DRIVELINE/AXLE

SECTION TF
TRANSFER
B

TF

E
CONTENTS
SERVICE INFORMATION ............................ 2 CONSULT-III Function (ALL MODE AWD/4WD) ....39 F
Self-Diagnosis Procedure ........................................42
MODIFICATION NOTICE .................................... 2 Trouble Diagnosis Chart by Symptom .....................45
Major Modification Item ............................................. 2 Component Inspection .............................................45 G
DTC INDEX .......................................................... 3 TRANSFER CONTROL UNIT ........................... 49
P1801-P1819 ............................................................ 3 Removal and Installation .........................................49
P1820-P1855, U1000 ................................................ 3 H
FRONT OIL SEAL ............................................. 50
PRECAUTIONS ................................................... 4 Removal and Installation .........................................50
Precaution for Supplemental Restraint System
REAR OIL SEAL ............................................... 52 I
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 4 Removal and Installation .........................................52
Precaution for Transfer Assembly and Transfer
Control Unit Replacement ......................................... 4
TRANSFER CONTROL DEVICE ...................... 54 J
Removal and Installation .........................................54
Precaution ................................................................. 6
Service Notice ........................................................... 6 AIR BREATHER HOSE .................................... 56
Removal and Installation .........................................56 K
PREPARATION ................................................... 8
Special Service Tool ................................................. 8 TRANSFER ASSEMBLY .................................. 57
Commercial Service Tool ........................................ 10 Removal and Installation .........................................57 L
4WD SYSTEM ....................................................11 Disassembly and Assembly .....................................57
Cross-Section View ................................................. 11 PLANETARY CARRIER ................................... 68
Power Transfer ........................................................ 11 Disassembly and Assembly .....................................68 M
System Description ................................................. 13
Schematic ............................................................... 15 SHIFT CONTROL .............................................. 69
Disassembly and Assembly .....................................69 N
TROUBLE DIAGNOSIS .....................................17
Location of Electrical Parts ...................................... 17 SERVICE DATA AND SPECIFICATIONS
Circuit Diagram ....................................................... 18 (SDS) ................................................................. 70
Wiring Diagram - T/F - ............................................. 20 General Specification ..............................................70 O
Transfer Control Unit Input/Output Signal Refer- Inspection and Adjustment ......................................70
ence Value .............................................................. 33
P

Revision: 2008 January TF-1 D40

 MODIFICATION NOTICE
< SERVICE INFORMATION >
SERVICE INFORMATION
MODIFICATION NOTICE
Major Modification Item INFOID:0000000003806726

Dust cover has been changed.

Revision: 2008 January TF-2 D40

 DTC INDEX
< SERVICE INFORMATION >
DTC INDEX
A
P1801-P1819 INFOID:0000000003261195

B
Items
DTC Reference
(CONSULT-III screen terms)
P1801 *INITIAL START*
C
P1802 CONTROL UNIT 1
P1803 CONTROL UNIT 2
P1804 CONTROL UNIT 3 TF
P1807 VHCL SPEED SEN·AT
P1808 VHCL SPEED SEN·ABS
E
P1809 CONTROL UNIT 4
TF-39, "CONSULT-III Function
P1810 4L POSI SW TF
(ALL MODE AWD/4WD)"
P1811 BATTERY VOLTAGE F
P1813 4WD MODE SW
P1814 4WD DETECT SWITCH
G
P1816 PNP SW/CIRC
P1817 SHIFT ACTUATOR
P1818 SHIFT ACT POSI SW H
P1819 SHIFT ACT CIR

P1820-P1855, U1000 INFOID:0000000003261196

I

Items
DTC Reference
(CONSULT-III screen terms) J
P1820 ENGINE SPEED SIG
P1854 VHCL SPEED SEN FR TF-39, "CONSULT-III Function
(ALL MODE AWD/4WD)"
K
P1855 VHCL SPEED SEN RR
U1000 CAN COMM CIRCUIT
L

Revision: 2008 January TF-3 D40

 PRECAUTIONS
< SERVICE INFORMATION >
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000003803840

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SUPPLEMENTAL
RESTRAINT SYSTEM” and “SEAT BELTS” of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SUPPLEMENTAL RESTRAINT SYSTEM”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
Precaution for Transfer Assembly and Transfer Control Unit Replacement INFOID:0000000002978580

• When replacing transfer assembly or transfer control unit, check the 4WD shift indicator pattern and adjust-
ment of the position between transfer assembly and transfer control unit if necessary.
CHECK 4WD SHIFT INDICATOR PATTERN
1. Set 4WD shift switch to “2WD”, “4H”, “4LO”, “4H” and “2WD” in order. Stay at each switch position for at
least 2 seconds.
2. Confirm 4WD shift indicator lamp and 4LO indicator lamp are changed properly as follows.

SDIA3289E

• If OK, the position between transfer assembly and transfer control unit is correct.
• If NG, the position is different between transfer assembly and transfer control unit.
Adjust the position between transfer assembly and transfer control unit. Refer to pattern table below.
Transfer position adjustment pattern
4WD shift switch condition Refer procedure
"METHOD FOR ADJUSTMENT WITH 4WD SHIFT
4WD shift switch is under “2WD” condition when engine is being stopped.
SWITCH AT “2WD”"
"METHOD FOR ADJUSTMENT WITH 4WD SHIFT
4WD shift switch is under “4H” or “4LO” condition when engine is being stopped.
SWITCH AT “4H” OR “4LO”"
NOTE:
Method of adjustment can be chosen voluntarily, according to location of 4WD shift switch.

METHOD FOR ADJUSTMENT WITH 4WD SHIFT SWITCH AT “2WD”

Select Adjustment Pattern

Revision: 2008 January TF-4 D40

 PRECAUTIONS
< SERVICE INFORMATION >
1. Start engine. Run engine for at least 10 seconds.
2. Check 4WD shift indicator lamp and 4LO indicator lamp. A

Indicator lamp condition Refer procedure

B
When 4WD shift indicator lamp or 4LO indicator lamp is flashing. "Pattern A"
Except for above. "Pattern B"

Pattern A C
1. Stay in the below for at least 2 seconds.
• For A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed. TF
• For M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
2. Turn 4WD shift switch to “4LO” position. Stay in "4LO" for at least 2 seconds. E
3. Turn ignition switch “OFF”.
4. Start engine.
5. Erase self-diagnosis. Refer to TF-39, "CONSULT-III Function (ALL MODE AWD/4WD)" (with CONSULT- F
III) or TF-42, "Self-Diagnosis Procedure" (without CONSULT-III).
6. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to "CHECK 4WD SHIFT INDICATOR
PATTERN". G
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
Pattern B H
1. Stay in the below for at least 2 seconds.
• For A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed. I
• For M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
2. Turn ignition switch “OFF”. J
3. Start engine.
4. Erase self-diagnosis. Refer to TF-39, "CONSULT-III Function (ALL MODE AWD/4WD)" (with CONSULT-
III) or TF-42, "Self-Diagnosis Procedure" (without CONSULT-III). K
5. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to "CHECK 4WD SHIFT INDICATOR
PATTERN".
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con- L
trol unit and retry the above check.
METHOD FOR ADJUSTMENT WITH 4WD SHIFT SWITCH AT “4H” OR “4LO”
1. Start engine. Run the engine for at least 10 seconds. M
2. Stay in the below for at least 2 seconds.
• For A/T models, stop the vehicle and move A/T selector lever to “N” position with the brake pedal
depressed. N
• For M/T models, stop the vehicle and move M/T shift lever to the neutral position with the brake and
clutch pedal depressed.
3. Turn 4WD shift switch to “2WD” position. Stay in "2WD" for at least 2 seconds. O
4. Turn ignition switch “OFF”.
5. Start engine.
6. Erase self-diagnosis. Refer to TF-39, "CONSULT-III Function (ALL MODE AWD/4WD)" (with CONSULT- P
III) or TF-42, "Self-Diagnosis Procedure" (without CONSULT-III).
7. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to "CHECK 4WD SHIFT INDICATOR
PATTERN".
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.

Revision: 2008 January TF-5 D40

 PRECAUTIONS
< SERVICE INFORMATION >
Precaution INFOID:0000000002978581

• Before connecting or disconnecting the transfer control unit

harness connector, turn ignition switch “OFF” and disconnect
battery ground cable. Because battery voltage is applied to
transfer control unit even if ignition switch is turned “OFF”.

SEF289H

• When connecting or disconnecting pin connectors into or

from transfer control unit, take care not to damage pin termi-
nals (bend or break).
When connecting pin connectors make sure that there are not
any bends or breaks on transfer control unit pin terminals.

SEF291H

• Before replacing transfer control unit, perform transfer con-

trol unit input/output signal inspection and make sure
whether transfer control unit functions properly or not. Refer
to TF-33, "Transfer Control Unit Input/Output Signal Refer-
ence Value".

MEF040DB

Service Notice INFOID:0000000002978582

• After overhaul refill the transfer with new transfer fluid.

• Check the fluid level or replace the fluid only with the vehicle parked on level ground.
• During removal or installation, keep inside of transfer clear of dust or dirt.
• Disassembly should be done in a clean work area.
• Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal
parts from becoming contaminated by dirt or other foreign matter.
• Check for the correct installation status prior to removal or disassembly. If match marks are required, be cer-
tain they do not interfere with the function of the parts when applied.
• All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.
• Gaskets, seals and O-rings should replaced any time the transfer is disassembled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tight-
ening sequence is specified, use it.
• Observe the specified torque when assembling.
• Clean and flush the parts sufficiently and blow-dry them.
• Be careful not to damage sliding surfaces and mating surfaces.

