DLN-4
Commercial Service Tools .....................................125
SYMPTOM DIAGNOSIS ............................126
NOISE, VIBRATION, AND HARSHNESS
(NVH) TROUBLESHOOTING ......................... .
126
NVH Troubleshooting Chart ................................ ..126
PERIODIC MAINTENANCE ..................... ..127
FRONT PROPELLER SHAFT ........................ .127
Inspection ............................................................ ..127
REMOVAL AND INSTALLATION ..............128
FRONT PROPELLER SHAFT ........................ .128
Exploded View ..................................................... ..128
Removal and Installation .......................................129
Disassembly and Assembly ...................................129
Inspection ..............................................................131
SERVICE DATA AND SPECIFICATIONS
(SDS) .............. ............................................
133
SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................... .
133
General Specification .......................................... ..133
Propeller Shaft Runout ..........................................133
Journal Axial Play ..................................................133
REAR PROPELLER SHAFT: 2F P26
SYMPTOM DIAGNOSIS .. ..........................
134
NOISE, VIBRATION, AND HARSHNESS
(NVH) TROUBLESHOOTING ......................... .
134
NVH Troubleshooting Chart ................................ ..134
PERIODIC MAINTENANCE ..................... ..135
REAR PROPELLER SHAFT .......................... .135
Inspection ............................................................ ..135
REMOVAL AND INSTALLATION ..............136
REAR PROPELLER SHAFT .......................... .136
Exploded View ..................................................... ..136
Removal and Installation .......................................137
Disassembly and Assembly ...................................137
Inspection ..............................................................139
SERVICE DATA AND SPECIFICATIONS
(SDS) .............. ............................................
140
SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................... .
140
General Specification .......................................... ..140
Propeller Shaft Runout ..........................................140
Journal Axial Play ..................................................140
REAR PROPELLER SHAFT: 2S1410
SYMPTOM DIAGNOSIS .. ..........................
141
NOISE, VIBRATION, AND HARSHNESS
(NVH) TROUBLESHOOTING ......................... ..
141
NVH Troubleshooting Chart ................................. .141
PERIODIC MAINTENANCE ......................142
REAR PROPELLER SHAFT .......................... ..142
Inspection ............................................................. .142
REMOVAL AND INSTALLATION .............143
REAR PROPELLER SHAFT .......................... ..143
Exploded View ..................................................... .143
Removal and Installation .......................................144
Disassembly and Assembly ..................................144
Inspection ..............................................................146
SERVICE DATA AND SPECIFICATIONS
(SDS) ........ .................................................
147
SERVICE DATA AND SPECIFICATIONS
(SDS) .............................................................. ..
147
General Specification ........................................... .147
Propeller Shaft Runout ..........................................147
Journal Axial Play .................................................147
FRONT FINAL DRIVE: R180A
PRECAUTION ............... ............................
148
PRECAUTIONS .............................................. ..148
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect ................................ .
148
Precaution for Servicing Front Final Drive ............148
PREPARATION .........................................149
PREPARATION .............................................. ..149
Special Service Tool ............................................ .149
Commercial Service Tool ......................................151
SYSTEM DESCRIPTION ..........................153
STRUCTURE AND OPERATION ................... ..153
Sectional View ..................................................... .153
SYMPTOM DIAGNOSIS ...........................154
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ......................... ..
154
NVH Troubleshooting Chart ................................. .154
PERIODIC MAINTENANCE ......................155
FRONT DIFFERENTIAL GEAR OIL .............. ..155
Inspection ............................................................. .155
Draining .................................................................155
Refilling .................................................................155
REMOVAL AND INSTALLATION .............156
FRONT OIL SEAL .......................................... ..156
Exploded View ..................................................... .156
Revision: 2010 May2011 QX56
DLN-5
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Removal and Installation .....................................
..
