND INSTALLATION >[TRANSFER: ATX90A]
REAR OIL SEAL
1. Install rear oil seal, with a drift (A) [SST: KV40104710 ( —
] within the dimension (L) show as follows.
CAUTION:
Never reuse front oil seal.
Apply transfer fluid onto circumference of oil seal.
2. Install the dust shield to the rear companion flange.
3. Install the rear companion flange to main shaft. CAUTION:
Align the matching marks (A) of main shaft and rear com-panion flange.
Install bolt (A) (M12 ×1.75 mm) to main shaft, then install
the rear companion flange by hammering while pulling the
bolt.
4. Install the O-ring (3) to gap between rear companion flange (1) and main shaft (2).
CAUTION:
Never reuse the O-ring.
Never damage the O-ring.
5. Select adjusting shim. Refer to DLN-112, "
Adjustment".
6. Install adjusting shim.
7. Install the snap ring.
8. Install the rear propeller shaft. Refer to DLN-144, "
Removal and
Installation".
9. Check fluid level and for fluid leakage. Refer to DLN-106,
"Inspection".
AdjustmentINFOID:0000000006222333
ADJUSTING SHIM
1. Remove the snap ring.
2. Remove the adjusting shim.
3. Remove the O-ring.L : 2.8 – 3.2
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Revision: 2010 May2011 QX56
REAR OIL SEALDLN-113
< REMOVAL AND INSTALLATION > [TRANSFER: ATX90A]
C
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M A
B
DLN
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4. Install the thinnest adjusting shim.
5. Install the snap ring to main shaft.
6. Install the bolt (A) (M12 ×1.75 mm) to main shaft, then hummer
the rear companion flange while pulling the bolt.
7. Fit a dial indicator onto the end of main shaft.
8. Check the clearance between rear companion flange and main shaft during pushing the bolt (A) at direction.
9. Use the formula below to calculate adjusting shim thickness.
CAUTION:
Adjusting shim thickness is in step of 0.1 mm. When a calculation result includes the second dec-
imal place, it must be rounded down.
10. Select the proper adjusting shim. For selecting adj usting shim, refer to the latest parts information.
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Shim selection equation:
T = T
0 + (C − 0.1)
T: Correct shim thickness
T
0: The thinnest shim thickness
C: Measured clearance between rear companion flange and main shaft
Example:
T = 2.1 + (0.34 − 0.1) = 2.34
T
0:2.1
C: 0.34
Caluculated value... T = 2.34 mm
Used shim... T = 2.3 mm
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Revision: 2010 May2011 QX56
DLN-114
< REMOVAL AND INSTALLATION >[TRANSFER: ATX90A]
TRANSFER CONTROL ACTUATOR
TRANSFER CONTROL ACTUATOR
Exploded ViewINFOID:0000000006222334
Removal and InstallationINFOID:0000000006222335
REMOVAL
CAUTION:
If DTC about transfer control actuator is
detected, perform inspection after removal.
1. Turn the ignition switch OFF.
2. Disconnect negative battery terminal. CAUTION:
Wait for 5 seconds after turn ing ignition switch OFF.
3. Disconnect the transfer control actuator connector.
4. Remove the bolts and detach the transfer control actuator.
5. Perform inspection after removal. Refer to DLN-114, "
Inspection".
INSTALLATION
Note the following, and installing the reverse order of removal.
Never damage oil seal of transfer motor.
If transfer control actuator has been replaced, perform writing the unit parameter. Refer to DLN-48, "
Work
Procedure"
Perform inspection after installation. Refer to DLN-114, "Inspection"
InspectionINFOID:0000000006222336
INSPECTION AFTER REMOVAL
1. Check the oil seal assembled transfer control act uator for wear, crack and damage. Replace if there is
malfunction.
2. Check the transfer assembly as follows.
1. Transfer assembly 2. Transfer control actuator
: Vehicle front
Refer to GI-4, "
Components" for symbols not described above.
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Revision: 2010 May2011 QX56
DLN-122
< UNIT REMOVAL AND INSTALLATION >[TRANSFER: ATX90A]
TRANSFER ASSEMBLY
When installing the transfer to the
transmission, install the mount-
ing bolts following the standard below, tighten bolts to the specified
torque.
