GI

TRANSFER
MA

SECTION TF EM

LC

EC

FE

CONTENTS CL

PREPARATION ...............................................................4 INSPECTION ...........................................................27

ASSEMBLY .............................................................27
MT
Special Service Tools ..................................................4
Commercial Service Tools ...........................................9 Main Gear ..................................................................27
DISASSEMBLY ........................................................27
AT
INSPECTION ...........................................................28
TX10A
ASSEMBLY .............................................................28
NOISE, VIBRATION AND HARSHNESS (NVH) Front Case .................................................................28
TROUBLESHOOTING ...................................................10 REMOVAL ...............................................................28
NVH Troubleshooting Chart.......................................10 INSTALLATION........................................................29
TRANSFER .............................................................10 Front Case Cover ......................................................29 PD
DESCRIPTION ...............................................................11 REMOVAL ...............................................................29
Cross-sectional View .................................................11 INSTALLATION........................................................29
ON-VEHICLE SERVICE ................................................12 Bearing Retainer........................................................29 AX
Replacing Oil Seal .....................................................12 REMOVAL ...............................................................29
INSTALLATION........................................................29
CENTER CASE OIL SEAL ........................................12
SHIFT SHAFT OIL SEAL ..........................................13 Center Case...............................................................30 SU
REAR OIL SEAL ......................................................13 REMOVAL ...............................................................30
Position Switch Check ...............................................14 INSTALLATION........................................................30
Rear Case..................................................................30 BR
REMOVAL AND INSTALLATION .................................15
REMOVAL ...............................................................30
Removal.....................................................................15
INSTALLATION........................................................30
Installation..................................................................15
Shift Control Components .........................................31
ST
M/T MODEL ............................................................15
INSPECTION ...........................................................31
A/T MODEL .............................................................15
ASSEMBLY....................................................................32 RS
OVERHAUL ...................................................................16
SERVICE DATA AND SPECIFICATIONS (SDS) .........39
Transfer Gear Control................................................16
General Specifications...............................................39
Case Components .....................................................17
Gear Components .....................................................18
Gear End Play ...........................................................39 BT
Available Snap Ring ..................................................39
Shift Control Components .........................................19
MAINSHAFT FRONT BEARING ................................39
DISASSEMBLY..............................................................20 HA
MAINSHAFT REAR BEARING ..................................39
REPAIR FOR COMPONENT PARTS ...........................24 MAIN GEAR BEARING.............................................39
Mainshaft ...................................................................24 Available Shim ...........................................................40
DISASSEMBLY ........................................................24 COUNTER GEAR REAR BEARING ...........................40 SC
INSPECTION ...........................................................25
ASSEMBLY .............................................................25
ATX14A EL
Front Drive Shaft .......................................................26
DISASSEMBLY ........................................................26 PRECAUTIONS .............................................................41
INSPECTION ...........................................................26 Supplemental Restraint System (SRS) ″AIR
ASSEMBLY .............................................................26 BAG″ and ″SEAT BELT PRE-TENSIONER″.............41
IDX
Counter Gear .............................................................26 Precautions ................................................................41
DISASSEMBLY ........................................................26
Service Notice............................................................42
 CONTENTS (Cont’d)
Wiring Diagrams and Trouble Diagnosis...................42 INSPECTION OF TRANSFER CONTROL UNIT..........88
ALL-MODE 4WD SYSTEM ...........................................43 TRANSFER CONTROL UNIT INSPECTION TABLE ....89
Cross-sectional View .................................................43 DTC U1000 CAN COMMUNICATION LINE (WITH
Control System ..........................................................44 VDC)...............................................................................95
ALL-MODE 4WD TRANSFER BASIC CONTROL ........45 Description .................................................................95
HYDRAULIC CONTROL CIRCUITS ...........................45 On Board Diagnosis Logic.........................................95
OUTLINE ................................................................45 Possible Cause..........................................................95
CONTROL SYSTEM DIAGRAM ................................46 DTC Confirmation Procedure ....................................95
INDICATIONS OF 4WD WARNING LAMP..................46 WITH CONSULT-II ..............................................95
CAN Communication (With VDC)..............................47 WITH GST .........................................................95
SYSTEM DESCRIPTION ..........................................47 Diagnostic Procedure ................................................96
Location of Electrical Parts........................................48 VEHICLE SPEED SENSOR (FRONT
Description of Electrical Parts ...................................49 REVOLUTION SENSOR) (WITHOUT VDC) .................97
TRANSFER MOTOR ................................................49 Diagnostic Procedure ................................................97
WAIT DETECTION SWITCH .....................................49 4WD SOLENOID VALVE.............................................100
2-4WD SHIFT SOLENOID VALVE .............................50
Diagnostic Procedure ..............................................100
LINE PRESSURE SWITCH .......................................50
2-4WD SHIFT SOLENOID VALVE AND 4WD
Circuit Diagram for Quick Pinpoint Check.................51
SHIFT SWITCH............................................................102
Wiring Diagram - TF -................................................52
Diagnostic Procedure ..............................................102
ON BOARD DIAGNOSTIC SYSTEM
TRANSFER MOTOR AND TRANSFER MOTOR
DESCRIPTION ...............................................................61
RELAY .........................................................................106
Trouble Diagnosis without CONSULT-II ....................61
Diagnostic Procedure ..............................................106
DESCRIPTION ........................................................61
TRANSFER FLUID TEMPERATURE SENSOR..........109
SELF-DIAGNOSTIC PROCEDURE............................62
INDICATIONS OF 4WD WARNING LAMP..................63 Diagnostic Procedure ..............................................109
Trouble Diagnosis with CONSULT-II .........................64 ATP SWITCH, WAIT DETECTION SWITCH AND
CONSULT-II FUNCTION ...........................................64 NEUTRAL-4LO SWITCH.............................................112
SELF-DIAGNOSIS ...................................................64 Diagnostic Procedure ..............................................112
SELF-DIAGNOSTIC ITEMS ......................................66 CLUTCH PRESSURE SWITCH ..................................116
DATA MONITOR......................................................67 Diagnostic Procedure ..............................................116
DATA MONITOR ITEMS ...........................................69 LINE PRESSURE SWITCH .........................................119
REFERENCE VALUE IN DATA MONITOR MODE ......71 Diagnostic Procedure ..............................................119
WORK SUPPORT ....................................................73 ABS OPERATION SIGNAL (WITHOUT VDC) ...........122
CLUTCH FORCE RELEASE LIMIT ADJUSTMENT .....74 Diagnostic Procedure ..............................................122
TROUBLE DIAGNOSIS - INTRODUCTION..................76 DATA ERASE/DISPLAY .............................................124
Introduction ................................................................76 Diagnostic Procedure ..............................................124
DESCRIPTION ........................................................76
SHIFT ACTUATOR......................................................125
DIAGNOSTIC WORKSHEET.....................................76
Diagnostic Procedure ..............................................125
Work Flow..................................................................78
SHIFT ACTUATOR POSITION SWITCH ....................128
HOW TO PERFORM TROUBLE DIAGNOSES FOR
QUICK AND ACCURATE REPAIR .............................78
Diagnostic Procedure ..............................................128
TROUBLE DIAGNOSIS - BASIC INSPECTION ...........79 SHIFT ACTUATOR CIRCUIT ......................................130
Listen to Customer Complaints .................................79 Diagnostic Procedure ..............................................130
Transfer Fluid Check .................................................79 TROUBLE DIAGNOSES FOR SYMPTOMS ...............134
Road Test...................................................................79 Symptom 1. 4WD Shift Indicator Lamp Does Not
PREPARATION FOR ROAD TEST ............................79 Turn ON ...................................................................134
1. CHECK BEFORE ENGINE IS STARTED ...............80 Symptom 2. 4WD Warning Lamp Does Not Turn
2. CHECK AT IDLE ..................................................81 ON............................................................................136
3. CRUISE TEST .....................................................85 Symptom 3. 4WD Shift Indicator Lamp Does Not
TROUBLE DIAGNOSIS - GENERAL Turn OFF .................................................................138
DESCRIPTION ...............................................................88 Symptom 4. ATP Warning Lamp Does Not Turn
Transfer Control Unit Terminals and Reference ON............................................................................138
Value ..........................................................................88 Symptom 5. 4LO Indicator Lamp Does Not Turn
REMOVAL AND INSTALLATION OF TRANSFER ON............................................................................140
CONTROL UNIT ......................................................88

TF-2
 CONTENTS (Cont’d) GI
Symptom 6. 4WD Shift Indicator Lamp Does Not Removal...................................................................155
Indicate ″4H″............................................................142 Installation................................................................155 MA
Symptom 7. 4WD Shift Indicator Lamp Repeats OVERHAUL .................................................................156
Flickering..................................................................143 Transfer Gear Control..............................................156
Symptom 8. Tight Corner Braking Symptom...........144 Transfer Components ..............................................157 EM
Symptom 9. 4WD System Does Not Operate.........145 DISASSEMBLY............................................................159
COMPONENT INSPECTION .......................................147 Rear Case................................................................159
4WD Shift Switch.....................................................147 DISASSEMBLY ......................................................159
LC
2-4WD Shift Solenoid Valve and Transfer Fluid Center Case.............................................................159
Temperature Sensor ................................................147 DISASSEMBLY ......................................................159 EC
4WD Solenoid Valve, Clutch Pressure Switch Front Case ...............................................................169
and Line Pressure Switch........................................147 DISASSEMBLY ......................................................169
Front Revolution Sensor..........................................148 REPAIR FOR COMPONENT PARTS .........................173 FE
Transfer Dropping Resistor......................................148 Front Case ...............................................................173
ATP Switch, Neutral-4LO Switch and Wait INSPECTION .........................................................173
Detection Switch ......................................................148 Center Case.............................................................174 CL
INSPECTION .........................................................174
Transfer Motor .........................................................149
ASSEMBLY..................................................................177
Transfer Motor Relay ...............................................149 MT
Front Case ...............................................................177
Transfer Sub-harness ..............................................149
ASSEMBLY ...........................................................177
FRONT REVOLUTION SENSOR SUB-HARNESS
Center Case.............................................................181
CONNECTOR ........................................................149
ASSEMBLY ...........................................................181
AT
TRANSFER SWITCH ASSEMBLY SUB-HARNESS
CONNECTOR ........................................................150 Final Assembly.........................................................189
TRANSFER TERMINAL CORD ASSEMBLY SUB- SERVICE DATA AND SPECIFICATIONS (SDS) .......192
HARNESS CONNECTOR .......................................150 General Specifications.............................................192
Transfer Shift Relay (High & low)............................150 Inner Gear and Outer Gear .....................................192
Actuator & Actuator Position Switch........................151 SUB-OIL PUMP .....................................................192 PD
ACTUATOR ...........................................................151 MAIN OIL PUMP ....................................................192
ACTUATOR POSITION SWITCH ............................151 Control Valve ...........................................................192
ON-VEHICLE SERVICE ..............................................152 VALVE ..................................................................192 AX
Replacing Oil Seal ...................................................152 SPRING ................................................................192
FRONT CASE OIL SEAL ........................................152 Clutch.......................................................................193
SHIFT SHAFT OIL SEAL ........................................153 DRIVE PLATE .......................................................193 SU
REAR OIL SEAL ....................................................153 DRIVEN PLATE .....................................................193
Transfer Motor .........................................................154 RETURN SPRING..................................................193
RETAINING PLATE................................................193 BR
REMOVAL .............................................................154
INSTALLATION......................................................154 Seal Ring (Mainshaft side) ......................................194
Transfer Oil Filter .....................................................154 Bearing Race (Thrust needle bearing side) ............194
ST
REMOVAL .............................................................154 Snap Ring (Sun gear side)......................................194
INSTALLATION......................................................154
REMOVAL AND INSTALLATION ...............................155 RS

BT

HA

SC

EL

IDX

TF-3
 PREPARATION
Special Service Tools

Special Service Tools NATF0093

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number
(Kent-Moore No.) Description
Tool name

KV38108300 Removing companion flange nut

(J44195) Installing companion flange nut
Companion flange
wrench

NT771

ST30021000 Removing low gear

(J22912-01) Removing counter gear front bearing
Puller (Use with ST36710010)
Removing L & H hub
a: 110 mm (4.33 in) dia.
b: 68 mm (2.68 in) dia.