Revision: 2008 January TF-6 D40

 PRECAUTIONS
< SERVICE INFORMATION >
• Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
with the operation of the transfer. A

TF

Revision: 2008 January TF-7 D40

 PREPARATION
< SERVICE INFORMATION >
PREPARATION
Special Service Tool INFOID:0000000002978583

Tool number
Description
Tool name
KV40104000 • Removing self-lock nut
Flange wrench • Installing self-lock nut
a: 85 mm (3.35 in)
b: 65 mm (2.56 in)

NT659

KV381054S0 • Removing front oil seal

Puller • Removing rear oil seal
• Removing metal bushing

ZZA0601D

KV38100500 • Installing front oil seal

Drift • Installing rear oil seal
a: 80 mm (3.15 in) dia. • Installing rear bearing
b: 60 mm (2.36 in) dia. • Installing front bearing

ZZA0811D

KV40105310 Installing dust cover

Drift
a: 89 mm (3.50 in) dia.
b: 80.7 mm (3.17 in) dia.

ZZA1003D

KV38100200 • Removing sun gear assembly and planetary

Drift carrier assembly
a: 65 mm (2.56 in) dia. • Removing input bearing
b: 49 mm (1.93 in) dia. • Installing sun gear assembly and planetary
carrier assembly

ZZA1143D

ST30720000 • Installing input bearing

Drift • Installing input oil seal
a: 77 mm (3.03 in) dia. • Installing carrier bearing
b: 55 mm (2.17 in) dia.

ZZA0811D

Revision: 2008 January TF-8 D40

 PREPARATION
< SERVICE INFORMATION >
Tool number
Description
Tool name A
KV32102700 Installing mainshaft rear bearing
Drift
a: 48 mm (1.89 in) dia. B
b: 41 mm (1.61 in) dia.

C
ZZA0534D

KV40104830 Installing input oil seal

Drift TF
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.50 in) dia.
E

ZZA1003D
F
ST35300000 • Removing carrier bearing
Drift • Installing metal bushing
a: 59 mm (2.32 in) dia. • Removing front bearing
b: 45 mm (1.77 in) dia. G

H
NT073

ST30021000 • Removing carrier bearing

Puller • Removing front bearing
• Removing rear bearing I

ZZA0537D

ST33710000 • Removing needle bearing K

Drift • Removing metal bushing
a: 89 mm (3.5 in) • Removing rear bearing
b: 30 mm (1.18 in) dia.
c: 24 mm (0.94 in) dia. L

ZZA1057D M
ST35325000 Removing metal bushing
Drift bar
a: 215 mm (8.46 in)
N
b: 25 mm (0.98 in) dia.
c: M12 × 1.5P

O
NT663

ST33220000 Installing needle bearing

Drift P
a: 37 mm (1.46 in) dia.
b: 31 mm (1.22 in) dia.
c: 22 mm (0.87 in) dia.

ZZA1046D

Revision: 2008 January TF-9 D40

 PREPARATION
< SERVICE INFORMATION >
Tool number
Description
Tool name
ST27863000 Installing carrier bearing
Drift
a: 75 mm (2.95 in) dia.
b: 62 mm (2.44 in) dia.

ZZA1003D

ST30901000 • Installing rear bearing

Drift • Installing front bearing
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.38 in) dia.

ZZA0978D

Commercial Service Tool INFOID:0000000002978584

Tool name Description

Puller • Removing companion flange
• Removing mainshaft rear bearing

NT077

Puller Removing mainshaft rear bearing

ZZB0823D

Pin punch Removing retaining pin

a: 6 mm (0.24 in) dia.

NT410

Revision: 2008 January TF-10 D40

 4WD SYSTEM
< SERVICE INFORMATION >
4WD SYSTEM
A
Cross-Section View INFOID:0000000002978585

TF

L
SDIA3288E

1. Mainshaft 2. Rear case 3. Oil pump assembly M

4. Clutch gear 5. 2-4 shift fork 6. 2-4 sleeve
7. Drive chain 8. Sprocket 9. L-H shift fork
10. L-H sleeve 11. Internal gear 12. Front case N
13. Planetary carrier assembly 14. Sun gear assembly 15. L-H shift rod
16. Control shift rod 17. Front revolution sensor 18. Companion flange
(A/T models) (Except for ABS models)
O
19. Front drive shaft 20. Control shift rod assembly 21. Transfer control device
(M/T models)
22. Speedometer drive gear
(Except for ABS models) P

Power Transfer INFOID:0000000002978586

POWER TRANSFER DIAGRAM

Revision: 2008 January TF-11 D40

 4WD SYSTEM
< SERVICE INFORMATION >

WDIA0223E

1. Mainshaft 2. Clutch gear 3. 2-4 sleeve

4. Drive chain 5. Sprocket 6. L-H sleeve
7. Planetary carrier assembly 8. Sun gear assembly 9. Front drive shaft

POWER TRANSFER FLOW

SDIA2213E

Revision: 2008 January TF-12 D40

 4WD SYSTEM
< SERVICE INFORMATION >
System Description INFOID:0000000002978587

A
TRANSFER CONTROL DEVICE
Actuator motor and actuator position switch are integrated. Transfer control device shifts from 4H⇔4LO and
between 2WD⇔4WD. B
Actuator Motor
Actuator motor is operated by signal from transfer control unit and it operates control shift rod so as to shift
from 4H⇔4LO and between 2WD⇔4WD. C
Actuator Position Switch
Actuator position switch detects actuator motor position and sends it to transfer control unit.
TF
WAIT DETECTION SWITCH
Wait detection switch detects if transfer gear is in 4WD by 2-4 shift fork position.
NOTE:
E
If 4WD shift switch is switched to 4H or 4LO, transfer is not in 4WD completely when gear does not engage.
(Wait detection system is operating.)
4LO SWITCH F
4LO switch detects if transfer gear is under 4LO condition by L-H shift fork position.
ATP SWITCH
ATP switch detects if transfer gear is under neutral condition by L-H shift fork position. G
NOTE:
Transfer gear may be under neutral condition when shifting between 4H⇔4LO.
TRANSFER CONTROL UNIT H
• Transfer control unit controls transfer control device by input signals of each sensor and each switch, and it
directs shifts from 4H⇔4LO and 2WD⇔4WD.
• Self-diagnosis can be done. I
TRANSFER SHIFT RELAY
Transfer shift high relay and transfer shift low relay apply power supply to transfer control device (actuator
motor). J
TRANSFER SHUT OFF RELAY
Transfer shut off relay 1 and transfer shut off relay 2 apply power supply to transfer control unit.
K
FRONT REVOLUTION SENSOR (EXCEPT FOR ABS MODELS)
Front revolution sensor detects a number of output revolution on the front side of transfer.
4WD SHIFT SWITCH AND INDICATOR LAMP L

Revision: 2008 January TF-13 D40

 4WD SYSTEM
< SERVICE INFORMATION >

SDIA3290E

4WD Shift Switch

4WD shift switch is able to select from 2WD, 4H or 4LO.
4WD Shift Indicator Lamp
• Displays driving conditions selected by 4WD shift switch with front, rear and center indicators, while engine
is running. (When shifting from 4H to 4LO, 4LO indicator lamp also turns on. And when 4WD warning lamp is
turned on, all 4WD shift indicator lamps are turned off.)
• Turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately 1 second
after the engine starts if system is normal.
4LO Indicator Lamp
• Displays 4LO condition while engine is running. 4LO indicator lamp flashes if transfer gear does not shift
completely under 4H⇔4LO. In this condition, transfer may be under neutral condition and A/T parking mech-
anism may not operate.
• Turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately 1 second
after the engine starts if system is normal.
4WD WARNING LAMP
Turns ON or flashes when there is a malfunction in 4WD system.
Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately 1 sec-
ond after the engine starts if system is normal.
4WD Warning Lamp Indication

Condition 4WD warning lamp

Turns ON when ignition switch is turned ON.
Lamp check
Turns OFF after engine start.
ON
4WD system malfunction
(For indicated malfunction items, see the “NOTE”)
During self-diagnosis Flashes at malfunction mode.
Large difference in diameter of front/ Slow flashing: 1 time/2 seconds
rear tires (Continues to flash until ignition switch is turned OFF)
Other than above (system normal) OFF
NOTE:

Revision: 2008 January TF-14 D40

 4WD SYSTEM
< SERVICE INFORMATION >
4WD warning lamp is turned on when the following one or more parts are malfunctioning.
• Vehicle speed signal A
[ABS models: from ABS actuator and electric unit (control unit), except for ABS models: from combination meter]
• CAN communication line
• AD converter B
• Engine speed signal
• 4WD shift switch
• Wait detection switch C
• Actuator motor
• Transfer control device
• Transfer shut off relay TF
• Transfer shift relay
• PNP switch signal

ATP WARNING LAMP (A/T MODELS) E

When A/T selector lever is in “P” position, vehicle may move because A/T parking mechanism does not oper-
ate when transfer is under neutral condition. ATP warning lamp is turned on to indicate this condition to the
driver. F
Schematic INFOID:0000000002978588

SDIA3291E N

COMPONENTS FUNCTION
O
Component parts Function
Transfer control unit Controls transfer control device and switches 4H⇔4LO under 4WD condition and 2WD⇔4WD.
Transfer control device Actuator motor and actuator position switch are integrated so as to switch driving modes. P
Actuator motor Controls shift rod by signals from transfer control unit.
Actuator position switch Detects actuator motor position.
Wait detection switch Detects that transfer is under 4WD condition.
4LO switch Detects that transfer is under 4LO condition.