156
SIDE OIL SEAL ................................................160
Exploded View .................................................... ..160
Removal and Installation .......................................160
UNIT REMOVAL AND INSTALLATION ....162
FRONT FINAL DRIVE ASSEMBLY ............... ..162
Exploded View .................................................... ..162
Removal and Installation .......................................162
UNIT DISASSEMBLY AND ASSEMBLY ..164
SIDE SHAFT ................................................... ..164
Exploded View .................................................... ..164
Disassembly ..........................................................165
Assembly ...............................................................166
Inspection ..............................................................166
DIFFERENTIAL ASSEMBLY ...........................167
Exploded View .................................................... ..167
Disassembly ..........................................................168
Assembly ...............................................................169
Adjustment ............................................................171
Inspection ..............................................................174
DRIVE PINION ..................................................176
Exploded View .................................................... ..176
Disassembly ..........................................................177
Assembly ...............................................................179
Adjustment ............................................................181
Inspection ..............................................................184
SERVICE DATA AND SPECIFICATIONS
(SDS) ......... ................................. ................
185
SERVICE DATA AND SPECIFICATIONS
(SDS) .............................................................. ..
185
General Specifications ........................................ ..185
Drive Gear Runout ................................................185
Preload Torque .....................................................185
Backlash ................................................................185
Companion Flange Runout ...................................185
REAR FINAL DRIVE: R230
PRECAUTION ................ ............................
186
PRECAUTIONS .............................................. ..186
Service Notice or Precautions for Rear Final Drive ..186
PREPARATION .........................................187
PREPARATION .............................................. ..187
Special Service Tool ........................................... ..187
Commercial Service Tool ......................................189
SYSTEM DESCRIPTION ...........................191
STRUCTURE AND OPERATION ...................191
Sectional View ..................................................... ..191
SYMPTOM DIAGNOSIS ............................192
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING .........................
192
NVH Troubleshooting Chart ................................ ..192
PERIODIC MAINTENANCE ......................193
REAR DIFFERENTIAL GEAR OIL .................193
Inspection ............................................................ ..193
Draining .................................................................193
Refilling ..................................................................193
REMOVAL AND INSTALLATION .............194
FRONT OIL SEAL ...........................................194
Exploded View ..................................................... ..194
Removal and Installation .......................................194
SIDE OIL SEAL ...............................................199
Exploded View .......................................................199
Removal and Installation .......................................199
UNIT REMOVAL AND INSTALLATION ....201
REAR FINAL DRIVE .......................................201
Exploded View ..................................................... ..201
Removal and Installation .......................................201
UNIT DISASSEMBLY AND ASSEMBLY ..203
DIFFERENTIAL ASSEMBLY ..........................203
Exploded View ..................................................... ..203
Disassembly ..........................................................204
Assembly ...............................................................206
Adjustment .............................................................210
Inspection ..............................................................215
DRIVE PINION ................................................216
Exploded View .......................................................216
Disassembly ..........................................................217
Assembly ...............................................................218
Adjustment .............................................................220
Inspection ..............................................................220
SERVICE DATA AND SPECIFICATIONS
(SDS) ............... ...........................................
222
SERVICE DATA AND SPECIFICATIONS
(SDS) ...............................................................
222
General Specification .......................................... ..222
Drive Gear Runout .................................................222
Side Gear Clearance .............................................222
Preload Torque ......................................................222
Backlash ................................................................222
Companion Flange Runout ....................................222
Revision: 2010 May2011 QX56
DLN-8
< PREPARATION >[TRANSFER: ATX90A]
PREPARATION
PREPARATION
PREPARATION
Special Service ToolsINFOID:0000000006222212
The actual shapes of Kent-Moore tool
s may differ from those of special service tools illustrated here.
Commercial Service ToolsINFOID:0000000006222213
Tool number
(Kent-Moore No.)
Tool name Description
ST30701000
(J-25742-2)
Drift
a: 61.5 mm (2.421 in) dia.
b: 41 mm (1.61 in) dia. Removing dust shield from companion flange
KV40104710
(—)
Drift
a: 76.3 mm (3.004 in) dia.
b: 67.9 mm (2.673 in) dia. Installing rear oil seal
Installing input oil seal
KV10119400
(—)
Spline socket Installing transfer control actuator
Installing transfer rotary position sensor
ZZA1000D
ZZA1003D
ZZA1205D
Tool name
Description
Puller Removing dust shield from shaft flange
Removing dust shield from companion
flange
Replacer Removing dust shield from shaft flange
Removing dust shield from companion
flange
ZZA0119D
ZZA0700D
Revision: 2010 May2011 QX56
PREPARATIONDLN-9
< PREPARATION > [TRANSFER: ATX90A]
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Drift
a: 63 mm (2.48 in) dia.