NT411

ST30031000 Removing counter gear rear bearing

(J22912-01) (Use with ST36710010)
Puller a: 90 mm (3.54 in) dia.
b: 50 mm (1.97 in) dia.

NT411

ST33290001 Removing center case oil seal

(J25810-A) Removing rear oil seal
Puller a: 250 mm (9.84 in)
b: 160 mm (6.30 in)

NT414

ST33051001 Removing companion flange

(J22888) a: 135 mm (5.31 in)
Puller b: 100 mm (3.94 in)
c: 130 mm (5.12 in)

NT657

ST30720000 1 Installing center case oil seal

1 (J25273) 2 Installing rear oil seal
2 (J25405) a: 77 mm (3.03 in) dia.
Drift b: 55.5 mm (2.185 in) dia.

NT658

TF-4
 PREPARATION
Special Service Tools (Cont’d)

Tool number GI
(Kent-Moore No.) Description
Tool name
MA
ST36710010 Removing counter gear front bearing
( — ) (Use with ST30021000)
Drift Removing counter gear rear bearing
(Use with ST30031000)
EM
a: 34.5 mm (1.358 in) dia.
NT063
LC
ST33061000 Removing main gear bearing
(J8107-2) a: 28.5 mm (1.122 in) dia.
Drift b: 38 mm (1.50 in) dia.
EC

NT116
FE
ST30613000 1 Installing main gear bearing
1 (J25742-3) 2 Installing front case cover oil seal
2 (J34339) a: 72 mm (2.83 in) dia. CL
Drift b: 48 mm (1.89 in) dia.

MT
NT073

(J35864) Installing shift shaft oil seal

Drift a: 26 mm (1.02 in) dia. AT
b: 20 mm (0.79 in) dia.
c: 150 mm (5.91 in)

NT117

(J26092) Seating counter gear assembly

Drift a: 44.5 mm (1.752 in) dia. PD
b: 38.5 mm (1.516 in) dia.

AX
NT065

(J34291) Selecting counter gear rear bearing shim

Shim setting gauge set SU

BR

NT101
ST
(J34291-20) Selecting counter gear rear bearing shim
Plunger-shim setting
gauge
RS

NT118
BT
KV40100621 Installing front drive shaft bearing
(J26091) a: 76 mm (2.99 in) dia.
Drift b: 69 mm (2.72 in) dia. HA

SC
NT086

EL

IDX

TF-5
 PREPARATION
Special Service Tools (Cont’d)

Tool number
(Kent-Moore No.) Description
Tool name

ST30032000 Installing front drive shaft bearing

( — ) a: 38 mm (1.50 in) dia.
Base b: 80 mm (3.15 in) dia.

NT660

ST33052000 Removing front drive shaft bearing

( — ) a: 28 mm (1.10 in) dia.
Adapter b: 22 mm (0.87 in) dia.

NT431

ST35271000 Installing rear oil seal

(J26091) Removing and installing press flange snap ring
Drift a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.

NT115

ST27863000 Removing and installing press flange snap ring

( — ) a: 74.5 mm (2.933 in) dia.
Support ring b: 62.5 mm (2.461 in) dia.

NT661

KV40104710 Removing and installing press flange snap ring

( — ) a: 76.3 mm (3.004 in) dia.
Support ring b: 67.9 mm (2.673 in) dia.

NT661

ST35291000 Removing mainshaft rear bearing

( — ) a: 40 mm (1.57 in) dia.
Remover b: 29.5 mm (1.161 in) dia.
c: 22.5 mm (0.886 in) dia.

NT662

TF-6
 PREPARATION
Special Service Tools (Cont’d)

Tool number GI
(Kent-Moore No.) Description
Tool name
MA
ST30090010 Removing mainshaft rear bearing
( — ) a: 165 mm (6.50 in)
Remover b: 25 mm (0.98 in) dia.
c: M16 x P2.0
EM

LC

NT663 EC
KV38100500 Installing front drive shaft oil seal
( — ) a: 80 mm (3.15 in) dia.
Drift b: 60 mm (2.36 in) dia. FE

NT115
CL
KV40100621 Installing mainshaft rear bearing
(J25273) a: 76 mm (2.99 in) dia. MT
Drift b: 69 mm (2.72 in) dia.

AT

NT104

KV32101100 Removing and installing L-H fork, 2-4 fork

( — ) a: 6 mm (0.24 in) dia.
Pin punch PD

AX
NT410

ST3306S001 Installing mainshaft rear bearing

(J22888-D) Removing sun gear assembly SU
Differential side bearing a: 28.5 mm (1.122 in) dia.
puller set b: 38 mm (1.50 in) dia.
1: ST33051001 BR
( — )
Puller
2: ST33061000
(J8107-2) ST
Adapter NT072

ST30911000 Installing mainshaft and planetary carrier assembly RS

( — ) a: 98 mm (3.86 in) dia.
Puller b: 40.5 mm (1.594 in) dia.
BT

HA
NT664
SC

EL

IDX

TF-7
 PREPARATION
Special Service Tools (Cont’d)

Tool number
(Kent-Moore No.) Description
Tool name

KV381054S0 Removing rear oil seal

( — )
Outer race puller

NT665

KV40105230 Installing planetary carrier assembly

( — ) a: 92 mm (3.62 in) dia.
Adapter b: 86 mm (3.39 in) dia.
c: 12 mm (0.47 in)

NT666

KV40105310 Installing planetary carrier assembly

( — ) a: 89.1 mm (3.508 in) dia.
Support ring b: 80.7 mm (3.177 in) dia.

NT661

KV40105500 Installing planetary carrier assembly

( — ) a: 69 mm (2.72 in) dia.
Support b: 52 mm (2.05 in) dia.
c: 120 mm (4.72 in) dia.

NT667

KV38100200 Installing transfer cover oil seal

( — ) a: 65 mm (2.56 in) dia.
Drift b: 49 mm (1.93 in) dia.

NT673

KV31103300 Removing and installing press flange snap ring

( — ) a: 76.3 mm (3.004 in) dia.
Drift b: 130 mm (5.12 in)

NT668

TF-8
 PREPARATION
Special Service Tools (Cont’d)

Tool number GI
(Kent-Moore No.) Description
Tool name
MA
KV31103400 Installing clutch piston
( — ) a: 88.5 mm (3.484 in) dia.
Clutch piston attachment b: 158 mm (6.22 in) dia.
1 Shaft-drift
EM
2 Guide-cylinder

LC

NT669 EC
(J35864) Installing oil seal
Drift
FE

CL

NT671
MT

AT
Commercial Service Tools NATF0094

Tool name Description

Puller Removing front drive shaft front bearing

Removing front drive shaft rear bearing
Removing main gear bearing PD

AX
NT077

Drift 1 Installing mainshaft rear bearing

2 Installing L & H hub SU
1 a: 50 mm (1.97 in) dia.
b: 42 mm (1.65 in) dia.
c: 180 mm (7.09 in) BR
2 a: 60 mm (2.36 in) dia.
NT117
b: 50 mm (1.97 in) dia.
c: 60 mm (2.36 in) ST
Power tool Loosening nuts and bolts

RS

BT

PBIC0190E HA

SC

EL

IDX

TF-9
 NOISE, VIBRATION AND HARSHNESS (NVH) NATF0095

TROUBLESHOOTING TX10A
NVH Troubleshooting Chart

NVH Troubleshooting Chart NATF0095S01

Use the chart below to help you find the cause of the symptom. The numbers indicate the order of inspection.
If necessary, repair or replace these parts.
TRANSFER NATF0095S0101

Refer to MA-22, “Checking

TF-17, 19
TF-17

TF-17

TF-19

TF-18

TF-18
Transfer Fluid”.
Reference page

CHECK SPRING AND CHECK BALL (Worn or damaged)

SUSPECTED PARTS

BEARING (Worn or damaged)

OIL SEAL (Worn or damaged)
LIQUID GASKET (Damaged)
(Possible cause)

GEAR (Worn or damaged)

FLUID (Level too high)

SHIFT FORK (Worn)

FLUID (Level low)

FLUID (Wrong)

Noise 1 2 3 3

Fluid leakage 3 1 2 2
Symptom
Hard to shift or will not shift 1 1

Jumps out of gear 1 2 2

TF-10
 DESCRIPTION TX10A
Cross-sectional View

Cross-sectional View NATF0096

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL
SMT164E
IDX

TF-11
 ON-VEHICLE SERVICE TX10A
Replacing Oil Seal

Replacing Oil Seal NATF0097

CENTER CASE OIL SEAL NATF0097S01
1. Remove exhaust front tube and heat insulator. Refer to
“Removal”, TF-15.
2. Remove front propeller shaft. Refer to PD-8, “Removal and
Installation”.
3. Remove companion flange nut.

SMT844DB

4. Remove companion flange.

SMT802C

5. Remove center case oil seal.

SMT803C

6. Install center case oil seal.

I Before installing, apply multi-purpose grease to seal lip.
7. Install companion flange.