Revision: 2008 January TF-15 D40

 4WD SYSTEM
< SERVICE INFORMATION >
Component parts Function
ATP switch
Detects that transfer is under neutral condition.
(A/T models)
4WD shift switch Able to select from 2WD, 4H or 4LO.
• Illuminates if malfunction is detected in electrical system of 4WD system.
4WD warning lamp
• There is 1 blink in 2 seconds if rotation difference of front wheels and rear wheels is large.
ATP warning lamp Indicates that A/T parking mechanism does not operate when A/T selector lever is in “P” position and
(A/T models) transfer is under neutral condition.
4WD shift indicator lamp Displays driving condition selected by 4WD shift switch.
4LO indicator lamp Displays 4LO condition.
PNP switch
Detects that manual transmission is under neutral condition.
(M/T models)
Transmits the following signals via CAN communication to Transfer control unit.
ABS actuator and electric unit
• Vehicle speed signal
(control unit)
• Stop lamp switch signal (brake signal)
Transmits the following signal via CAN communication to Transfer control unit.
TCM
• Output shaft revolution signal
(A/T models)
• A/T position indicator signal (PNP switch signal)
Transmits engine speed signal via CAN communication to Transfer control unit.
ECM
• Engine speed signal
Combination meter Transmits the following signals via CAN communication to Transfer control unit.
(Except for ABS models) • Vehicle speed signal

Revision: 2008 January TF-16 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
TROUBLE DIAGNOSIS
A
Location of Electrical Parts INFOID:0000000002978589

A/T MODELS B

TF

SDIA3587E

M/T MODELS

Revision: 2008 January TF-17 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

SDIA3588E

Circuit Diagram INFOID:0000000002978590

A/T MODELS

Revision: 2008 January TF-18 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TF

TDWB0099E

P
M/T MODELS

Revision: 2008 January TF-19 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TDWB0100E

Wiring Diagram - T/F - INFOID:0000000002978591

A/T MODELS

Revision: 2008 January TF-20 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TF

TDWB0101E

Revision: 2008 January TF-21 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TDWB0102E

Revision: 2008 January TF-22 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TF

TDWB0103E

Revision: 2008 January TF-23 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TDWB0104E

Revision: 2008 January TF-24 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TF

TDWB0105E

Revision: 2008 January TF-25 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TDWB0106E

M/T MODELS

Revision: 2008 January TF-26 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TF

TDWB0108E

Revision: 2008 January TF-27 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TDWB0109E

Revision: 2008 January TF-28 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TF

TDWB0110E

Revision: 2008 January TF-29 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TDWB0111E

Revision: 2008 January TF-30 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TF

TDWB0112E

Revision: 2008 January TF-31 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TDWB0113E

Revision: 2008 January TF-32 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TF

TDWB0114E

P
Transfer Control Unit Input/Output Signal Reference Value INFOID:0000000002978592

TRANSFER CONTROL UNIT INSPECTION TABLE

Specifications with CONSULT-III

Revision: 2008 January TF-33 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

Monitored item [Unit] Content Condition Display value

Vehicle stopped 0 km/h (0 mph)

VHCL/S SEN·FR [km/h] Vehicle running Approximately

Wheel speed (Front wheel) CAUTION: equal to the indica-
or [mph]
Check air pressure of tire under standard condi- tion on speedome-
tion. ter (Inside of ±10%)
Vehicle stopped 0 km/h (0 mph)

VHCL/S SEN·RR [km/h] Vehicle running Approximately

Wheel speed (Rear wheel) CAUTION: equal to the indica-
or [mph]
Check air pressure of tire under standard condi- tion on speedome-
tion. ter (Inside of ±10%)
Engine stopped
0 rpm
(Engine speed: Less than 400 rpm)
ENGINE SPEED [rpm] Engine speed Approximately
Engine running
equal to the indica-
(Engine speed: 400 rpm or more)
tion on tachometer
Power supply voltage for
BATTERY VOLT [V] Ignition switch: ON Battery voltage
transfer control unit

Input condition from 4WD 4WD shift switch: 2WD ON

2WD SWITCH [ON/OFF]
shift switch 4WD shift switch: 4H and 4LO OFF

Input condition from 4WD 4WD shift switch: 4H ON

4H SWITCH [ON/OFF]
shift switch 4WD shift switch: 2WD and 4LO OFF

Input condition from 4WD 4WD shift switch: 4LO ON

4L SWITCH [ON/OFF]
shift switch 4WD shift switch: 2WD and 4H OFF
• Vehicle stopped 4WD shift switch: 4LO ON
• Engine running
• For A/T models, A/T se-
lector lever “N” position
with brake pedal de-
4L POSI SW [ON/OFF] Condition of 4LO switch
pressed. Except the above OFF
• For M/T models, M/T
shift lever neutral posi-
tion with clutch and
brake pedal depressed.

• Vehicle stopped 4WD shift switch:

• Engine running 4H to 4LO or 4LO to 4H
ON
ATP SWITCH [ON/OFF] Condition of ATP switch • A/T selector lever “N” (While actuator motor is
position with brake ped- operating.)
al depressed. Except the above OFF
• Vehicle stopped 4WD shift switch:
ON
• Engine running 4H and 4LO
• For A/T models, A/T se-
lector lever “N” position
WAIT DETCT SW [ON/ Condition of wait detection with brake pedal de-
OFF] switch pressed.
• For M/T models, M/T 4WD shift switch: 2WD OFF
shift lever neutral posi-
tion with clutch and
brake pedal depressed.
Control status of 4WD 2WD 2H
(Output condition of 4WD 4WD shift switch
4WD MODE [2H/4H/4L] 4H 4H
shift indicator lamp and (Engine running)
4LO indicator lamp) 4LO 4L

Revision: 2008 January TF-34 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Monitored item [Unit] Content Condition Display value
A
Vehicle stopped 0 km/h (0 mph)

VHCL/S COMP [km/h] or Vehicle running Approximately

Vehicle speed CAUTION: equal to the indica-
[mph]
Check air pressure of tires under standard condi- tion on speedome- B
tion. ter (Inside of ±10%)
• Vehicle stopped 4WD shift switch:
• Engine running 2WD to 4H or 4H to 4LO ON C
• For A/T models, A/T se- or 2WD to 4LO
lector lever “N” position
Output condition to actua- with brake pedal de-
SHIFT ACT 1 [ON/OFF] TF
tor motor (clockwise) pressed.
• For M/T models, M/T Except the above OFF
shift lever neutral posi-
tion with clutch and
brake pedal depressed. E
• Vehicle stopped 4WD shift switch:
• Engine running 2WD to 4H or 4H to 4LO ON
• For A/T models, A/T se- or 2WD to 4LO F
lector lever “N” position
SHIFT AC MON1 [ON/ Check signal for transfer with brake pedal de-
OFF] control unit signal output pressed.
• For M/T models, M/T Except the above OFF
G
shift lever neutral posi-
tion with clutch and
brake pedal depressed.
H
• Vehicle stopped 4WD shift switch:
• Engine running 4LO to 4H or 4H to 2WD ON
• For A/T models, A/T se- or 4LO to 2WD
lector lever “N” position I
Output condition to actua-
with brake pedal de-
SHIFT ACT 2 [ON/OFF] tor motor (counterclock-
pressed.
wise)
• For M/T models, M/T Except the above OFF
shift lever neutral posi- J
tion with clutch and
brake pedal depressed.
• Vehicle stopped 4WD shift switch: K
• Engine running 4LO to 4H or 4H to 2WD ON
• For A/T models, A/T se- or 4LO to 2WD
lector lever “N” position
SHIFT AC MON2 [ON/ Check signal for transfer with brake pedal de- L
OFF] control unit signal output pressed.
• For M/T models, M/T Except the above OFF
shift lever neutral posi-
tion with clutch and
M
brake pedal depressed.
• Vehicle stopped When 4WD shift switch is
ON N
• Engine running operated
• For A/T models, A/T se-
lector lever “N” position
Operating condition of ac-
SHIFT ACT/R MON [ON/ with brake pedal de-
tuator motor relay (integrat- O
OFF] pressed. When 4WD shift switch is
ed in transfer control unit) OFF
• For M/T models, M/T not operated
shift lever neutral posi-
tion with clutch and
P
brake pedal depressed.

Revision: 2008 January TF-35 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Monitored item [Unit] Content Condition Display value
4WD shift switch:
SHIFT POS SW1 [ON/ Condition of actuator posi- ON
2WD and 4LO
OFF] tion switch 1
• Vehicle stopped 4WD shift switch: 4H OFF
• Engine running 4WD shift switch: 4LO ON
SHIFT POS SW2 [ON/ Condition of actuator posi- • For A/T models, A/T se-
OFF] tion switch 2 lector lever “N” position 4WD shift switch:
OFF
with brake pedal de- 2WD and 4H
pressed. 4WD shift switch:
SHIFT POS SW3 [ON/ Condition of actuator posi- • For M/T models, M/T ON
2WD and 4H
OFF] tion switch 3 shift lever neutral posi-
tion with clutch and 4WD shift switch: 4LO OFF
brake pedal depressed. 4WD shift switch:
SHIFT POS SW4 [ON/ Condition of actuator posi- ON
4H and 4LO
OFF] tion switch 4
4WD shift switch: 2WD OFF

4WD FAIL LAMP [ON/ 4WD warning lamp condi- 4WD warning lamp: ON ON
OFF] tion 4WD warning lamp: OFF OFF

Rear indicator of 4WD shift Rear indicator of 4WD shift indicator lamp: ON ON
2WD IND [ON/OFF]
indicator lamp condition Rear indicator of 4WD shift indicator lamp: OFF OFF
Front and center indicator of 4WD shift indicator lamp:
Front and center indicator ON
ON
4H IND [ON/OFF] of 4WD shift indicator lamp
condition Front and center indicator of 4WD shift indicator lamp:
OFF
OFF

4LO indicator lamp condi- 4LO indicator lamp: ON ON

4L IND [ON/OFF]
tion 4LO indicator lamp: OFF OFF

Specifications Between Transfer Control Unit Terminals

TRANSFER CONTROL UNIT TERMINAL CONNECTOR LAYOUT

SDIA3402E

NOTE:
Data are reference value and are measured between each terminal and ground.