b: 59 mm (2.32 in) dia. Installing front oil seal
Power tool Loosening bolts and nuts
Tool name
Description
ZZA1003D
PBIC0190E
Revision: 2010 May2011 QX56
DIAGNOSIS SYSTEM (TRANSFER CONTROL UNIT)
DLN-23
< SYSTEM DESCRIPTION > [TRANSFER: ATX90A]
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WORK SUPPORT
*: “LOCK SLEEVE SENSOR” means transfer lock position sensor.
VHCL/S SEN-RR [km/h] X Wheel speed (rear) average calculated by
transfer control.
ENG SPEED [rpm] X Engine status via CAN communication line is
displayed.
INTERNL SPEED SEN [count] X Transfer internal speed sensor status is dis-
played.
TRANSFER TORQUE [Nm] X Commanded transfer communication torque is
displayed.
UNIT PARAMETER [A1 - A9, B1 - B9, C1 - C9, D1
- D9, E1 - E9, F1 - F9, G1 - G9, H1 - H9, J1 - J9] Unit parameter of transfer recognized by trans-
fer control unit is displayed.
Monitor item (Unit)
SELECT MONITOR ITEM
Remarks
ECU INPUT
SIGNALS MAIN SIG-
NALS
Function Description
UNIT CHARACTERISTIC WRITE Writes the unit parameter of transfer to transfer control unit.
START CALIBRATION Perform initial calibration of transfer control unit.
LOCK SLEEVE SENSOR
* INITIALIZE Format learning the transfer lock position sensor written to transfer control unit.
LOCK SLEEVE SENSOR
* LEARNING Perform learning the transfer lock position sensor.
OIL DETERIORATION INFO RESET Format the transfer fl uid viscosity written to transfer control unit.
Revision: 2010 May2011 QX56
TRANSFER CONTROL UNITDLN-29
< ECU DIAGNOSIS INFORMATION > [TRANSFER: ATX90A]
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DTC Inspection Priority ChartINFOID:0000000006222229
If some DTCs are displayed at the same time, per form inspections one by one based on the following priority
chart.
DTC IndexINFOID:0000000006222230
Priority Detected items (DTC)
1 U1000 CAN COMM CIRCUIT
U1010 CONTROL UNIT (CAN)
2 P1802 CONTROL UNIT 1
P1803 CONTROL UNIT 2
P1804 CONTROL UNIT 3
P1809 CONTROL UNIT 4
P180C SEN POWER SUPPLY (5V)
P180E SEN POWER SUPPLY (8V)
P1811 BATTERY VOLTAGE
P181B INCOMP SELFSHUT
P181C MOTOR POWER SUPPLY
P181F INCOMP CALIBRATION
3 P1807 VECL SPEED SEN-AT
P1808 VECL SPEED SEN-ABS
P1816 PNP SW/CIRC
P181E ST ANGLE SEN SIG
P1820 ENGINE SPEED SIG
P1829 THROTTLE POSI SEN
P1830 ABS OP SIG
P1831 VDC OP SIG
P1832 TCS OP SIG
4 P180D ROTARY POSITION SEN
P1813 4WD MODE SW
P181A MOTOR TEMP SEN
P1826 OIL TEMP SEN
P182A HI-LO POSITION SEN
P182B LOCK POSITION SEN
5 P180F MOTOR SYSTEM
P1817 SHIFT ACTUATOR
DTC Display Items Reference
P1802 CONTROL UNIT 1 DLN-51, "
DTC Logic"
P1803 CONTROL UNIT 2DLN-51, "DTC Logic"
P1804 CONTROL UNIT 3DLN-51, "DTC Logic"
P1807 VHCL SPEED SEN-ATDLN-52, "DTC Logic"
P1808 VHCL SPEED SEN-ABSDLN-53, "DTC Logic"
P1809 CONTROL UNIT 4DLN-51, "DTC Logic"
P180C SEN POWER SUPPLY (5V) DLN-54, "DTC Logic"