SMT183E

8. Tighten nut to the specified torque.

9. Install front propeller shaft.
10. Install exhaust front tube and heat insulator.

SMT845DB

TF-12
 ON-VEHICLE SERVICE TX10A
Replacing Oil Seal (Cont’d)
SHIFT SHAFT OIL SEAL NATF0097S02 GI
1. Remove front propeller shaft. Refer to PD-8, “Removal and
Installation”.
2. Remove companion flange. Refer to center case oil seal, MA
TF-12.
3. Remove transfer control lever from transfer outer shift lever.
Then remove outer shift lever. EM

LC
SMT863C

4. Remove shift shaft oil seal. EC

I Be careful not to damage cross shaft.
FE

CL

MT
SMT491A
AT
5. Install shift shaft oil seal.
I Before installing, apply multi-purpose grease to seal lip.
6. Install outer shift lever. Then install transfer control lever to
transfer outer shift lever.
7. Install companion flange. Refer to center case oil seal, TF-12.
8. Install front propeller shaft.
PD

AX

SMT805C SU
REAR OIL SEAL NATF0097S03
1. Remove rear propeller shaft. Refer to PD-8, “Removal and
Installation”.
BR
2. Remove rear oil seal.
ST

RS

SMT806C BT
3. Install rear oil seal.
I Before installing apply multi-purpose grease to seal lip. HA
4. Install rear propeller shaft.
SC

EL

IDX
SMT807C

TF-13
 ON-VEHICLE SERVICE TX10A
Position Switch Check

Position Switch Check NATF0098

Switch Gear position Continuity

4WD Yes
4WD switch
Except 4WD No

Neutral No
Neutral position switch
Except neutral Yes

SMT790CA

TF-14
REMOVAL AND INSTALLATION TX10A
Removal

Removal NATF0099
GI
1. Drain fluid from transfer and oil from transmission.
2. Remove exhaust front and rear tubes. Refer to FE-9, “Removal
and Installation”. MA
3. Remove front and rear propeller shaft. Refer to PD-8,
“Removal and Installation”. EM
4. Insert plug into rear oil seal after removing propeller shaft.
I Be careful not to damage spline, sleeve yoke and rear oil
seal, when removing propeller shaft. LC
5. Disconnect neutral position and 4WD switch harness connec-
SMT800C
tors.
6. Remove transfer control lever from transfer outer shift lever. EC
7. Remove transfer from transmission.
WARNING: FE
Support transfer while removing it.

CL

MT
SMT863C
AT
Installation NATF0100
I Apply recommended sealant to mating surface to transmis-
sion. (M/T model only)
Recommended sealant:
Genuine Anaerobic Liquid Gasket or equivalent PD
Refer to TF-17.

AX

SMT495A SU
I Tighten bolts securing transfer.
M/T MODEL NATF0100S01
BR
Tightening torque
Bolt No.  mm (in)
N·m (kg-m, ft-lb) ST
1 32 - 42 (3.2 - 4.3, 24 - 31) 60 (2.36)

2 32 - 42 (3.2 - 4.3, 24 - 31) 45 (1.77) RS

A/T MODEL NATF0100S02

SMT496AB BT
Tightening torque
Bolt No.  mm (in)
N·m (kg-m, ft-lb)

1 32 - 42 (3.2 - 4.3, 24 - 31) 45 (1.77) HA

2 32 - 42 (3.2 - 4.3, 24 - 31) 45 (1.77)
SC

EL

IDX

TF-15
 OVERHAUL TX10A
Transfer Gear Control

Transfer Gear Control NATF0101

SMT184E

TF-16
 OVERHAUL TX10A
Case Components

Case Components NATF0102

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL
SMT165EB
IDX

TF-17
 OVERHAUL TX10A
Gear Components

Gear Components NATF0103

SMT185E

TF-18
 OVERHAUL TX10A
Shift Control Components

Shift Control Components NATF0104

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL
SMT186EA
IDX

TF-19
 NATF0105

DISASSEMBLY TX10A

1. Remove nut of companion flange.

2. Remove companion flange.

SMT846DA

3. Remove 4WD switch.

4. Remove rear case.
I Be careful not to damage the mating surface.

SMT270A

5. Remove oil cover and oil gutter.

6. Remove snap ring and retainer ring from 2-4 shift rod.

SMT435C

7. Remove bolts securing bearing retainer.

I This step is necessary to remove mainshaft from center
case.

SMT273A

8. Remove bolts securing center case to front case and then

separate center case and front case.

SMT274A

TF-20
 DISASSEMBLY TX10A

9. Measure end play of low gear. GI

Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)
I If end play is beyond the maximum value, check low gear MA
and L & H hub for wear.
EM

LC
SMT342A

10. Disassemble center case assembly. EC

a. Remove snap ring from mainshaft.
FE

CL

MT
SMT275A
AT
b. Pull out low gear with L & H hub.

PD

AX

SMT757A SU
c. Remove needle bearing of low gear.
BR

ST

RS

SMT758A BT
d. Make sure of the direction of the drive chain before removing
it. (It must be reinstalled in the same direction.) HA

SC

EL

IDX
SMT788C

TF-21
 DISASSEMBLY TX10A

e. Remove mainshaft, front drive and drive chain as a set by

tapping front end of mainshaft and front drive shaft alternately.
I Be careful not to bend drive chain.

SMT279A

11. Disassemble front case assembly.

a. Remove neutral position switch, plugs, check springs and
check balls.

SMT822D

b. Remove outer shift lever.

SMT867C

c. Remove lock pin of inner shift lever and drive out cross shaft
with plug.

SMT282A

d. Remove 2-4 shift rod.

SMT283A

TF-22
 DISASSEMBLY TX10A

e. Remove L & H shift rod and fork assembly with coupling GI

sleeve.

MA

EM

LC
SMT284A

f. Remove needle bearing from main gear. EC

FE

CL

MT
SMT286A
AT
g. Remove bolts securing front case cover and then remove
case.

PD

AX

SMT287A SU
h. Remove counter gear by tapping lightly.
BR

ST

RS

SMT759A BT
i. Remove main gear by tapping lightly.
HA

SC

EL

IDX
SMT288A

TF-23
 REPAIR FOR COMPONENT PARTS TX10A
Mainshaft

Mainshaft
DISASSEMBLY NATF0106
1. Check end play of front drive sprocket.
Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)
I If end play is beyond the maximum value, check front
drive sprocket and clutch gear for wear.

SMT347A

2. Remove retainer ring, speedometer drive gear and steel ball.

I Be careful not to lose the steel ball.

SMT289A

3. Remove snap ring and spacer.

SMT290A

4. Press out front drive sprocket with mainshaft rear bearing and
clutch gear together.
5. Remove needle bearing.

SMT291A

6. Remove bearing retainer and then remove snap ring.

SMT292A

TF-24
REPAIR FOR COMPONENT PARTS TX10A
Mainshaft (Cont’d)
7. Press out mainshaft front bearing from mainshaft. GI

MA

EM

LC
SMT293A

INSPECTION EC
NATF0107
Gear and Shaft NATF0107S01
I Check gears for excessive wear, chips or cracks. FE
I Check shaft for cracks, wear or bending.
I Check coupling sleeve for wear or damage.
CL

MT
SMT348A
AT
Bearing NATF0107S02
I Make sure bearings roll freely and are free from noise, crack,
pitting or wear.

PD

AX

SMT042E SU
ASSEMBLY NATF0108
1. Press mainshaft front bearing onto mainshaft.
BR
I Pay special attention to its direction.

ST

RS

SMT294A BT
2. Select snap ring with proper thickness and install it.
Allowable clearance between snap ring and groove: HA
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring for mainshaft front bearing:
Refer to SDS, TF-39.
SC
3. Regarding to further procedures, refer to “ASSEMBLY”, TF-32.
EL

IDX
SMT295A

TF-25
 REPAIR FOR COMPONENT PARTS TX10A
Front Drive Shaft

Front Drive Shaft

DISASSEMBLY NATF0109
I Front drive shaft front bearing and rear bearing

SMT437C

INSPECTION NATF0110
Sprocket and Shaft NATF0110S01
I Check sprocket for excessive wear, chips or cracks.
I Check shaft for cracks or wear.
Bearing NATF0110S02
I Make sure bearings roll freely and are free from noise, crack,
pitting or wear.

SMT357A

ASSEMBLY NATF0111
I Press front drive shaft front bearing and rear bearing.

SMT438C

Counter Gear
DISASSEMBLY NATF0112
1. Press out counter gear front bearing.

SMT300A

2. Press out counter gear rear bearing.

I Remove rear sub-gear, spacer and dish plate (M/T model
only).

SMT301A

TF-26
REPAIR FOR COMPONENT PARTS TX10A
Counter Gear (Cont’d)
INSPECTION NATF0113 GI
Gear and Shaft NATF0113S01
I Check gears for excessive wear, chips or cracks.
I Check shaft for cracks or wear.
MA
Bearing
I
NATF0113S02
Make sure bearings roll freely and are free from noise, crack, EM
pitting or wear.
LC
SMT358A

ASSEMBLY EC
NATF0114
1. Press on counter gear front bearing.
2. Install rear sub-gear, dish plate and spacer. FE
I Press on counter gear rear bearing (M/T model only).

CL

MT
SMT439C
AT
Main Gear
DISASSEMBLY NATF0115
Main Gear Bearing NATF0115S01
1. Remove snap ring.
PD

AX

SMT304A SU
2. Pull out main gear bearing.
BR

ST

RS

SMT305A BT
Plug NATF0115S02
I Always replace it with new one whenever it is removed. HA

SC

EL

IDX
SMT187E

TF-27
 REPAIR FOR COMPONENT PARTS TX10A
Main Gear (Cont’d)
INSPECTION NATF0116
Gear and Shaft NATF0116S01
I Check gears for excessive wear, chips or cracks.
I Check shaft for cracks or wear.
Bearing NATF0116S02
I Make sure bearings roll freely and are free from noise, crack,
pitting or wear.

SMT359A

ASSEMBLY NATF0117
Main Gear Bearing NATF0117S01
1. Press on main gear bearing.

SMT307A

2. Select snap ring with proper thickness and install it.

Allowable clearance between snap ring and groove:
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring for main gear bearing:
Refer to SDS, TF-39.

SMT030D

Plug NATF0117S02
I Apply sealant to plug and install it.
Sealant:
Refer to Gear Components, TF-18.

SMT188E

Front Case
REMOVAL NATF0118
Shift Shaft Oil Seal NATF0118S01
I Use a screwdriver to pry out old seal.
I Be careful not to damage case.
I Always replace with a new one whenever it has been removed.

SMT310A

TF-28
REPAIR FOR COMPONENT PARTS TX10A
Front Case (Cont’d)
INSTALLATION NATF0119 GI
Shift Shaft Oil Seal NATF0119S01
I Install new shift shaft oil seal until flush with case.
I Before installing, apply multi-purpose grease to seal lip.
MA

EM

LC
SMT805C

Front Case Cover EC

REMOVAL NATF0120
Cover Oil Seal NATF0120S01
FE
I Drive out old seal from inside of front case cover.
I Be careful not to damage front case cover.
CL

MT
SMT189E
AT
INSTALLATION NATF0121
Cover Oil Seal NATF0121S01
I Install new front case cover oil seal until it stops.
I Before installing, apply multi-purpose grease to seal lip.
PD

AX

SMT868C SU
Bearing Retainer
REMOVAL NATF0122 BR
Oil Catcher NATF0122S01
I Drive out oil catcher from inside of bearing retainer.
I Be careful not to damage bearing retainer.
ST

RS

SMT190E BT
INSTALLATION NATF0123
Oil Catcher NATF0123S01
HA
I Install oil catcher until it stops.
I Be careful not to damage or distort oil catcher or bearing
retainer.
SC
I Before installing, apply multi-purpose grease to seal lip.
EL

IDX
SMT191E

TF-29
 REPAIR FOR COMPONENT PARTS TX10A
Center Case

Center Case
REMOVAL NATF0124
Center Case Oil Seal NATF0124S01
I Remove center case oil seal.