Wire
Terminal Item Condition Data (Approx.)
color
1 L CAN-H – –
2 P CAN-L – –
3 SB K-LINE (CONSULT-III signal) – –
Approx. 1 V [30
5
km/h (19 MPH)]
(Except 4WD shift switch:
W Front revolution sensor (+) Vehicle running Voltage rises in
for ABS 4H
response to ve-
models)
hicle speed.
6 B Ground Always 0V
7
(Except
B Front revolution sensor (-) Ignition switch: ON Less than 1 V
for ABS
models)

Revision: 2008 January TF-36 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Wire
Terminal Item Condition Data (Approx.)
color A
• Vehicle stopped 4WD shift switch: 2WD and 4LO 0V
10 GR Actuator position switch 1 • Engine running
4WD shift switch: 4H Battery voltage
• For A/T models, B
A/T selector le- 4WD shift switch: 4LO 0V
11 W Actuator position switch 2 ver “N” position
4WD shift switch: 2WD and 4H Battery voltage
with brake pedal
depressed. 4WD shift switch: 2WD and 4H 0V C
12 Y Actuator position switch 3 • For M/T models, 4WD shift switch: 4LO Battery voltage
M/T shift lever
neutral position 4WD shift switch: 4H and 4LO 0V
with clutch and TF
13 L Actuator position switch 4
brake pedal de- 4WD shift switch: 2WD Battery voltage
pressed.
4WD shift switch: 2WD Battery voltage E
14 G 4WD shift switch (2WD)
4WD shift switch: 4H and 4LO 0V
4WD shift switch: 4H Battery voltage
15 O 4WD shift switch (4H) Ignition switch: ON F
4WD shift switch: 2WD and 4LO 0V
4WD shift switch: 4LO Battery voltage
16 SB 4WD shift switch (4LO)
4WD shift switch: 2WD and 4H 0V G
• Vehicle stopped 4WD shift switch: 4H and 4LO 0V
• Engine running
• For A/T models,
A/T selector le- H
ver “N” position
with brake pedal
17 V Wait detection switch depressed.
4WD shift switch: 2WD Battery voltage I
• For M/T models,
M/T shift lever
neutral position
with clutch and J
brake pedal de-
pressed.
18 B Ground Always 0V
K
Power supply Ignition switch: ON
19 G Battery voltage
(Memory back-up) Ignition switch: OFF
• Vehicle stopped 4WD shift switch: L
• Engine running 4H to 4LO or 4LO to 4H 0V
• For A/T models, (While actuator motor is operating.)
A/T selector le-
ver “N” position M
with brake pedal
23 R ATP switch depressed.
• For M/T models,
Except the above Battery voltage N
M/T shift lever
neutral position
with clutch and
brake pedal de- O
pressed.

Revision: 2008 January TF-37 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Wire
Terminal Item Condition Data (Approx.)
color
• Vehicle stopped 4WD shift switch: 4LO 0V
• Engine running
• For A/T models,
A/T selector le-
ver “N” position
with brake pedal
24 BR 4LO switch depressed.
• For M/T models, Except the above Battery voltage
M/T shift lever
neutral position
with clutch and
brake pedal de-
pressed.
Ignition switch: ON Battery voltage
25 LG Ignition switch monitor
Ignition switch: OFF 0V
Ignition switch: ON Battery voltage
27 L Actuator motor power supply Ignition switch: OFF
0V
(5 seconds after ignition switch is turned OFF)
• Vehicle stopped When 4WD shift switch is operated (while Battery voltage
28 SB Actuator motor (+) • Engine running actuator motor is operating) →0V
• For A/T models,
When 4WD shift switch is not operated 0V
A/T selector le-
ver “N” position
with brake pedal
depressed.
• For M/T models,
31 W Actuator motor (-) M/T shift lever Always 0V
neutral position
with clutch and
brake pedal de-
pressed.
32 B Ground Always 0V
33 M/T shift lever neutral position 0V
(For M/T P Park/neutral position switch Ignition switch: ON
models) Except the above Battery voltage

Rear indicator of 4WD shift indicator

0V
4WD shift indicator lamp lamp: ON
35 V
(Rear indicator) Rear indicator of 4WD shift indicator
Battery voltage
lamp: OFF
Front and center indicator of 4WD shift in-
0V
4WD shift indicator lamp dicator lamp: ON
36 BR
(Front and center indicator) Engine running Front and center indicator of 4WD shift in-
Battery voltage
dicator lamp: OFF
4LO indicator lamp: ON 0V
37 L 4LO indicator lamp
4LO indicator lamp: OFF Battery voltage
4WD warning lamp: ON 0V
38 GR 4WD warning lamp
4WD warning lamp: OFF Battery voltage
• Vehicle stopped 4WD shift switch:
• Engine running 4H to 4LO or 4LO to 4H Battery voltage
39
• A/T selector le- (While actuator motor is operating.)
(For A/T LG ATP warning lamp
ver “P” position
models)
• Brake pedal de- Except the above 0V
pressed
Ignition switch: ON 0V
40 SB Transfer shut off relay Ignition switch: OFF
Battery voltage
(5 seconds after ignition switch is turned OFF)

Revision: 2008 January TF-38 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Wire
Terminal Item Condition Data (Approx.)
color A
• Vehicle stopped 4WD shift switch:
0V
• Engine running 2WD to 4H or 4H to 4LO or 2WD to 4LO
• For A/T models, B
A/T selector le-
ver “N” position
with brake pedal
42 G Transfer shift high relay depressed. C
• For M/T models, Except the above Battery voltage
M/T shift lever
neutral position
with clutch and TF
brake pedal de-
pressed.
Ignition switch: ON Battery voltage E
44 G Power supply Ignition switch: OFF
0V
(5 seconds after ignition switch is turned OFF)
Ignition switch: ON Battery voltage F
45 GR Power supply Ignition switch: OFF
0V
(5 seconds after ignition switch is turned OFF)

• Vehicle stopped 4WD shift switch: G

Battery voltage
Transfer shift high relay moni- • Engine running 2WD to 4H or 4H to 4LO or 2WD to 4LO
47 O →0V
tor • For A/T models, (while actuator motor is operating)
A/T selector le- Except the above 0V H
ver “N” position
with brake pedal 4WD shift switch:
Battery voltage
Transfer shift low relay moni- depressed. 4LO to 4H or 4H to 2WD or 4LO to 2WD
48 R →0V
tor • For M/T models, (while actuator motor is operating)
I
M/T shift lever Except the above 0V
neutral position
with clutch and 4WD shift switch:
0V
50 Y Transfer shift low relay brake pedal de- 4LO to 4H or 4H to 2WD or 4LO to 2WD J
pressed. Except the above Battery voltage
CAUTION:
When using a circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals. K

CONSULT-III Function (ALL MODE AWD/4WD) INFOID:0000000002978593

L
FUNCTION
CONSULT-III can display each diagnostic item using the diagnostic test modes shown following.
M
Diagnostic test mode Function
Self-diagnostic results • Self-diagnostic results can be read and erased quickly.
Data monitor • Input/Output data in the transfer control unit can be read. N
CAN diagnostic support monitor • The results of transmit/receive diagnosis of CAN communication can be read.

SELF-DIAG RESULT MODE O

Display Item List

Items (CONSULT-III P
Diagnostic item is detected when... Check item
screen terms)
• Check transfer control unit power
*INITIAL START* Due to removal of battery which cuts off power supply to transfer supply
[P1801] control unit, self-diagnosis memory function is suspended. • Check transfer control unit ground
• Check transfer shut off relay 1, 2
CONTROL UNIT 1 Malfunction is detected in the memory (RAM) system of transfer
• Replace transfer control unit
[P1802] control unit.