When installing transfer breather hose, make sure t here are no pinched or restricted areas on the transfer
breather hose caused by bending or winding.
- Install the transfer breather hose (1) of transmission side with the
paint mark (A) facing upward and the mark (B) (: ) facing right
side.
- Install the transfer breather hose (1) of transfer side with the paint mark (A) facing upward, and insert breather hose to breather tube
(2) until dimension (B) shown as follows.
- Be sure to fix breather hose in (A) and (B) positions. Fix with the
paint mark facing upward in the (A) position.
Check oil level and check for oil leakage after installation. Refer to DLN-106, "
Inspection".
If replacing transfer assembly, perform writing unit parameter,
learning of fluid viscosity and initial calibration. Refer to DLN-42,
"Work Procedure".
Bolt symbol A B
Insertion direction Transfer to transmission Transmission to transfer
: Tightening the bolt with bracket
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B: 20 mm (0.79 in)
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Revision: 2010 May2011 QX56
DLN-148
< PRECAUTION >[FRONT FINAL DRIVE: R180A]
PRECAUTIONS
PRECAUTION
PRECAUTIONS
Precaution Necessary for Steering W
heel Rotation after Battery Disconnect
INFOID:0000000006222372
NOTE:
Before removing and installing any control units, first tu rn the push-button ignition switch to the LOCK posi-
tion, then disconnect bot h battery cables.
After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If a DTC is detected, perform trouble diagnos is according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the bat tery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables. NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the push-button ignition switch to ACC position. (At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock wi ll remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect bot h battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button igniti on switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT-III.
Precaution for Servicing Front Final DriveINFOID:0000000006222373
Before starting diagnosis of the vehicle, understand the symptoms well. Perform correct and systematic
operations.
Check for the correct installation status prior to re moval or disassembly. When matching marks are required,
be certain they do not interfere with the f unction of the parts they are applied to.
Overhaul should be done in a clean work area, a dust proof area is recommended.
Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
Always use shop paper for cleaning the inside of components.
Avoid using cotton gloves or a shop cloth to prevent the entering of lint.
Check appearance of the disassembled parts for dam age, deformation, and abnormal wear. Replace them
with new ones if necessary.
Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
Clean and flush the parts sufficiently and blow them dry.
Be careful not to damage sliding surfaces and mating surfaces.
When applying sealant, remove the old sealant from the mating surface; then remove any moisture, oil, and
foreign materials from the application and mating surfaces.
In principle, tighten nuts or bolts gradually in severa l steps working diagonally from inside to outside. If a
tightening sequence is specified, observe it.
During assembly, observe the specified tightening torque.
Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.
Revision: 2010 May2011 QX56
FRONT DIFFERENTIAL GEAR OILDLN-155
< PERIODIC MAINTENANCE > [FRONT FINAL DRIVE: R180A]
C
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DLN
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PERIODIC MAINTENANCE
FRONT DIFFERENTIAL GEAR OIL
InspectionINFOID:0000000006222378
OIL LEAKAGE
Check that oil is not leaking from the front final drive assembly or around it.
OIL LEVEL
Remove filler plug (1) and check oil level from filler plug mounting
hole as shown in the figure.
CAUTION:
Never start engine while checking oil level.
Set a gasket on filler plug (1) and install it on final drive assembly. Refer to DLN-167, "
Exploded View".
CAUTION:
Never reuse gasket.
DrainingINFOID:0000000006222379
1. Stop engine.
2. Remove drain plug (1) and drain gear oil.
3. Set a gasket on drain plug (1) and install it to final drive assem- bly and tighten to the specified torque. Refer to DLN-167,
"Exploded View".
CAUTION:
Never reuse gasket.
RefillingINFOID:0000000006222380
1. Remove filler plug (1). Fill with new gear oil until oil level reaches the specified level near filler plug mounting hole.
2. After refilling oil, check oil level. Set a gasket to filler plug (1), then install it to final drive assembly. Refer to DLN-167,
"Exploded View".
CAUTION:
Never reuse gasket.
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Oil grade and Viscosity : Refer to MA-10, "Fluids
and Lubricants".
Oil capacity : Refer to DLN-185, "
Gen-
eral Specifications".
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Revision: 2010 May2011 QX56