SMT863D

INSTALLATION NATF0125
Center Case Oil Seal NATF0125S01
I Install center case oil seal.

SMT864D

Rear Case
REMOVAL NATF0126
Rear Oil Seal NATF0126S01
I Pull out rear oil seal.

SMT316A

INSTALLATION NATF0127
Rear Oil Seal NATF0127S01
I Install new rear oil seal until it stops.
I Before installing, apply multi-purpose grease to seal lip.

SMT317A

Air Breather NATF0127S02

I Install as shown in illustration.

SMT799A

TF-30
REPAIR FOR COMPONENT PARTS TX10A
Shift Control Components

Shift Control Components GI

INSPECTION NATF0128
I Check contact surface and sliding surface for wear, scratches,
projections or other faulty conditions.
MA

EM

LC
SMT360A

L & H Shift Rod & Fork EC

NATF0128S01
I Assemble as shown in illustration.
* Retaining pin is the same size as the one for 2-4 shift rod.
FE
Tool number: KV32101100 ( — )

CL

MT
SMT823D
AT
2-4 Shift Rod & Fork NATF0128S02
I Assemble as shown in illustration.
* Retaining pins are the same size.
Tool number: KV32101100 ( — )
PD

AX

SMT320A SU
I Pay special attention to the direction of fork guide collar.
BR

ST

RS

SMT031D BT

HA

SC

EL

IDX

TF-31
 NATF0129

ASSEMBLY TX10A

1. Assemble front case.

a. Install main gear assembly by tapping lightly.

SMT323A

b. Apply sealant to the mating surface of front case cover and

install it on front case.
I These ten bolts should be coated with sealant.
I Tightening torque
A: 20 - 23 N·m (2.0 - 2.4 kg-m, 15 - 17 ft-lb)
B: 24 - 28 N·m (2.4 - 2.9 kg-m, 18 - 20 ft-lb)
(Always replace after every disassembly.)
Sealant:
Refer to Case Components, TF-17.
SMT166E

c. Apply gear oil to needle bearing and install it into main gear.

SMT326A

d. Install counter gear assembly by tapping lightly.

SMT327A

e. Install cross shaft and inner shift lever.

I When replacing cross shaft, outer shift lever or lock pin of
outer shift lever, replace them as a set.

SMT032D

TF-32
 ASSEMBLY TX10A

f. Apply sealant to plug and install it into front case. GI

Sealant:
Refer to Case Components, TF-17.
MA

EM

LC
SMT330A

g. Insert interlock plunger into front case. EC

FE

CL

MT
SMT331A
AT
h. Install L & H shift rod and fork assembly with coupling sleeve.
CAUTION:
L & H coupling sleeve have directional property. (A/T vehicle
only)

PD

AX

SMT167E SU
i. Install 2-4 shift rod.
BR

ST

RS

SMT333A BT
j. Install neutral position switch, check balls, check springs and
plugs. HA
I Apply sealant to switches and plugs.
Sealant:
Refer to Case Components, TF-17. SC

EL

IDX
SMT822D

TF-33
 ASSEMBLY TX10A

2. Select counter gear rear bearing shim.

a. Seat counter gear assembly.

SMT033D

b. Place J34291-1 (bridge), J34291-2 (legs) and J34291-5 (gaug-

ing cylinder) on machined surface of center case and allow
gauging cylinder to rest on top outer portion of counter gear
rear bearing. Lock gauging cylinder in place.

SMT591A

c. Insert J34291-20 (gauging plunger) into J34291-5 (gauging

cylinder).

SMT592A

d. Place bridge, legs, gauging cylinder and gauging plunger onto

machined surface of front case assembly, and allow gauging
plunger to drop until it contacts counter gear rear bearing mat-
ing surface.

SMT034D

TF-34
 ASSEMBLY TX10A

e. Lock gauging plunger in place and use feeler gauge to mea- GI

sure gap between gauging cylinder and gauging plunger.
f. Use measured distance and following chart to select correct
shim. MA
Counter gear end play:
0 - 0.2 mm (0 - 0.008 in)
Counter gear rear bearing shim:
EM
Refer to SDS, TF-40.
g. Select counter gear rear bearing shim. LC
SMT035D

3. Place suitable shim on counter gear rear bearing with grease. EC

4. Apply ATF to each part in front case.
FE

CL

MT
SMT036D
AT
5. Assemble center case assembly.
a. Install mainshaft on center case by tapping lightly.
I Apply ATF to mainshaft front bearing.

PD

AX

SMT406A SU
b. Install bearing retainer.
BR

ST

RS

SMT407A BT

HA

SC

EL

IDX

TF-35
 ASSEMBLY TX10A

c. Put drive chain onto the front drive sprocket and front drive
shaft, and then put them in center case.

SMT168E

SMT409A

d. Install front drive shaft by tapping lightly.

I Make sure shafts are lined up in the case.

SMT410A

e. Apply ATF to needle bearings and install them into front drive
sprocket.
I These needle bearings can be installed more easily if front
drive sprocket is rotated while installing them.

SMT411A

f. Install 2-4 coupling sleeve with 2-4 shift fork.

I Pay special attention to direction of coupling sleeve.

SMT412A

TF-36
 ASSEMBLY TX10A

g. Install clutch gear and mainshaft rear bearing. GI

I Place wooden block under mainshaft in order to protect
mainshaft front bearing.
MA

EM

LC
SMT192E

h. Install spacer. EC
i. Select snap ring with proper thickness and install it.
Allowable clearance between snap ring and groove: FE
0 - 0.15 mm (0 - 0.0059 in)
Available snap ring for mainshaft rear bearing:
Refer to SDS, TF-39. CL

MT
SMT414A
AT
j. Install steel ball, speedometer drive gear and retainer ring.
I Steel ball is the smallest of check balls for this unit.

PD

AX

SMT415A SU
k. Install low gear and its bearing to mainshaft.
I Apply ATF to needle bearing.
BR

ST

RS

SMT340A BT
l. Install L & H hub and snap ring to mainshaft.
I Pay special attention to direction of L & H hub. HA

SC

EL

IDX
SMT193E

TF-37
 ASSEMBLY TX10A

m. Measure end play of low gear.

Standard:
0.2 - 0.35 mm (0.0079 - 0.0138 in)

SMT342A

6. Apply sealant to mating surface and put center case assem-

bly onto front case and tighten bolts.
Sealant:
Refer to Case Components, TF-17.

SMT343A

7. Install snap ring to 2-4 shift rod.

SMT272A

8. Install oil gutter and oil cover.

9. Apply ATF to each part in center case.

SMT344A

10. Apply sealant to mating surface and install rear case on cen-
ter case.
11. Install 4WD switch.
I Apply sealant to thread of switch.
Sealant:
Refer to Case Components, TF-17.

SMT037D

TF-38
 SERVICE DATA AND SPECIFICATIONS (SDS) TX10A
General Specifications

General Specifications NATF0130

GI
Transfer model TX10A

High 1.000 MA
Gear ratio
Low 2.020

Main gear 29 EM
Low gear 37

High 38 LC
Number of teeth Counter gear
Low 24

Front drive sprocket 41

EC
Front drive shaft 41

Fluid capacity  (US qt, Imp qt)* 2.2 (2-3/8, 2)

FE
*: Refer to MA-12, “Fluids and Lubricants”.
CL
Gear End Play NATF0131
Unit: mm (in)

Front drive sprocket 0.2 - 0.35 (0.0079 - 0.0138) MT

Low gear 0.2 - 0.35 (0.0079 - 0.0138)

Counter gear 0 - 0.2 (0 - 0.008)

AT

Available Snap Ring NATF0132

MAINSHAFT FRONT BEARING NATF0132S01

Allowable clearance 0 - 0.15 mm (0 - 0.0059 in)

PD
Thickness mm (in) Part number*

3.10 (0.1220)
3.19 (0.1256)
33138-73P10
33138-73P11
AX
3.28 (0.1291) 33138-73P12

*: Always check with the Parts Department for the latest parts information. SU
MAINSHAFT REAR BEARING NATF0132S02

Allowable clearance 0 - 0.15 mm (0 - 0.0059 in) BR

Thickness mm (in) Part number*

1.80 (0.0709) 33138-73P20

ST
1.89 (0.0744) 33138-73P21
1.98 (0.0780) 33138-73P22
2.07 (0.0815) 33138-73P23 RS
2.16 (0.0850) 33138-73P24

*: Always check with the Parts Department for the latest parts information.
BT
MAIN GEAR BEARING NATF0132S03

Allowable clearance 0 - 0.15 mm (0 - 0.0059 in)

HA
Thickness mm (in) Part number*

2.60 (0.1024)
2.69 (0.1059)
33114-73P00
33114-73P01
SC
2.78 (0.1094) 33114-73P02

*: Always check with the Parts Department for the latest parts information. EL

IDX

TF-39
 SERVICE DATA AND SPECIFICATIONS (SDS) TX10A
Available Shim

Available Shim NATF0133

COUNTER GEAR REAR BEARING NATF0133S01

Allowable clearance 0 - 0.2 mm (0 - 0.008 in)

Thickness mm (in) Part number*

0.1 (0.004) 33112-C6900

0.2 (0.008) 33112-C6901
0.3 (0.012) 33112-C6902
0.4 (0.016) 33112-C6903
0.5 (0.020) 33112-33G00
0.6 (0.024) 33112-33G01

*: Always check with the Parts Department for the latest parts information.

TF-40
 PRECAUTIONS ATX14A
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

Supplemental Restraint System (SRS) “AIR GI

BAG” and “SEAT BELT PRE-TENSIONER” NATF0001
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of
MA
collision. The SRS system composition which is available to NISSAN MODEL PATHFINDER is as follows:
I For a frontal collision EM
The Supplemental Restraint System consists of driver air bag module (located in the center of the steer-
ing wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt
pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable. LC
I For a side collision
The Supplemental Restraint System consists of side air bag module (located in the outer side of front seat),
satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, EC
warning lamp (one of components of air bags for a frontal collision).
Information necessary to service the system safely is included in the RS section of this Service Manual.
FE
WARNING:
I 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 CL
by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air MT
Bag Module, see the RS section.
I 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 with yellow harness connector (and with AT
yellow harness protector or yellow insulation tape before the harness connectors).

PD

AX

SU
Precautions NATF0092
I Before connecting or disconnecting the Transfer control BR
unit harness connector, turn ignition switch OFF and dis-
connect negative battery terminal. Failure to do so may
damage the Transfer control unit. Because battery voltage ST
is applied to Transfer control unit even if ignition switch
is turned off.
RS

SEF289H BT
I When connecting or disconnecting pin connectors into or
from Transfer control unit, take care not to damage pin HA
terminals (bend or break).
Make sure that there are not any bends or breaks on
Transfer control unit pin terminal, when connecting pin SC
connectors.