Revision: 2008 January TF-39 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Items (CONSULT-III
Diagnostic item is detected when... Check item
screen terms)
CONTROL UNIT 2 Malfunction is detected in the memory (ROM) system of transfer
• Replace transfer control unit
[P1803] control unit.
CONTROL UNIT 3 Malfunction is detected in the memory (EEPROM) system of trans-
• Replace transfer control unit
[P1804] fer control unit.
• Malfunction is detected in output shaft revolution signal that is
VHCL SPEED SEN·AT • Perform self-diagnosis with TCM
output from TCM through CAN communication.
[P1807] • Check transfer control unit
• Improper signal is input while driving.
• Malfunction is detected in vehicle speed signal that is output from
• Perform self-diagnosis with ABS ac-
VHCL SPEED SEN·ABS ABS actuator and electric unit (control unit) through CAN com-
tuator and electric unit (control unit)
[P1808] munication.
• Check transfer control unit
• Improper signal is input while driving.
CONTROL UNIT 4
AD converter system of transfer control unit is malfunctioning. • Replace transfer control unit
[P1809]
• Check 4LO switch
4L POSI SW TF Improper signal from 4LO switch is input due to open or short cir-
• Check 4LO switch circuit
[P1810] cuit.
• Check transfer control unit
• Check transfer control unit power
BATTERY VOLTAGE Power supply voltage for transfer control unit is abnormally low supply
[P1811] while driving. • Check transfer control unit ground
• Check transfer shut off relay 1, 2
• Check 4WD shift switch
4WD MODE SW More than two switch inputs are simultaneously detected due to
• Check 4WD shift switch circuit
[P1813] short circuit of 4WD shift switch.
• Check transfer control unit
• Check wait detection switch
4WD DETECT SWITCH Improper signal from wait detection switch is input due to open or
• Check wait detection switch circuit
[P1814] short circuit.
• Check transfer control unit
PNP SW/CIRC When A/T PNP switch signal is malfunction or communication error • Perform self-diagnosis with TCM
[P1816] between the vehicles. • Check transfer control unit
• Motor does not operate properly due to open or short circuit in
• Check actuator motor
actuator motor.
• Check actuator motor circuit
SHIFT ACTUATOR • Malfunction is detected in the actuator motor. (When 4WD shift
• Check transfer relay
[P1817] switch is operated and actuator motor is not operated)
• Check transfer relay circuit
• Malfunction is detected in transfer shift high relay and transfer
• Check transfer control unit
shift low relay.
• Improper signal from actuator position switch is input due to open • Check actuator position switch cir-
SHIFT ACT POSI SW
or short circuit. cuit
[P1818]
• Malfunction is detected in actuator position switch. • Check transfer control unit
• Check transfer control unit power
• Malfunction is detected in transfer shut off relay 1 and transfer supply
SHIFT ACT CIR
shut off relay 2. • Check transfer control unit ground
[P1819]
• Malfunction occurs in transfer control device drive circuit. • Check transfer shut off relay 1, 2
• Check transfer control unit
• Malfunction is detected in engine speed signal that is output from
ENGINE SPEED SIG • Perform self-diagnosis with ECM
ECM through CAN communication.
[P1820] • Check transfer control unit
• Improper signal is input while driving.
• Check front revolution sensor
VHCL SPEED SEN FR • Malfunction is detected in front revolution sensor.
• Check front revolution sensor circuit
[P1854] • Improper signal is input while driving.
• Check transfer control unit
• Malfunction is detected in vehicle speed signal that is output from • Perform self-diagnosis with combi-
VHCL SPEED SEN RR
combination meter through CAN communication. nation meter
[P1855]
• Improper signal is input while driving. • Check transfer control unit
CAN COMM CIRCUIT When transfer control unit is not transmitting or receiving CAN
• Check CAN communication line
[U1000] communication signal for 2 seconds or more.
NO DTC IS DETECTED.
FURTHER TESTING No NG item has been detected. —
MAY BE REQUIRED.

Revision: 2008 January TF-40 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
CAUTION:
If “CAN COMM CIRCUIT [U1000]” is displayed with other DTCs, first perform the trouble diagnosis for CAN communication A
line.
NOTE:
If “SHIFT ACT POSI SW [P1818]” or “SHIFT ACT CIR [P1819]” is displayed, first erase self-diagnostic results. (“SHIFT ACT POSI SW B
[P1818]” or “SHIFT ACT CIR [P1819]” may be displayed after installing transfer control unit or transfer assembly.)

DATA MONITOR MODE

C
Display Item List
×: Standard : Optional Item

Monitor item selection TF

Monitored item (Unit) ECU INPUT MAIN Remarks
SIGNALS SIGNALS
For ABS models, wheel speed calculated by ABS actuator E
and electric unit (control unit). Signal input with CAN commu-
VHCL/S SEN·FR [km/h] or [mph] × nication line.
Except for ABS models, wheel speed calculated by front rev-
F
olution sensor.
For ABS models, wheel speed calculated by TCM. Signal in-
put with CAN communication line.
VHCL/S SEN·RR [km/h] or [mph] × G
Except for ABS models, wheel speed calculated by combina-
tion meter. Signal input with CAN communication line.
Engine speed is displayed.
ENGINE SPEED [rpm] × H
Signal input with CAN communication line.

BATTERY VOLT [V] × Power supply voltage for transfer control unit.

2WD SWITCH [ON/OFF] × I

4WD shift switch signal status is displayed.
4H SWITCH [ON/OFF] ×
(4L means 4LO of 4WD shift switch.)
4L SWITCH [ON/OFF] × J
This means 4LO switch.
4L POSI SW [ON/OFF] ×
4LO switch signal status is displayed.

ATP SWITCH [ON/OFF] × ATP switch signal status is displayed. K

WAIT DETCT SW [ON/OFF] × Wait detection switch signal status is displayed.

Control status of 4WD recognized by transfer control unit. L

4WD MODE [2H/4H/4L] ×
(2WD, 4H or 4LO)
VHCL/S COMP [km/h] or [mph] × Vehicle speed recognized by transfer control unit.

SHIFT ACT 1 [ON/OFF] × Output condition to actuator motor (clockwise) M

SHIFT AC MON 1 [ON/OFF] Check signal for transfer control unit signal output

SHIFT ACT 2 [ON/OFF] × Output condition to actuator motor (counterclockwise) N

SHIFT AC MON 2 [ON/OFF] Check signal for transfer control unit signal output
Operating condition of actuator motor relay (integrated in O
SFT ACT/R MON [ON/OFF]
transfer control unit)

SHIFT POS SW 1 [ON/OFF] × Condition of actuator position switch 1

SHIFT POS SW 2 [ON/OFF] × Condition of actuator position switch 2 P

SHIFT POS SW 3 [ON/OFF] × Condition of actuator position switch 3

SHIFT POS SW 4 [ON/OFF] × Condition of actuator position switch 4

4WD FAIL LAMP [ON/OFF] × Control status of 4WD warning lamp is displayed.

2WD IND [ON/OFF] Control status of 4WD shift indicator lamp (rear) is displayed.

Revision: 2008 January TF-41 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Monitor item selection
Monitored item (Unit) ECU INPUT MAIN Remarks
SIGNALS SIGNALS
Control status of 4WD shift indicator lamp (front and center)
4H IND [ON/OFF]
is displayed.

4L IND [ON/OFF] Control status of 4LO indicator lamp is displayed.

Voltage [V] The value measured by the voltage probe is displayed.

Frequency [Hz]

DUTY-HI (high) [%]

DUTY-LOW (low) [%] The value measured by the pulse probe is displayed.

PLS WIDTH-HI [msec]

PLS WIDTH-LOW [msec]

Self-Diagnosis Procedure INFOID:0000000002978594

SELF-DIAGNOSTIC PROCEDURE (WITH CONSULT-III)

Refer to TF-39, "CONSULT-III Function (ALL MODE AWD/4WD)".
SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-III)
Description
If the engine starts when there is something wrong with the 4WD system, the 4WD warning lamp turns ON or
flickers in the combination meter. When the system functions properly, the warning lamp turns ON when the
ignition switch is turned to “ON”, and it turns OFF after engine starts. To begin trouble diagnosis, start the self-
diagnosis function. The 4WD warning lamp in the combination meter will flicker according to the self-diagnos-
tic results. As for the details of the 4WD warning lamp flickering patterns, refer to "Diagnostic Procedure (A/T
models)", "Diagnostic Procedure (M/T models)".
Diagnostic Procedure (A/T models)
1. Warm up engine.
2. Turn ignition switch “ON” and “OFF” at least twice, and then turn ignition switch “OFF”.
3. Move A/T selector lever to “P” position.
4. Turn 4WD shift switch to “2WD” position.
5. Turn ignition switch “ON”. (Do not start engine.)
6. 4WD warning lamp ON.
If 4WD warning lamp does not turn ON, refer to TF-45, "Trouble Diagnosis Chart by Symptom".
7. Move A/T selector lever to “R” position.
8. Turn 4WD shift switch to “2WD”, “4H” and “2WD” in order.
9. Move A/T selector lever to “P” position.
10. Turn 4WD shift switch to “4H”, “2WD” and “4H” in order.
11. Move A/T selector lever to “N” position.
12. Turn 4WD shift switch to “2WD” position.
13. Move A/T selector lever to “P” position.
14. Read the flickering of 4WD warning lamp.
Refer to "Judgment self-diagnosis".
Diagnostic Procedure (M/T models)
1. Warm up engine.
2. Turn ignition switch “ON” and “OFF” at least twice, and then turn ignition switch “OFF”.
3. Move M/T shift lever to neutral position.
4. Turn 4WD shift switch to “2WD” position.
5. Turn ignition switch “ON”. (Do not start engine.)