P180D ROTARY POSITION SENDLN-57, "DTC Logic"
P180E SEN POWER SUPPLY (8V)DLN-59, "DTC Logic"
P180F MOTOR SYSTEMDLN-61, "DTC Logic"
P1811 BATTERY VOLTAGEDLN-64, "DTC Logic"
P1813 4WD MODE SW DLN-67, "DTC Logic"
P1816 PNP SW/CIRCDLN-69, "DTC Logic"
P1817 SHIFT ACTUATORDLN-70, "DTC Logic"
P181A MOTOR TEMP SEN DLN-72, "DTC Logic"
P181B IMCOMP SELFSHUTDLN-74, "DTC Logic"
Revision: 2010 May2011 QX56
DLN-30
< ECU DIAGNOSIS INFORMATION >[TRANSFER: ATX90A]
TRANSFER CONTROL UNIT
P181C MOTOR POWER SUPPLY
DLN-76, "DTC Logic"
P181E ST ANGLE SEN SIGDLN-77, "DTC Logic"
P181F INCOMP CALIBRATIONDLN-78, "DTC Logic"
P1826 OIL TEMP SENDLN-80, "DTC Logic"
P1820 ENGINE SPEED SIGDLN-79, "DTC Logic"
P1829 THROTTLE POSI SENDLN-82, "DTC Logic"
P182A HI-LO POSITION SEN DLN-83, "DTC Logic"
P182B LOCK POSITION SENDLN-85, "DTC Logic"
P1830 ABS OP SIGDLN-88, "DTC Logic"
P1831 VDC OP SIGDLN-89, "DTC Logic"
P1832 TCS OP SIGDLN-90, "DTC Logic"
U1000 CAN COMM CIRCUIT DLN-91, "DTC Logic"
U1010 CONTROL UNIT (CAN)DLN-92, "DTC Logic"
DTC Display Items Reference
Revision: 2010 May2011 QX56
DLN-42
< BASIC INSPECTION >[TRANSFER: ATX90A]
ADDITIONAL SERVICE WHEN
REPLACING TRANSFER ASSEMBLY
ADDITIONAL SERVICE WHEN REPLACING TRANSFER ASSEMBLY
DescriptionINFOID:0000000006222236
Perform writing unit parameter, transfer fluid viscosity learning and initial calibration after replacing transfer
assembly. Refer to DLN-42, "
Work Procedure".
Work ProcedureINFOID:0000000006222237
NOTE:
In fail-safe mode, can not perform work s upport. (Except that DTC P181F is detected.)
1.WRITE UNIT PARAMETER
Perform writing unit parameter to control unit. Refer to DLN-48, "
Work Procedure".
>> GO TO 2.
2.PREPARATION BEFORE WORK
With CONSULT-III
1. Start the engine. CAUTION:
Never drive the vehicle.
2. Check “4WD MODE”, “T/M RANGE”, “COMER V HCL SPEED”, “MOTOR POWER SUP” of CONSULT-III
“DATA MONITOR” for “ALL MODE AWD/4WD”.
3. Continue the following condition more than 10 seconds.
>> GO TO 3.
3.PERFORM TRANSFER FLUID VISCOSITY LEARNING
With CONSULT-III
1. Select “OIL DETERIORATION INFO RESET” of CONSULT-III “WORK SUPPORT” for “ALL MODE AWD/
4WD”.
2. Select “Start”.
>> GO TO 4.
4.INITIAL CALIBRATION
With CONSULT-III
1. Select “START CALIBRATION” of CONSULT- III “WORK SUPPORT” for “ALL MODE AWD/4WD”.
2. Wait until the motor operation stop. (After approximately 10 seconds)
>> GO TO 5.
5.PERFORM SELF-DIAGNOSIS
With CONSULT-III
1. Erase self-diagnosis result for “ALL MODE AWD/4WD”.
2. Turn the ignition switch ON to OFF. CAUTION:
Wait for 10 seconds after turn ing ignition switch OFF.
3. Start the engine. CAUTION:
Never drive the vehicle.
4. Perform self-diagnosis for “ALL MODE AWD/4WD”.
4WD MODE : AUTO
T/M RANGE : N
COMPER VHCL SPEED : 0 km/h (Never drive the vehicle)
MOTOR POWER SUP : More than 11 V
Revision: 2010 May2011 QX56