EL

IDX
SEF291H

TF-41
 PRECAUTIONS ATX14A
Precautions (Cont’d)
I Before replacing Transfer control unit, perform Transfer
control unit input/output signal inspection and make sure
whether Transfer control unit functions properly or not.
(See page TF-89.)

MEF040DB

Service Notice NATF0002

1) Before proceeding with disassembly, thoroughly clean the outside of the all-mode 4WD transfer. It is
important to prevent the internal parts from becoming contaminated by dirt or other foreign matter.
2) Disassembly should be done in a clean work area.
3) Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could inter-
fere with the operation of the all-mode 4WD transfer.
4) Place disassembled parts in order for easier and proper assembly.
5) All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
6) Gaskets, seals and O-rings should be replaced any time the all-mode 4WD transfer is disassembled.
7) It is very important to perform functional tests whenever they are indicated.
8) The valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place removed parts in a parts rack in order to replace them in correct positions and sequences. Care will
also prevent springs and small parts from becoming scattered or lost.
9) Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
10) Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings
and seals, and to hold bearings and washers in place during assembly. Do not use grease.
11) Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
12) After overhaul, refill the transfer with new ATF.
13) When the all-mode 4WD transfer drain plug is removed, only some of the fluid is drained. Old all-mode
4WD transfer fluid will remain in torque converter and ATF cooling system. Always follow the procedures,
MA-24, “Changing All-mode 4WD Transfer Fluid”.
Wiring Diagrams and Trouble Diagnosis NATF0003
When you read wiring diagrams, refer to the following:
I GI-11, “HOW TO READ WIRING DIAGRAMS”
I EL-11, “POWER SUPPLY ROUTING”
When you perform trouble diagnosis, refer to the following:
I GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSIS”
I GI-24, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”

TF-42
ALL-MODE 4WD SYSTEM ATX14A
Cross-sectional View

Cross-sectional View NATF0006

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL
SMT953CA
IDX

TF-43
 ALL-MODE 4WD SYSTEM ATX14A
Control System

Control System NATF0007

SMT210E

TF-44
ALL-MODE 4WD SYSTEM ATX14A
Control System (Cont’d)
ALL-MODE 4WD TRANSFER BASIC CONTROL NATF0007S01
GI

MA

EM

LC

EC

FE

CL

SMT043D MT
HYDRAULIC CONTROL CIRCUITS NATF0007S02
AT

PD

AX

SU

BR

ST

SMT040D
RS
OUTLINE NATF0007S03
All-mode 4WD transfer is controlled by the transfer control unit and BT
sensors.
If a malfunction occurs in the all-mode 4WD system, the 4WD
warning lamp lights up to indicate the system malfunction. There HA
are two ways to identify the cause of the malfunction.
1) Performing the self-diagnosis. (The 4WD warning lamp will
indicate what kind of malfunction has occurred by flickering.) SC
2) Performing diagnosis using CONSULT-II.
EL

IDX

TF-45
 ALL-MODE 4WD SYSTEM ATX14A
Control System (Cont’d)
CONTROL SYSTEM DIAGRAM NATF0007S04

SMT211E

INDICATIONS OF 4WD WARNING LAMP NATF0007S05

Condition Content 4WD warning lamp

During self-diagnosis Indicates the malfunction position by number of flickers. Flickers at malfunction mode.

Checks the lamp by turning ON during engine starting. After

Lamp check* ON
engine starts, it turns OFF if there are no malfunctions.

Turns ON to indicate malfunction. When ignition switch is

Malfunction in 4WD system* ON
turned to “OFF” or the malfunction is corrected, it turns OFF.

When vehicle is driven with different Flickers once every 2 seconds. Flickers once every 2 sec-
diameters of front and rear tires Turns OFF when ignition switch is “OFF”. onds.

When fluid temperature is high or fluid temperature sensor

High fluid temperature in transfer
circuit is shorted, it flickers twice every second. Flickers twice a second.
unit
It turns OFF when fluid temperature becomes normal.

Other than above (System is nor-

Lamp is OFF. OFF
mal.)

*: When 4WD warning lamp is ON, all the 4WD shift indicator lamps turn OFF.

TF-46
 ALL-MODE 4WD SYSTEM ATX14A
CAN Communication (With VDC)

CAN Communication (With VDC) =NATF0134

GI
SYSTEM DESCRIPTION NATF0134S01
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many
MA
electronic control units are equipped onto a vehicle, and each control unit shares information and links with
other control units during operation (not independent). In CAN communication, control units are connected with EM
2 communication lines (CAN H line, CAN L line). These allow a high rate of information transmission with less
wiring. Each control unit transmits/receives data but selectively reads required data only.
For details, refer to EL-409, “CAN Communication Unit”. LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-47
 ALL-MODE 4WD SYSTEM ATX14A
Location of Electrical Parts

Location of Electrical Parts NATF0008

SMT171E

TF-48
 ALL-MODE 4WD SYSTEM ATX14A
Description of Electrical Parts

Description of Electrical Parts NATF0067

GI
TRANSFER MOTOR NATF0067S01
1. The transfer motor drives the sub-oil pump to provide proper lubrication and oil pressure control when the
vehicle is at standstill, during low-speed operations or is being driven in reverse.
MA
2. The main oil pump is operated by the driving force of the mainshaft. In other words, sufficient oil pressure
buildup does not occur when the vehicle is at standstill or during low-speed operations. While the vehicle EM
is being driven in reverse, the main oil pump rotates in the reverse direction. Therefore the main oil pump
does not discharge oil pressure. During any of the above vehicle operations, the transfer motor drives the
sub-oil pump to compensate for insufficient oil pressure. LC
3. The transfer motor operates as follows:
1) The motor relay turns OFF in the 2WD mode.
2) The motor relay operates as described in the table below in modes other than the 2WD mode. EC
Table 1
PNP switch “R” position VFF (Vehicle speed) A/T position Motor relay drive command FE
ON — R ON

Positions other than the “P” or

CL
0 km/h ON
“N” positions

—
“P” or “N” position (See Table
—
MT
2.)
OFF
0 < VFF % 30 km/h — ON
AT
30 < VFF < 35 km/h — HOLD

35 km/h % VFF — OFF

Table 2 PD
Throttle position
A/T position N-4L SW 4WD mode
0 - 0.07/8 0.07/8 - 1/8 1/8 - MAX AX
LOCK (4H) ON ON ON

OFF Positions other than SU

N the LOCK position See NOTE. HOLD ON
(2WD or AUTO)

ON — See NOTE. HOLD ON

BR
P — — See NOTE. HOLD ON
NOTE: ST
OFF (after 2.5 seconds have elapsed.)
4. 4WD shift switch, PNP switch, Neutral-4LO switch, vehicle speed sensor and throttle position sensor are
used in conjunction with the transfer motor.
RS
WAIT DETECTION SWITCH
1. The wait detection switch releases the “booming” torque produced in the propeller shaft. After the release
NATF0067S02
BT
of the “booming” torque, the wait detection switch helps provide the 4WD lock gear (clutch drum) shifts.
A difference may occur between the operation (“4LO” to “4H” shift only) of the 4WD shift switch and actual
drive mode. At this point, the wait detection switch senses an actual drive mode. HA
2. The wait detection switch operates as follows:
4WD lock gear (clutch drum) locked: ON SC
4WD lock gear (clutch drum) released: OFF
3. The wait detection switch senses an actual drive mode and the 4WD shift indicator lamp indicates the
vehicle drive mode. EL

IDX

TF-49
 ALL-MODE 4WD SYSTEM ATX14A
Description of Electrical Parts (Cont’d)
2-4WD SHIFT SOLENOID VALVE NATF0067S03
The 2-4WD shift solenoid valve operates to apply oil pressure to the wet, multiplate clutch, depending on the
drive mode. The driving force is transmitted to the front wheels through the clutch so the vehicle is set in the
4WD mode. Setting the vehicle in the 2WD mode requires no pressure buildup. In other words, pressure force
applied to the wet, multiplate clutch becomes zero.
LINE PRESSURE SWITCH NATF0067S04
1. With the transfer system design, control of the oil pressure provides the transmission of drive torque to
the front wheels. The main pressure to control the oil pressure is referred to as the line pressure.
The line pressure switch determines whether or not adequate line pressure has built up under different
operating conditions.
2. The line pressure switch turns ON when line pressure is produced.
3. The line pressure switch senses line pressure abnormalities and turns the 4WD warning lamp ON.

TF-50
ALL-MODE 4WD SYSTEM ATX14A
Circuit Diagram for Quick Pinpoint Check

Circuit Diagram for Quick Pinpoint Check NATF0009

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL
MTF263A
IDX

TF-51
 ALL-MODE 4WD SYSTEM ATX14A
Wiring Diagram — TF —

Wiring Diagram — TF — NATF0010

MTF261A

TF-52
ALL-MODE 4WD SYSTEM ATX14A
Wiring Diagram — TF — (Cont’d)

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL
MTF173A

IDX

TF-53
 ALL-MODE 4WD SYSTEM ATX14A
Wiring Diagram — TF — (Cont’d)

MTF262A

TF-54
ALL-MODE 4WD SYSTEM ATX14A
Wiring Diagram — TF — (Cont’d)

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL
MTF264A

IDX

TF-55
 ALL-MODE 4WD SYSTEM ATX14A
Wiring Diagram — TF — (Cont’d)

MTF176A

TF-56
ALL-MODE 4WD SYSTEM ATX14A
Wiring Diagram — TF — (Cont’d)

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL
MTF177A

IDX

TF-57
 ALL-MODE 4WD SYSTEM ATX14A
Wiring Diagram — TF — (Cont’d)

MTF178A

TF-58
ALL-MODE 4WD SYSTEM ATX14A
Wiring Diagram — TF — (Cont’d)

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL
MTF179A

IDX

TF-59
 ALL-MODE 4WD SYSTEM ATX14A
Wiring Diagram — TF — (Cont’d)

MTF180A

TF-60
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis without CONSULT-II

Trouble Diagnosis without CONSULT-II NATF0011

GI
DESCRIPTION NATF0011S01
If the engine starts when there is something wrong with the all-
mode 4WD system, the 4WD warning lamp turns ON or flickers in
MA
the combination meter. When the system functions properly, the
warning lamp turns ON when the ignition switch is turned to “ON”, EM
and it turns OFF after engine starts.
To locate the cause of a problem, start the self-diagnosis function.
The 4WD warning lamp in the combination meter will indicate the LC
problem area by flickering according to the self-diagnostic results.
As for the details of the 4WD warning lamp flickering patterns, refer
to TF-63. EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-61
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis without CONSULT-II (Cont’d)
SELF-DIAGNOSTIC PROCEDURE NATF0011S02

SMT993D

*1: TF-136 *2: TF-63

TF-62
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis without CONSULT-II (Cont’d)
INDICATIONS OF 4WD WARNING LAMP NATF0011S03
GI
Flickering pattern or flick-
Malfunction Check items
ering condition
MA
Revolution sensor (front) circuit,
1 Front revolution sensor circuit is shorted or open.
TF-97.
EM
Revolution sensor (rear) [Refer to
2 Rear revolution sensor circuit is shorted or open. AT-114, “DTC P0720 Vehicle Speed
Sensor·A/T (Revolution sensor)”.]
LC
3 4WD solenoid valve circuit is shorted or open. 4WD solenoid valve circuit, TF-100.