Revision: 2008 January TF-42 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
6. 4WD warning lamp ON.
If 4WD warning lamp does not turn ON, refer to TF-45, "Trouble Diagnosis Chart by Symptom". A
7. Move M/T shift lever to any position other than neutral.
8. Turn 4WD shift switch to “2WD”, “4H” and “2WD” in order.
9. Move M/T shift lever to neutral position. B
10. Turn 4WD shift switch to “4H”, “2WD” and “4H” in order.
11. Move M/T shift lever to any position other than neutral.
C
12. Turn 4WD shift switch to “2WD” position.
13. Move M/T shift lever to neutral position.
14. Read the flickering of 4WD warning lamp. TF
Refer to "Judgment self-diagnosis".
Judgment Self-diagnosis
When a malfunction is detected, the malfunction route is indicated by flickering of the 4WD warning lamp. E

H
PDIA0227E

Flickering I
Items Diagnostic item is detected when... Check item
pattern
• Check front revolution sensor
Vehicle speed signal
1 (from front revolution
• Malfunction is detected in front revolution sensor. • Check front revolution sensor J
• Improper signal is input while driving. circuit
sensor)
• Check transfer control unit
• Malfunction is detected in output shaft revolution sig- K
• Perform self-diagnosis with
Output shaft revolution nal that is output from TCM through CAN communica-
2 TCM
signal (from TCM) tion.
• Check transfer control unit
• Improper signal is input while driving.
Vehicle speed signal • Malfunction is detected in vehicle speed signal that is • Perform self-diagnosis with L
[from ABS actuator and output from ABS actuator and electric unit (control ABS actuator and electric unit
3
electric unit (control unit) through CAN communication. (control unit)
unit)] • Improper signal is input while driving. • Check transfer control unit
M
When transfer control unit is not transmitting or receiving • Check CAN communication
4 CAN communication
CAN communication signal for 2 seconds or more. line
AD converter system of transfer control unit is malfunc- N
5 AD converter • Replace transfer control unit
tioning.
• Check 4LO switch
Improper signal from 4LO switch is input due to open or
6 4LO switch • Check 4LO switch circuit
short circuit. O
• Check transfer control unit
• Malfunction is detected in engine speed signal that is • Perform self-diagnosis with
Engine speed signal
7 output from ECM through CAN communication. ECM
(from ECM)
• Improper signal is input while driving. • Check transfer control unit P
• Check transfer control unit
power supply
Power supply voltage for transfer control unit is abnor- • Check transfer control unit
8 Power supply
mally low while driving. ground
• Check transfer shut off relay 1,
2

Revision: 2008 January TF-43 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Flickering
Items Diagnostic item is detected when... Check item
pattern
• Check 4WD shift switch
More than two switch inputs are simultaneously detect-
9 4WD shift switch • Check 4WD shift switch circuit
ed due to short circuit of 4WD shift switch.
• Check transfer control unit
• Check wait detection switch
Improper signal from wait detection switch is input due • Check wait detection switch
10 Wait detection switch
to open or short circuit. circuit
• Check transfer control unit
• Motor does not operate properly due to open or short
circuit in actuator motor. • Check actuator motor
• Malfunction is detected in the actuator motor. (When • Check actuator motor circuit
11 Actuator motor 4WD shift switch is operated and actuator motor is not • Check transfer relay
operated.) • Check transfer relay circuit
• Malfunction is detected in transfer shift high relay and • Check transfer control unit
transfer shift low relay.
• Improper signal from actuator position switch is input • Check actuator position switch
12 Actuator position switch due to open or short circuit. circuit
• Malfunction is detected in the actuator position switch. • Check transfer control unit
• Check transfer control unit
power supply
• Malfunction is detected in transfer shut off relay 1 and
• Check transfer control unit
transfer shut off relay 2.
13 Transfer control device ground
• Malfunction occurs in transfer control device drive cir-
• Check transfer shut off relay 1,
cuit.
2
• Check transfer control unit
• Perform self-diagnosis with
When A/T PNP switch signal is malfunction or commu-
14 PNP switch signal TCM
nication error between the vehicles.
• Check transfer control unit
• Malfunction is detected in vehicle speed signal that is
Vehicle speed signal • Perform self-diagnosis with
output from combination meter through CAN commu-
15 (from combination combination meter
nication.
meter) • Check transfer control unit
• Improper signal is input while driving.
• Check transfer control unit
power supply
Repeats flick- • Power supply malfunction of memory back-up.
• Check transfer control unit
ering every Data erase display • Battery is disconnected for a long time.
ground
0.25 sec. • Battery performance is poor.
• Check transfer shut off relay 1,
2
Repeats flick-
Circuits that the self-diagnosis covers have no malfunc-
ering every 2 — —
tion.
to 5 sec.
• Perform self-diagnosis with
TCM
PNP switch or 4WD shift PNP switch or 4WD shift switch circuit is shorted or
No flickering • Check 4WD shift switch
switch open.
• Check 4WD shift switch circuit
• Check transfer control unit
NOTE:
If flickering pattern 12 or 13 is displayed, first erase self-diagnostic results. Flickering pattern 12 or 13 may be displayed after installing
transfer control unit or transfer assembly.

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 ignition switch “OFF” after performing self-diagnostics or by
erasing the memory using the CONSULT-III.

Revision: 2008 January TF-44 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Trouble Diagnosis Chart by Symptom INFOID:0000000002978595

A
If 4WD warning lamp turns ON, perform self-diagnosis. Refer to TF-42, "Self-Diagnosis Procedure".
Symptom Condition Check item
4WD shift indicator lamp and 4LO indicator Power supply and ground for transfer control unit B
lamp do not turn ON
Ignition switch: ON Transfer shut off relay
(4WD shift indicator lamp and 4LO indicator
lamp check) Combination meter
C
Power supply and ground for transfer control unit
4WD warning lamp does not turn ON
Ignition switch: ON Transfer shut off relay
(4WD warning lamp check)
Combination meter TF
4WD shift switch
Wait detection switch
4WD shift indicator lamp or 4LO indicator lamp E
Engine running 4LO switch
does not change
ATP switch
Transfer inner parts F
CAN communication line
4WD shift switch
PNP switch signal G
ATP warning lamp does not turn ON Engine running
ATP switch
Combination meter
H
Transfer inner parts
Wait detection switch
4WD shift indicator lamp repeats flashing Engine running 4LO switch I
Transfer inner parts
4WD warning lamp flashes slowly
While driving Tire size is different between front and rear of vehicle. J
Slow flashing: 1 time/2 seconds

Component Inspection INFOID:0000000002978596

K
TRANSFER SHUT OFF RELAY 1, 2
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Remove transfer shut off relay 1 and transfer shut off relay 2. Refer to TF-17, "Location of Electrical L
Parts".
3. Apply 12V direct current between transfer shut off relay termi-
nals 1 and 2. M
4. Check continuity between relay terminals 3 and 5.

Condition Continuity
N

12V direct current supply between terminals 1 and 2 Yes

OFF No
O
5. If NG, replace transfer shut off relay 1 or transfer shut off relay 2.
Refer to TF-17, "Location of Electrical Parts".
SCIA1245E
P
4LO SWITCH
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Disconnect 4LO switch harness connector.
3. Remove 4LO switch. Refer to TF-17, "Location of Electrical Parts".

Revision: 2008 January TF-45 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
4. Push and release 4LO switch and check continuity between
4LO switch terminals 12 and 13.

Terminal Condition Continuity

Push 4LO switch Yes
12 - 13
Release 4LO switch No
5. If NG, replace the 4LO switch. Refer to TF-17, "Location of Elec-
trical Parts".

PDIA0204E

4WD SHIFT SWITCH

1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Remove 4WD shift switch harness connector.
3. Operate 4WD shift switch and check continuity between 4WD
shift switch terminals.

Terminal Condition Continuity

4WD shift switch: 2WD Yes
1-3
4WD shift switch: 4H and 4LO No
4WD shift switch: 4H Yes
1-5
4WD shift switch: 2WD and 4LO No
4WD shift switch: 4LO Yes SDIA2805E
1-6
4WD shift switch: 2WD and 4H No
4. If NG, replace the 4WD shift switch.
WAIT DETECTION SWITCH
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Disconnect wait detection switch harness connector.
3. Remove wait detection switch. Refer to TF-17, "Location of Electrical Parts".
4. Push and release wait detection switch and check continuity
between wait detection switch terminals 10 and 11.

Terminal Condition Continuity

Push wait detection switch Yes
10 - 11
Release wait detection switch No
5. If NG, replace the wait detection switch. Refer to TF-17, "Loca-
tion of Electrical Parts".

PDIA0208E

ACTUATOR MOTOR
1. Remove transfer control device. Refer to TF-54, "Removal and Installation".
2. Check operation by applying battery voltage to transfer control
device (actuator motor) terminals 23 and 24.
CAUTION:
Be careful not to overheat the harness.

Terminal Actuator motor

24 (Battery voltage) - 23 (Ground) Clockwise rotate
23 (Battery voltage) - 24 (Ground) Counterclockwise rotate

SDIA2386E

Revision: 2008 January TF-46 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
3. If NG, replace transfer control device (actuator motor). Refer to TF-54, "Removal and Installation".
A
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-17, "Location of Electrical Parts". B
3. Apply 12V direct current between transfer relay terminals 1 and 2.
4. Check continuity between relay terminals 3 and 4, and 3 and 5.
C
Terminal Condition Continuity
12V direct current supply between terminals 1 and 2 No
3-4 TF
OFF Yes
12V direct current supply between terminals 1 and 2 Yes
3-5
OFF No E
5. If NG, replace transfer shift high relay or transfer shift low relay.
Refer to TF-17, "Location of Electrical Parts". LDIA0099E

FRONT REVOLUTION SENSOR F

1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Disconnect front revolution sensor harness connector.
G
3. Checks resistance or continuity between the following terminals.

1-2 : Approx. 500 - 650 Ω H

1-3 : Continuity should no exist.
2-3 : Continuity should no exist.
I
4. If NG, replace the front revolution sensor. Refer to TF-17, "Loca-
tion of Electrical Parts".

J
SDIA3312E

ATP SWITCH
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.) K
2. Disconnect ATP switch harness connector.
3. Remove ATP switch. Refer to TF-17, "Location of Electrical Parts".
L
4. Push and release ATP switch and check continuity between ATP
switch terminals 8 and 9.
M
Terminal Condition Continuity
Push ATP switch Yes
8-9
Release ATP switch No N
5. If NG, replace the ATP switch. Refer to TF-17, "Location of Elec-
trical Parts".
O
SDIA2395E

PARK/NEUTRAL POSITION SWITCH

1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.) P
2. Disconnect park/neutral position switch harness connector.
3. Remove park/neutral position switch. Refer to TF-17, "Location of Electrical Parts".

Revision: 2008 January TF-47 D40

 TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
4. Push and release park/neutral position switch and check conti-
nuity between park/neutral position switch terminals 1 and 2.

Terminal Condition Continuity

Push park/neutral position switch Yes
1-2
Release park/neutral position switch No
5. If NG, replace the park/neutral position switch. Refer to TF-17,
"Location of Electrical Parts".

WDIA0248E

Revision: 2008 January TF-48 D40

 TRANSFER CONTROL UNIT
< SERVICE INFORMATION >
TRANSFER CONTROL UNIT
A
Removal and Installation INFOID:0000000002978597

REMOVAL B
• Switch 4WD shift switch to 2WD and set transfer assembly to 2WD.
CAUTION:
When removal transfer control unit, transfer state must be at 2WD or AUTO. C
INSTALLATION
Installation is in the reverse order of removal.
• When installing the transfer control unit, tighten bolts to the speci- TF
fied torque.

Transfer control unit bolts : 3.4 N·m (0.35 kg-m, 30 in-lb) E

CAUTION:
Do not connect harness connector to transfer control unit
when 4WD shift switch is at 4LO. F
• After the installation, check 4WD shift indicator pattern. If NG,
adjust position between transfer assembly and transfer control
unit. Refer to TF-4, "Precaution for Transfer Assembly and Trans-
fer Control Unit Replacement". SDIA3201E G

Revision: 2008 January TF-49 D40

 FRONT OIL SEAL
< SERVICE INFORMATION >
FRONT OIL SEAL
Removal and Installation INFOID:0000000002978598

REMOVAL
• 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.

SDIA2779E

• Remove the front oil seal from the front case, using Tool.

Tool number : KV381054S0

CAUTION:
Do not damage front case.

LDIA0144E

INSTALLATION
• Install the front oil seal until it is flush with the end face of the front
case, using Tool.

Tool number : KV38100500

CAUTION:
• Do not reuse oil seal.
• Apply petroleum jelly to oil seal.

LDIA0145E

• Align the matching mark of the front drive shaft with the matching
mark of the companion flange, then install the companion flange.

SDIA2214E

Revision: 2008 January TF-50 D40

 FRONT OIL SEAL
< SERVICE INFORMATION >
• Install the self-lock nut and tighten to the specified torque, using
Tool. Refer to TF-57, "Disassembly and Assembly". A

Tool number : KV40104000

CAUTION: B
Do not reuse self-lock nut.

LDIA0147E

TF

Revision: 2008 January TF-51 D40

 REAR OIL SEAL
< SERVICE INFORMATION >
REAR OIL SEAL
Removal and Installation INFOID:0000000002978599

REMOVAL
• Remove the dust cover from the rear case.
CAUTION:
Do not damage the rear case.

WDIA0127E

• Remove the rear oil seal from the rear case, using Tool.
CAUTION:
Do not damage the rear case.

Tool number : KV381054S0

LDIA0139E

INSTALLATION
• Install the rear oil seal until it is flush with the end face of the rear
case, using Tool.

Tool number : KV38100500

CAUTION:
• Do not reuse oil seal.
• Apply petroleum jelly to oil seal.

LDIA0140E

• Apply petroleum jelly to the circumference of the new dust cover

(1). Position the dust cover as shown in the figure.
CAUTION:
• Do not reuse dust cover.
• Position the projection (A) in the position as shown in the
figure.

PDIA1294E

Revision: 2008 January TF-52 D40

 REAR OIL SEAL
< SERVICE INFORMATION >
• Install the dust cover to the rear case, using Tool.
A
Tool number : KV40105310
CAUTION:
• Do not reuse dust cover. B
• Apply petroleum jelly to dust cover.

PDIA0116E

TF

Revision: 2008 January TF-53 D40

 TRANSFER CONTROL DEVICE
< SERVICE INFORMATION >
TRANSFER CONTROL DEVICE
Removal and Installation INFOID:0000000002978600

REMOVAL
1. Switch the 4WD shift switch to 2WD and set the transfer assembly to 2WD.
2. Disconnect the transfer control device connector.
3. Remove the breather hose from the transfer control device.
4. Remove the bolts and detach the transfer control device.

LDIA0136E

INSTALLATION
1. Install the O-ring to the transfer control device.
CAUTION:
• Do not reuse O-ring.
• Apply petroleum jelly to O-ring.

SDIA3378E

2. Install the transfer control device.

a. Turn the control shift rod fully counterclockwise using a flat-
bladed screwdriver, and then put a mark on the control shift rod.

PDIA0119E

b. Align the transfer control device shaft cutout with the mark on
the control shift rod, and install.
NOTE:
Turn the transfer control device when the transfer control device
connection does not match.

PDIA0120E

Revision: 2008 January TF-54 D40

 TRANSFER CONTROL DEVICE
< SERVICE INFORMATION >
c. Tighten the bolts to the specified torque. Refer to TF-57, "Disas-
sembly and Assembly". A
3. Install the breather hose to the transfer control device.
4. Connect the transfer control device connector.
5. After the installation, check the 4WD shift indicator pattern. If B
NG, adjust the position between the transfer assembly and
transfer control unit. Refer to TF-4, "Precaution for Transfer
Assembly and Transfer Control Unit Replacement". C

SDIA2212E

TF

Revision: 2008 January TF-55 D40

 AIR BREATHER HOSE
< SERVICE INFORMATION >
AIR BREATHER HOSE
Removal and Installation INFOID:0000000002978601

A/T MODELS
Refer to the figure for air breather hose removal and installation information.

SDIA3351E

1. Breather tube 2. Clip A 3. Clip B

4. Clip C 5. Clip D 6. Breather tube (transfer)
7. Air breather hose clamp 8. Transfer control device

M/T MODELS
Refer to the figure for air breather hose removal and installation information.

SDIA3352E

1. Breather tube 2. Clip A 3. Clip B

4. Clip C 5. Breather tube (transfer) 6. Air breather hose clamp
7. Transfer control device

Revision: 2008 January TF-56 D40

 TRANSFER ASSEMBLY
< SERVICE INFORMATION >
TRANSFER ASSEMBLY
A
Removal and Installation INFOID:0000000002978602

REMOVAL B
• Switch 4WD shift switch to 2WD and set transfer assembly to 2WD.
• Remove the front and rear propeller shafts. Refer to PR-3, "Removal and Installation" (front) and PR-4,
"Removal and Installation" (rear). C
CAUTION:
Do not damage spline, sleeve yoke and rear oil seal when removing rear propeller shaft.
NOTE:
Insert a plug into the rear oil seal after removing the rear propeller shaft. TF
• Remove the transmission crossmember.
WARNING:
Support transmission and transfer assembly using two suitable jacks while removing transmission E
crossmember.
• Remove the transfer to transmission and transmission to transfer
bolts.
F
WARNING:
Support transfer assembly with suitable jack while removing
it.
• Remove the transfer assembly. G
CAUTION:
Do not damage transmission rear oil seal.
H

SDIA3181E

INSTALLATION I
Note the following, and install in the reverse order of removal.
• Tighten the bolts to specification.
J
Bolt length : 45 mm (1.77 in)
Tightening torque : 36 N·m (3.7 kg-m, 27 ft-lb)
• After the installation, check the transfer fluid level and fluid leak- K
age. Refer to MA-41, "Checking Transfer Fluid".
• After filling, start the engine for one minute. Then stop the engine
and recheck the transfer fluid. L
• After the installation, check the 4WD shift indicator pattern. If NG,
adjust the position between the transfer assembly and transfer
SDIA3181E
control unit. Refer to TF-4, "Precaution for Transfer Assembly and
M
Transfer Control Unit Replacement".
Disassembly and Assembly INFOID:0000000002978603

N
COMPONENTS

Revision: 2008 January TF-57 D40

 TRANSFER ASSEMBLY
< SERVICE INFORMATION >

SDIA3420E

1. Baffle plate 2. Breather tube 3. Front case

4. Snap ring 5. Input oil seal 6. Front revolution sensor
7. Self-lock nut 8. Companion flange 9. Front oil seal
10. 4LO switch (gray with green paint) 11. ATP switch (black) 12. Rear case
13. Wait detection switch (gray) 14. Gasket 15. Filler plug
16. Check ball 17. Check spring 18. Check plug
19. Drain plug 20. O-ring 21. Transfer control device
22. Harness bracket 23. Dust cover 24 Rear oil seal
25. Retainer bolt 26. Gasket 27. Air breather hose clamp

Revision: 2008 January TF-58 D40

 TRANSFER ASSEMBLY
< SERVICE INFORMATION >

TF

SDIA3308E
K

1. Input bearing 2. Snap ring 3. Internal gear

4. Carrier bearing 5. Sun gear 6. Needle bearing L
7. Metal bushing 8. Planetary carrier assembly 9. L-H sleeve
10. Drive chain 11. Mainshaft 12. Sprocket
13. 2-4 sleeve 14. Clutch gear 15. Oil pump assembly M
16. Retainer 17. Mainshaft rear bearing 18. Speedometer drive gear
19. Front bearing 20. Front drive shaft 21. Rear bearing
22. Clevis pin 23. Shift collar 24. L-H shift fork N
25. L-H shift rod 26. Retaining pin 27. 2-4 shift bracket
28. 2-4 shift fork 29. Fork guide collar 30. 2-4 shift fork spring
31. Retaining ring 32. Snap ring 33. Drum cam O
34. Control shift rod 35. Spacer 36. Control shift rod assembly

DISASSEMBLY P

Revision: 2008 January TF-59 D40

 TRANSFER ASSEMBLY
< SERVICE INFORMATION >
• 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.