2-4WD shift solenoid valve circuit is shorted or 2WD switch of 2-4WD shift solenoid valve circuit or EC
4
4WD shift switch is shorted. 4WD shift switch circuit, TF-102.

5 Transfer motor relay circuit is shorted or open. Transfer motor relay circuit, TF-106.
FE
If unexpected signal is detected because of ABS wheel sensor Refer to ABS wheel sensor signal
6
malfunction or communications error between the vehicles circuit diagnosis.

Refer to CAN communication system CL

7 When malfunction in CAN communication system is detected
diagnosis.

Power supply voltage of throttle position sensor is improper. Or

Throttle position sensor (Refer to MT
8 AT-179, “DTC P1705 Throttle Posi-
A/D converter of transfer control unit functions improperly.
tion Sensor”.)

Transfer fluid temperature sensor AT

9 Transfer fluid temperature sensor circuit is open.
circuit, TF-109.

10 Neutral-4LO switch circuit is shorted or open. Neutral-4LO switch circuit, TF-112.

2-4WD shift solenoid valve circuit, 2WD switch of 4WD shift 2-4WD shift solenoid valve circuit,
11 switch circuit or clutch pressure switch circuit is shorted or 4WD shift switch circuit or clutch
open. pressure switch circuit, TF-102, 116. PD
12 Line pressure switch circuit is shorted or open. Line pressure switch circuit, TF-119.

Engine speed signal (Refer to AX

13 Engine speed signal circuit is shorted or open. AT-119, “DTC P0725 Engine Speed
Signal”.)
SU
Throttle position sensor (Refer to
14 Throttle position sensor circuit is shorted or open. AT-179, “DTC P1705 Throttle Posi-
tion Sensor”.) BR
15 Malfunction in power supply circuit of transfer control unit. Power supply of transfer control unit

16 4WD shift switch circuit is shorted. 4WD shift switch circuit, TF-102. ST
17 ABS operation signal circuit is shorted. ABS operation signal circuit, TF-122.

18
ATP switch, wait detection switch or neutral-4LO switch circuit is ATP switch, wait detection switch or RS
shorted or open. neutral-4LO switch circuit*, TF-112.

Transfer control device actuator motor is malfunctioning. (Mal-

19 functions are detected when actuator motor fails to operate
Actuator motor and motor circuit, BT
TF-151, 125.
while shifting from “4H” to “4LO” or vice versa.)

Transfer control device actuator motor arm position sensing

Actuator motor arm position sensing HA
20 switch and sensing switch circuit,
switch is malfunctioning.
TF-151, 128.

Actuator motor, actuator motor arm SC

Transfer control device actuator circuit is shorted or open. (Mal-
position sensing switch and their
21 functions are detected when motor relay circuit is open/shorted
associated circuits, TF-150, 151 and
or relay monitor circuit is open/shorted.) EL
130.

If VDC operation signal is being input because of VDC malfunc-

22 Refer to VDC/TCS/ABS diagnosis.
tion or communication error between the vehicles
IDX

TF-63
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis without CONSULT-II (Cont’d)

Flickering pattern or flick-

Malfunction Check items
ering condition

If TCS operation signal is being input because of TCS malfunc-

23 Refer to VDC/TCS/ABS diagnosis.
tion or communication error between the vehicles

If unexpected signal is input because of A/T PNP switch circuit

24 Refer to A/T trouble diagnosis.
or communication error between the vehicles

Repeats flickering every

Circuits that the self-diagnosis covers have no malfunction. —
2 to 5 sec.

I Power supply failure of memory back-up.

Repeats flickering every
I Battery is disconnected for a long time. Data erase/display circuit, TF-124.
0.25 sec.
I Battery performance is poor.

PNP switch (Refer to AT-102, “DTC

P0705 Park/Neutral Position
No flickering PNP switch or 4WD shift switch circuit is shorted or open.
Switch”.) or 4WD shift switch circuit,
TF-102.

*: If revolution sensor malfunction is simultaneously detected, check revolution sensor first.

Trouble Diagnosis with CONSULT-II NATF0012

CONSULT-II FUNCTION NATF0012S10

Diagnostic test mode Function

I This mode enables a technician to adjust some devices faster and more accurately
Work support
by following the indications on the CONSULT-II unit.

Self-diagnostic results I Self-diagnostic results can be read and erased quickly.

Data monitor I Input/Output data in the AWD control unit can be read.

CAN diagnostic support monitor I The results of transmit/receive diagnosis of CAN communication can be read.

I Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the
Active test
AWD control unit and also shifts some parameters in a specified range.

ECU part number I AWD control unit part number can be read.

SELF-DIAGNOSIS NATF0012S01
CONSULT-II Setting Procedure NATF0012S0101
I For details, refer to the “CONSULT-II Operation Manual”.
1. Turn ignition switch to “OFF” position.

SAT601J

TF-64
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis with CONSULT-II (Cont’d)
2. Connect CONSULT-II and CONSULT-II CONVERTER to data GI
link connector which is located in instrument lower panel on
driver side.
MA

EM

LC
SEF941Y

3. Start engine. EC
4. On CONSULT-II screen, touch “START (NISSAN BASED
VHCL)”.
FE

CL

MT
SAIA0450E
AT
5. Touch “ALL MODE AWD/4WD” on SELECT SYSTEM screen.
If “ALL MODE AWD/4WD” is not displayed, go to GI-42, “CON-
SULT-II Data Link Connector (DLC) Circuit”.

PD

AX

SDIA2216E SU
6. Touch “SELF-DIAG RESULTS” on SELECT DIAG MODE
screen.
BR

ST

RS

SMT212E BT
7. Self-diagnostic results are displayed.
HA

SC

EL

IDX
SMT966D

TF-65
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis with CONSULT-II (Cont’d)
SELF-DIAGNOSTIC ITEMS NATF0012S02

Detected items
(Screen terms for CONSULT-II, Malfunction is detected when... Check items
“SELF-DIAG RESULT” mode)

I Front revolution sensor (installed on T/F) signal is not

Revolution sensor (front) (Note 3) Revolution sensor (front) circuit,
input due to open circuit.
(VHCL SPEED SEN·FR) TF-97.
I Improper signal is input while driving.

Revolution sensor (rear) [Refer to

I Signal from vehicle speed sensor 1 (installed on A/T)
Revolution sensor (rear) AT-114, “DTC P0720 Vehicle
is not input due to open circuit.
(VHCL SPEED SEN·RR) Speed Sensor·A/T (Revolution
I Improper signal is input while driving.
sensor)”.]

4WD solenoid valve

4WD solenoid valve, TF-100.
(DUTY SOLENOID) I Proper voltage is not applied to solenoid valve due to
2-4WD shift solenoid valve open or short circuit. 2-4WD shift solenoid valve or
(2-4WD SOLENOID) 4WD shift switch circuit, TF-102.

Transfer motor relay I Motor does not operate properly due to open or short Transfer motor relay circuit,
(MOTOR RELAY) circuit in transfer motor or motor relay. TF-106.

I Signal voltage from fluid temperature sensor is abnor-

Transfer fluid temperature sensor Transfer fluid temperature sensor
mally high (T/F fluid temperature is abnormally low)
(FLUID TEMP SENSOR) circuit, TF-109.
while driving.

Neutral-4LO switch
I Improper signal is input while driving. Neutral-4LO switch, TF-112.
(N POSI SW TF)

Clutch pressure I Improper signal is input due to open or short circuit. Clutch pressure switch circuit
(CLUTCH PRESSURE) I Malfunction occurs in clutch pressure hydraulic circuit. (*1), TF-116.

Line pressure I Improper signal is input due to open or short circuit. Line pressure switch circuit (*1),
(LINE PRESSURE) I Malfunction occurs in line pressure hydraulic circuit. TF-119.

Engine speed signal (Refer to

Engine speed signal (Note 1)
I Engine speed is abnormally low while driving. AT-119, “DTC P0725 Engine
(ENGINE SPEED SIG)
Speed Signal”.)

I Signal voltage from throttle position sensor is abnor-

Throttle position sensor (Refer to
Throttle position sensor mally high.
AT-179, “DTC P1705 Throttle
(THRTL POSI SEN) I Signal voltage from throttle position sensor is abnor-
Position Sensor”.)
mally low when closed throttle position switch is OFF.

I Power supply voltage for throttle position sensor is Throttle position sensor (Refer to
Transfer control unit (ADC)
improper or A/D converter system of transfer control AT-179, “DTC P1705 Throttle
C/U (ADC)/THRTL SEN
unit is malfunctioning. Position Sensor”.)

Power supply circuit (Refer to

Battery voltage (Note 1) I Power supply voltage for transfer control unit is abnor-
AT-99, “Wiring Diagram — AT —
(BATTERY VOLTAGE) mally low while driving.
MAIN”.)

4WD shift switch I More than two switch inputs are simultaneously
4WD shift switch circuit, TF-102.
(4WD MODE SW) detected due to short circuit of 4WD shift switch.

I When a malfunction signal due to disconnection or

ABS operation signal (Note 4) shorting is detected. ABS operation signal circuit,
(ABS OPER SIGNAL) I When a defect signal is entered from the ABS control TF-122.
unit.

ATP switch, wait detection switch

Wait detection switch (Note 2)
I Improper signal is input due to open or short circuit. and neutral-4LO switch circuits
(WAIT DETECT SWITCH)
(*2), TF-112.

Transfer control device actuator motor is malfunctioning.

Shift actuator abnormal Actuator motor and motor circuit,
(Malfunctions are detected when actuator motor fails to
(SHIFT ACT) TF-151, 125.
operate while shifting from “4H” to “4LO” or vice versa.)

TF-66
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis with CONSULT-II (Cont’d)

Detected items GI
(Screen terms for CONSULT-II, Malfunction is detected when... Check items
“SELF-DIAG RESULT” mode)
MA
Shift actuator position switch Actuator motor arm position
Transfer control device actuator motor arm position sens-
abnormal sensing switch and sensing
ing switch is malfunctioning.
(SHIFT ACT P/S) switch circuit, TF-151, 128.
EM
Actuator motor, actuator motor
Transfer control device actuator circuit is shorted or
Shift actuator circuit abnormal arm position sensing switch and
open. (Malfunctions are detected when motor relay circuit
(SHIFT ACT CIR)
is open/shorted or relay monitor circuit is open/shorted.)
their associated circuits, TF-150, LC
151 and 130.