SDIA2779E

• Remove the front oil seal from the front case, using Tool.

Tool number : KV381054S0

CAUTION:
Do not damage front case or front drive shaft.

SDIA2423E

• Remove the dust cover from the rear case, using suitable tool.
CAUTION:
Do not damage rear case.

PDIA0092E

• Remove the rear oil seal from the rear case, using Tool.
CAUTION:
Do not damage rear case or mainshaft.

Tool number : KV381054S0

SDIA2424E

Revision: 2008 January TF-60 D40

 TRANSFER ASSEMBLY
< SERVICE INFORMATION >
• Remove the input oil seal from the front case, using suitable tool.
CAUTION: A
Do not damage front case, sun gear or input bearing.

PDIA0094E

TF
• Separate the front case from the rear case. Then remove the rear
case by prying it up, using suitable tool.
CAUTION: E
Do not damage the mating surface.
• Remove the spacer from the control shift rod (A/T models only).
CAUTION:
Do not drop spacer. F

G
PDIA0096E

• Remove the snap ring from the sun gear. H

CAUTION:
Do not damage sun gear or input bearing.
I

K
PDIA0099E

ASSEMBLY
L
• Install the breather tube.
CAUTION:
Install breather tube in the direction shown.
M

O
PDIA0107E

Revision: 2008 January TF-61 D40

 TRANSFER ASSEMBLY
< SERVICE INFORMATION >
• Install the baffle plate to the front case. Tighten the bolt to the
specified torque. Refer to "COMPONENTS".
CAUTION:
Install baffle plate by pushing it in the direction shown while
tightening the bolt.

SDIA2479E

• Install the internal gear with the groove facing up into the front
case.

PDIA0102E

• Install the snap ring to the sun gear.

CAUTION:
Do not damage sun gear.

PDIA0099E

• Install the control shift rod assembly to the front case.

CAUTION:
Set pin of L-H shift fork assembly into the groove of drum
cam.

WDIA0215E

Revision: 2008 January TF-62 D40

 TRANSFER ASSEMBLY
< SERVICE INFORMATION >
• Install the L-H shift rod assembly through the L-H shift fork assem-
bly opening to the front case. A
CAUTION:
Set pin of L-H shift rod assembly into the groove of drum cam.
B

WDIA0216E

TF
• Install the drive chain to the front drive shaft and sprocket.
CAUTION:
Install with the identification mark of drive chain on the side of E
the rear bearing of front drive shaft.

G
PDIA0110E

• Install the 2-4 sleeve and 2-4 shift fork assembly to the mainshaft. H
CAUTION:
• Install with proper orientation of 2-4 sleeve.
• Install 2-4 shift fork with engaging the grooves of 2-4 shift I
fork in the retaining pin of 2-4 shift bracket.

K
SDIA2467E

• Install the retainer to the mainshaft.

L
CAUTION:
Set the projection of oil pump assembly to the identification
hole, and then align locating hole of retainer to the L-H shift
rod assembly. M

SDIA2468E
O

Revision: 2008 January TF-63 D40

 TRANSFER ASSEMBLY
< SERVICE INFORMATION >
• Install the mainshaft rear bearing to the mainshaft, using Tool.

Tool number : KV32102700

CAUTION:
Do not push too hard in order to avoid snap rings becoming
dislodged from mainshaft.

SDIA2469E

• Apply recommended sealant to the mating surface of the front

case. Refer to "COMPONENTS".
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.

SDIA3305E

• Tighten the bolts to the specified torque. Refer to "COMPO-

NENTS".
CAUTION:
Be sure to install the harness brackets and air breather hose
clamp.

SDIA3422E

• Install the retainer bolts with new gaskets. Tighten the bolts to the
specified torque. Refer to "COMPONENTS".
CAUTION:
Tighten them to the specified torque again.

SDIA2789E

Revision: 2008 January TF-64 D40

 TRANSFER ASSEMBLY
< SERVICE INFORMATION >
• Apply petroleum jelly to the circumference of the input oil seal, and
install it to the front case, using Tools. A

Dimension A : 4.0 - 4.6 mm (0.157 - 0.181 in)

B
Tool number A: ST30720000
B: KV40104830
C
CAUTION:
• Do not reuse oil seal.
• Apply petroleum jelly to oil seal. SDIA3191E

TF
• Install the rear oil seal until it is flush with the end face of the rear
case, using Tool.
E
Tool number : KV38100500
CAUTION:
• Do not reuse oil seal. F
• Apply petroleum jelly to oil seal.

G
PDIA0115E

H
• Apply petroleum jelly to the circumference of the new dust cover
(1). Position the dust cover as shown in the figure.
CAUTION:
• Do not reuse dust cover. I
• Position the projection (A) in the position as shown in the
figure.
J

K
PDIA1294E

• Apply recommended sealant to thread of check plug, then install it to rear case and tighten to the specified
L
torque (M/T models only). Refer to "COMPONENTS".
CAUTION:
Remove old sealant and oil adhering to threads.
M
• Apply recommended sealant to the threads of the wait detection
switch (gray). Then install it to the rear case and tighten to the
specified torque. Refer to "COMPONENTS". N
CAUTION:
Remove old sealant and oil adhering to threads.
O

P
SDIA3389E

Revision: 2008 January TF-65 D40

 TRANSFER ASSEMBLY
< SERVICE INFORMATION >
• Apply recommended sealant to the threads of the 4LO switch (gray
with green paint) and ATP switch (black). Then install them to the
front case and tighten to the specified torque. Refer to "COMPO-
NENTS".
CAUTION:
Remove old sealant and oil adhering to threads.

SDIA3390E

• Align the matching mark on the front drive shaft with the mark on
the companion flange, then install the companion flange.

SDIA2779E

• Install the transfer control device to the rear case.

1. Turn the control shift rod fully counterclockwise using a flat-
bladed screwdriver, and then put a mark on the control shift rod.

PDIA0119E

2. Align the transfer control device shaft cutout with the mark on
the control shift rod, and install it.
NOTE:
Turn the transfer control device when the transfer control device
connection does not match.

PDIA0120E

Revision: 2008 January TF-66 D40

 TRANSFER ASSEMBLY
< SERVICE INFORMATION >
3. Tighten the bolts to the specified torque. Refer to "COMPO-
NENTS". A

SDIA2212E

TF

Revision: 2008 January TF-67 D40

 PLANETARY CARRIER
< SERVICE INFORMATION >
PLANETARY CARRIER
Disassembly and Assembly INFOID:0000000002978604

ASSEMBLY
• Apply ATF to the metal bushing, then install the metal bushing until
it becomes “Dimension A”, using Tool.

Dimension A : 7.7 - 8.3 mm (0.303 - 0.327 in)

Tool number : ST35300000

CAUTION:
Do not reuse metal bushing.

SDIA3189E

• Apply ATF to the needle bearing, then install the needle bearing
until it becomes “Dimension B”, using Tool.

Dimension B : 62.5 - 63.1 mm (2.461 - 2.484 in)

Tool number : ST33220000

CAUTION:
Do not reuse needle bearing.

SDIA3190E

Revision: 2008 January TF-68 D40

 SHIFT CONTROL
< SERVICE INFORMATION >
SHIFT CONTROL
A
Disassembly and Assembly INFOID:0000000002978605

ASSEMBLY B
• Install clevis pin and shift collar to L-H shift fork after assembling them.
CAUTION:
Use caution when installing L-H shift fork, clevis pin or shift collar. C
• Install clevis pin and shift collar to 2-4 shift bracket after assembling them.
CAUTION:
Use caution when installing 2-4 shift bracket.
• Install the fork guide collar and 2-4 shift fork spring to the 2-4 shift TF
fork, and then secure it with the retaining ring.
CAUTION:
• Do not reuse retaining ring. E
• Be careful with orientation.

SDIA3391E
G

Revision: 2008 January TF-69 D40

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000002978606

Applied model YD25DDTi

Transfer model TX15B
Fluid capacity (Approx.) (lmp qt) 2.0 (1-3/4)
High 1.000
Gear ratio
Low 2.625

Planetary Sun gear 56

gear Internal gear 91
Number of teeth
Front drive sprocket 38
Front drive shaft 38

Inspection and Adjustment INFOID:0000000002978607

PINION GEAR END PLAY

Unit: mm (in)

Item Standard
Pinion gear end play 0.1 - 0.7 (0.004 - 0.028)

CLEARANCE BETWEEN SHIFT FORK AND SLEEVE

Unit: mm (in)

Item Standard
2-4 shift fork to 2-4 sleeve Less than 0.46 (0.018)
L-H shift fork to L-H sleeve Less than 0.46 (0.018)

Revision: 2008 January TF-70 D40