I Due to removal of battery which cuts off power supply

Memory power supply stop to transfer control unit, self-diagnosis memory function
Data erase/display circuit, EC
TF-124.
is suspended.

Transfer control unit (RAM) I Malfunction is detected in the memory (RAM) system FE
[CONTROL UNIT (RAM)] of transfer control unit.

Transfer control unit (ROM) I Malfunction is detected in the memory (ROM) system
[CONTROL UNIT (ROM)] of transfer control unit.
CL
Transfer control unit (EEPROM) I Malfunction is detected in the memory (EEPROM) sys-
[CONTROL UNIT (EEPROM)] tem of transfer control unit. MT
Longitudinal G-sensor Displayed, but do not use.

I ABS vehicle speed sensor signal is not input due to an AT

open circuit. Refer to ABS vehicle speed sen-
ABS VHL SPD SEN
I An unexpected signal is input when vehicle is being sor diagnosis.
driven.

STEERING ANGLE SENSOR Displayed, but do not use.

VDC OPER SIG

If VDC operation signal is being input because of VDC Refer to VDC/TCS/ABS diagno- PD
malfunction or communication error between the vehicles sis.

If TCS operation signal is being input because of TCS Refer to VDC/TCS/ABS diagno-
TCS OPER SIG
malfunction or communication error between the vehicles sis.
AX
CAN COMM Malfunction is detected in CAN communication. CAN communication circuit
SU
When AT PNP switch circuit is malfunction or communi- Refer to AT PNP switch circuit
A/T POSITION SIGNAL
cation error between the vehicles diagnosis.

Note 1: When a malfunction occurs, it is only displayed and not stored in the memory. BR
Note 2: When the wait detection switch has been properly fixed, malfunction information is erased from the memory.
Note 3: If 4WD shift switch is left between 4H and 4LO for a while, this indication may be displayed.
(*1): If the malfunction is detected only while driving in reverse, check the continuity of “R” position on A/T PNP switch. When there is ST
nothing wrong with the electrical system, check the hydraulic system.
(*2): If a revolution sensor malfunction is detected at the same time, check the revolution sensor circuit first.
Note 4: When this malfunction is detected with the ABS warning lamp off, first check for disconnection or shorting in the harness between RS
the transfer control unit and the ABS control unit.

BT
DATA MONITOR NATF0012S03
CONSULT-II Setting Procedure NATF0012S0301
HA
I For details, refer to the “CONSULT-II Operation Manual”.
1. Turn ignition switch to “OFF” position.
SC
2. Connect CONSULT-II and CONSULT-II CONVERTER to data
link connector, which is located in instrument lower panel on
driver side. EL
3. Turn ignition switch to “ON” position.
4. Touch “START (NISSAN BASED VHCL)”.
IDX
SEF941Y

TF-67
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis with CONSULT-II (Cont’d)
5. Touch “ALL MODE AWD/4WD”.
If “ALL MODE AWD/4WD” is not displayed, go to GI-42, “CON-
SULT-II Data Link Connector (DLC) Circuit”.

SDIA2216E

6. Touch “DATA MONITOR”.

SMT212E

7. Touch “ECU INPUT SIGNALS” or “MAIN SIGNALS”.

8. Select “Numerical Display”, “Bar Chart Display” or “Line Graph
Display”.
9. Touch “SETTING” to set record conditions.

SAT972J

10. Touch “AUTO TRIG” or “MANU TRIG”.

11. Return to “SELECT MONITOR ITEM” on “DATA MONITOR”
screen and touch “START”.

SAT973J

12. Monitored data are displayed.

SMT963D

TF-68
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis with CONSULT-II (Cont’d)
DATA MONITOR ITEMS NATF0012S04
GI
q: Standard H: Option

Monitor item selection

MA
SELEC-
Item [Unit] ECU Remarks
MAIN SIG- TION
INPUT SIG-
NALS
NALS FROM EM
MENU

Revolution sensor-front [km/h (MPH)] q H Revolution sensor installed on T/F

LC
Revolution sensor-rear [km/h (MPH)] q H Vehicle speed sensor·A/T

Engine speed [rpm] q H

EC
Throttle position sensor [V] q H

Transfer fluid temperature sensor [V] q H FE

Battery voltage [V] q H

2WD switch [ON-OFF] q H 2WD switch of 4WD shift switch CL

AUTO switch [ON-OFF] q H AUTO switch of 4WD shift switch

Lock switch [ON-OFF] q H 4H switch of 4WD shift switch MT

4L switch [ON-OFF] q H 4LO switch of 4WD shift switch

N position switch TF [ON-OFF] q H N position switch of transfer AT

Line pressure switch [ON-OFF] q H Line pressure switch

Clutch pressure switch [ON-OFF] q H Clutch pressure switch

ATP switch [ON-OFF] q H

N position switch [ON-OFF] q H “N” position on A/T PNP switch

PD
R position switch [ON-OFF] q H “R” position on A/T PNP switch
AX
P position switch [ON-OFF] q H “P” position on A/T PNP switch

Closed throttle position switch

q H Displayed, but do not use. SU
[ON/OFF]

ABS operation switch [ON-OFF] q H ABS operation switch

Wait detection switch [ON-OFF] q H BR

Throttle opening recognized by transfer control
Throttle opening q H
unit ST
4WD-mode recognized by transfer control unit
4WD-mode q H
(2WD, AUTO, 4H & 4LO)
RS
Vehicle speed recognized by transfer control
Vehicle speed comp [km/h (MPH)] q H
unit

Calculated torque recognized by transfer control

BT
*Control torque [N·m (kg-m, ft-lb)] q H
unit

Duty solenoid valve [%]

q H
HA
(Transfer 4WD solenoid valve)

2-4WD shift solenoid valve [ON-OFF] q H

SC
Transfer motor relay [ON-OFF] q H
Control signal outputs of transfer control unit
Shift activating 1 [ON-OFF] q H
EL
Shift activating 2 [ON-OFF] q H

IDX

TF-69
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis with CONSULT-II (Cont’d)

Monitor item selection

SELEC-
Item [Unit] ECU Remarks
MAIN SIG- TION
INPUT SIG-
NALS FROM
NALS
MENU

2-4WD shift solenoid valve monitor

H
[ON-OFF]
Check signal (re-input signal) of transfer control
Transfer motor relay monitor [ON-OFF] H unit control signal output is displayed. If circuit
is shorted or open, ON/OFF state does not
Shift activating monitor 1 [ON-OFF] H change.
Shift activating monitor 2 [ON-OFF] H

Transfer control unit control signal output for

4WD fail lamp [ON-OFF] q H
4WD warning lamp (left)

Shift position switch 1 [ON-OFF] q H

Shift position switch 2 [ON-OFF] q H

Transfer control unit control signal output for

2WD indicator lamp [ON-OFF] H
4WD shift indicator lamp (rear)

Transfer control unit control signal output for

AUTO indicator lamp [ON-OFF] H
4WD shift indicator lamp (front & rear)

Transfer control unit control signal output for

LOCK indicator lamp [ON-OFF] H
4WD shift indicator lamp (center)

Transfer control unit control signal output for

4LO indicator lamp [ON-OFF] H
4WD shift indicator lamp (right)

Offset at starting H Appears on monitor but does not function.

Clutch force release limit value set in WORK

Clutch limit [N·m (kg-m, ft-lb)] H
SUPPORT

Voltage [V] H Value measured by voltage probe is displayed.

Value measured by pulse probe is displayed. If

measurement is impossible, “#” sign is dis-
Frequency [Hz] H played. “#” sign is also displayed at the final
data value until the measurement result is
obtained.

DUTY-HI H Duty cycle value for measurement probe is dis-

DUTY-LOW H played.

PLS WIDTH-HI H Measured pulse width of measurement probe is

PLS WIDTH-LOW H displayed.

Indicates average vehicle speed of ABS front

VHCL SPEED SEN-FR [km/h] q H
left/right wheel.

Indicates average vehicle speed of ABS rear

VHCL SPEED SEN-RR [km/h] q H
left/right wheel.

LONGITUDINAL G-SENSOR [G] q H Displayed, but do not use.

TF VHCL SPD-FR [km/h] q H Displayed, but do not use.

AT VHCL SPD-RR q H Indicates A/T rear vehicle speed.

A/T actual gear position q H A/T actual gear position is displayed.

VDC OPER SIG [ON-OFF] q H VDC operation signal is displayed.

TCS OPER SIG [ON-OFF] q H TCS operation signal is displayed.

TF-70
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis with CONSULT-II (Cont’d)

Monitor item selection GI

SELEC-
Item [Unit] ECU Remarks
INPUT SIG-
MAIN SIG- TION MA
NALS FROM
NALS
MENU

C/U control signal output of ATP lamp is dis- EM

ATP LAMP [ON-OFF] H
played.

*: This item is indicated as “COMP CL TORQ”. LC

REFERENCE VALUE IN DATA MONITOR MODE NATF0012S09

Indicated items EC
(Screen terms for CONSULT-II, Display Conditions
“DATA MONITOR” mode)
FE
Throttle position sensor
Approx. 0.5 - 4.0V Throttle valve fully closed to fully open
(THRTL POS SEN)

Transfer fluid temperature sensor Transfer fluid temperature approx. 20 - 80°C (68 - CL
Approx. 1.5 - 0.5V
(FLUID TEMP SE) 176°F)

Closed throttle position switch MT

OFF Displayed, but do not use.
(CLOSED THL/SW) (Without VDC)

ABS operation switch OFF ABS is not operating.

(ABS OPER SW)
AT
ON ABS is operating.

2WD position ON 4WD shift switch is in “2WD”.

(2WD SW) OFF Except the above condition

ON 4WD shift switch is in “4H”.

Lock position PD
(LOCK SWITCH) OFF Except the above condition

2WD, AUTO,
4WD shift switch position
4H
(N) 4LO AX
Neutral-4LO switch ATP switch OFF ON OFF
(N POSI SW TF) SU
ATP switch Neutral-4LO switch OFF ON
(ATP SWITCH) OFF ON
Wait detection switch Wait detection switch BR
(WAIT DETCT SW) See Note.

Note: When shifting from “4LO” to “2WD”, “AUTO”, “4H”, it turns ON when “Wait” function
is operating (and it turns OFF when “Wait” function is canceled). ST
4WD shift A/T selector
Throttle valve Motor relay Remarks
switch lever RS
2WD — OFF
Transfer motor relay
AUTO, P, N OFF ON for approx. 2 sec. after BT
(MOTOR RELAY)
Fully closed 4LO Others ON shifting to “P” and “N”

P OFF ON for approx. 2 sec. after

HA
4H
Others ON shifting to “P”

The vehicle has been left at room temperature for 5 min- SC

OFF
Line pressure switch utes and more with ignition switch in “OFF” position.
(LINE PRES SW)
ON
Ignition switch in “ON”, and 4WD shift switch in “AUTO” EL
or “4H” and A/T selector lever in “D”.

IDX

TF-71
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis with CONSULT-II (Cont’d)

Indicated items
(Screen terms for CONSULT-II, Display Conditions
“DATA MONITOR” mode)

Ignition switch in “ON”, and 4WD shift switch in “2WD”.

OFF
(“Wait” function is not operating.)
Clutch pressure switch
(CL PRES SW) Ignition switch in “ON”, and 4WD shift switch in “AUTO”
ON or “4H” and A/T selector lever in “D”. (“Wait” function is
not operating.)

0 kg-m In “2WD” position

39 - 1,079 N·m
Control torque In “AUTO” position
(4 - 110 kg-m, 29 - 796 ft-lb)
(COMP CL TORQ)
1,079 N·m 4WD shift switch
(110 kg-m, 796 ft-lb) (“Wait” function is not oper- In “4H” or “4LO” position
ating.)
4% In “2WD” position
4WD solenoid
94 - 4% In “AUTO” position
(DUTY SOLENOID)
4% In “4H” or “4LO” position

OFF In “2WD” position

ON (“Wait” function is not oper-

ating.)
In “AUTO” position
OFF (“Wait” function is operat-
2-4WD shift solenoid valve ing.)
4WD shift switch
(2-4WD SOL) ON (“Wait” function is not oper-
ating.)
In “4H” position
OFF (“Wait” function is operat-
ing.)

ON In “4LO” position

Battery voltage Approx. 12V Key switch “ON” and engine at rest

Approx. 13 - 14V During idling

AUTO switch OFF 4WD shift switch in other than “AUTO” position

ON 4WD shift switch in “AUTO” position

4L switch OFF 4WD shift switch in other than “4LO” position

ON 4WD shift switch in “4LO” position

N position switch OFF A/T selector lever in other than “N” position

ON A/T selector lever in “N” position

R position swtich OFF A/T selector lever in other than “R” position

ON A/T selector lever in “R” position

P position switch OFF A/T selector lever in other than “P” position

ON A/T selector lever in “P” position

Throttle opening 0.0/8 - 8.0/8 Throttle fully closed (0.0/8) or throttle fully open (8.0/8)

2WD In “2WD” position

AUTO In “AUTO” position

4WD-mode 4WD shift switch
LOCK In “4H” position

4L In “4LO” position

TF-72
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis with CONSULT-II (Cont’d)

Indicated items GI
(Screen terms for CONSULT-II, Display Conditions
“DATA MONITOR” mode)
MA
Front wheel speed 0 - 255 km/h (0 - 158 MPH) 0 km/h (vehicle at standstill)

Rear wheel speed 0 - 255 km/h (0 - 158 MPH) 0 km/h (vehicle at standstill)
EM
Shift ACTR operating 1, OFF During normal operation
Shift activating monitor 1
ON During shifts from “4H” to “4LO” position
LC
Shift ACTR operating 2, OFF During normal operation
Shift activating monitor 2
ON During shifts from “4LO” to “4H” position
EC
4WD fail lamp OFF During normal operation

ON
During 2-second period (after key switch turned to “ON”) FE
or when system is out of order

Shift ACTR position sensing switch 1 OFF 4WD shift switch is in a position other than “4LO”.
CL
ON 4WD shift switch in “4LO” position

Shift ACTR position sensing switch 2 OFF 4WD shift switch in “4LO” position
MT
ON 4WD shift switch is in a position other than “4LO”.

2WD indicator lamp OFF Engine at rest or system out of order

AT
ON Except the above condition

AUTO indicator lamp Engine at rest during 2WD-mode operation or system

OFF
out of order

ON 4WD shift switch in “4LO” or “4H” or “AUTO” position

PD
LOCK indicator lamp Engine at rest and 4WD shift switch in “AUTO” position
OFF
during 2WD-mode operation or system out of order

ON 4WD shift switch in “4H” or “4LO” position AX

4LO indicator lamp Engine at rest and 4WD shift switch in “AUTO” position
OFF
during 2WD-mode operation or system out of order SU
ON 4WD shift switch in “4LO” position

VDC operation signal OFF VDC is not operating. BR

(VDC OPER SIG)
ON VDC is operating.

TCS operation signal OFF TCS is not operating. ST

(TCS OPER SIG)
ON TCS is operating.
RS
WORK SUPPORT NATF0012S06
Purpose NATF0012S0601
When there is no problem with transfer and 4WD system, follow- BT
ing symptoms in “AUTO” mode may be claimed by a customer.
I Tight corner braking symptom after accelerator (throttle) open-
ing (Note 1)
HA
I Vibration when accelerating on a low µ road (snow-covered or
icy road) (Note 2) SC
It is possible to deal with these symptoms by changing
“CLUTCH FORCE RELEASE LIMIT VALUE”. However, be
careful when changing the values because it may adversely EL
affect driving performance.
NOTE:
1) When the accelerator is slightly open (approx. 1/8) or fully IDX
closed after being opened. The tight corner braking symptom
TF-73
 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis with CONSULT-II (Cont’d)
during idle creep driving with accelerator fully closed cannot be
solved by this method. Refer to SYMPTOM 8, TF-144.
2) A slight shock is felt at a few hertz as if it were being pushed
lightly from behind.

CONSULT-II Setting Procedure NATF0012S0602

I For details, refer to the “CONSULT-II Operation Manual”.
1. Turn ignition switch to “OFF” position.
2. Connect CONSULT-II and CONSULT-II CONVERTER to data
link connector, which is located in instrument lower panel on
driver side.
3. Turn ignition switch to “ON” position.
4. Touch “START (NISSAN BASED VHCL)”.
5. Touch “ALL MODE AWD/4WD”.
If “ALL MODE AWD/4WD” is not displayed, go to GI-42, “CON-
SEF941Y SULT-II Data Link Connector (DLC) Circuit”.
6. Touch “WORK SUPPORT”.

SMT212E

7. Select WORK ITEM by touching “CLUTCH/F RLS LIM ADJ”.

NOTE:
“START TORQ OFFSET ADJ” is displayed, but the transfer does
not have this function.

SMT967D

CLUTCH FORCE RELEASE LIMIT ADJUSTMENT NATF0012S07

1.2 kg-m: Tight corner braking symptom is alleviated. However,
vibration may occur when accelerating on a low µ road (icy road,
etc.).
0.3 kg-m: Initial set value
0.2 kg-m: Do not set to this value because the tight corner braking
symptom will get worse.

TF-74
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ATX14A
Trouble Diagnosis with CONSULT-II (Cont’d)
1. Current CLUTCH FORCE RELEASE LIMIT value “0.3 kg-m” GI
appears under “CONDITION SETTING” on CONSULT-II dis-
play.
2. Touch “1.2” on the display. MA

EM

LC
SMT968D

3. Display changes to “NOW ADJUSTING” in a short time. EC

FE

CL

MT
SMT969D
AT
4. When clutch force release limit value is set to “1.2 kg-m”, cur-
rent value “0.3 kg-m” shown on display will be replaced by “1.2
kg-m” and “ADJUSTING COMPLETE” will appear at the same
time. Clutch force release limit value setting is now complete.

PD

AX

SMT970D SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-75
 TROUBLE DIAGNOSIS — INTRODUCTION ATX14A
Introduction

Introduction NATF0013
DESCRIPTION NATF0013S01
When a malfunction (indicated by the 4WD warning lamp illumination) occurs, collect information first from the
customer about how the malfunction occurs. Then, proceed with the diagnosis presuming it is the cause. Also
inspect the electrical system, paying close attention to other possibilities such as fluid level and leaks.
All-mode 4WD transfer is controlled by transfer control unit and sensors.
If a malfunction occurs in the all-mode 4WD system, the 4WD warning lamp lights up to inform of the system
malfunction. There are two ways to identify the cause of the malfunction.
1) Performing the self-diagnosis. (The 4WD warning lamp will indicate what kind of malfunction has occurred
by flickering.)
2) Performing diagnosis using CONSULT-II.
DIAGNOSTIC WORKSHEET NATF0013S02
Information from Customer NATF0013S0201
KEY POINTS
WHAT ..... Vehicle model
WHEN..... Date, Frequencies
WHERE..... Road conditions
HOW..... Operating conditions, Symptoms
Information sheet from customer

Customer name MR/MS Model & Year VIN

Transfer model Engine Mileage

ATX14A

Incident Date Manuf. Date In Service Date

Frequency l Continuous l Intermittent ( times a day)

Symptoms l 4WD shift indicator lamp does not turn on.

l 4WD warning lamp does not turn on.

l 4WD shift indicator lamp does not turn off.

l ATP warning lamp does not turn on.

l 4LO indicator lamp does not turn on.

l 4WD shift indicator lamp does not indicate “4H”.

l 4WD shift indicator lamp repeats flicking.

l Tight corner braking symptom occurs.

l 4WD system does not operate.

l Others.

4WD warning lamp l Continuously lit l Not lit

TF-76
 TROUBLE DIAGNOSIS — INTRODUCTION ATX14A
Introduction (Cont’d)
Diagnostic Worksheet NATF0013S0202
GI
1. l Listen to customer complaints. TF-79

2. l Check transfer fluid. TF-79 MA

l Leakage
l Fluid condition EM
l Fluid level

3. l Road testing TF-79

LC
l 1. Check before engine is started.
l 2. Check at idle.
l 3. Cruise test EC
4. l Perform self-diagnosis NG items (with CONSULT-II and without CONSULT-II). TF-64, TF-61

5. l Check component. Repair or replace the damaged parts. TF-147 FE

6. l Perform final check. Perform road test (1 through 3). TF-79

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-77
 TROUBLE DIAGNOSIS — INTRODUCTION ATX14A
Work Flow

Work Flow =NATF0014

HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR NATF0014S01
A good understanding of the malfunction conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is important to fully understand the symptoms
or conditions for a customer complaint.
Make good use of the two sheets provided, “Information from Customer” (Refer to TF-76.) and “Diagnostic
Worksheet” (Refer to TF-77.), to perform the best troubleshooting possible.

MTF013A

*1: TF-79 *3: TF-79 *5: TF-97 - TF-130

*2: TF-79 *4: TF-134 - TF-145 *6: TF-79

TF-78
TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A
Listen to Customer Complaints

Listen to Customer Complaints NATF0015

GI
I Each customer feels differently about a problem. It is important
to fully understand the symptoms or conditions for a customer
complaint. MA
I Listen to the customer about how and when the malfunction
occurs, and make good use of it when performing the road test.
EM

LC

Transfer Fluid Check EC

NATF0016
I Check fluid for leaks and fluid level. Refer to MA-24, “Check-
ing All-mode 4WD Transfer Fluid”. FE

CL

MT

AT
Road Test NATF0017
PREPARATION FOR ROAD TEST NATF0017S01
I The purpose of the test is to determine overall performance of
transfer and analyze causes of problems.
I The road test consists of the following three parts: PD
I When a malfunction is found in any part of transfer, perform the
road test to locate the malfunction area and repair the malfunc-
tion parts. AX
1. Check before engine is started
2. Check at idle
SMT089D
3. Cruise test
SU
I Perform road test and place checks for NG items on the diag-
nostic worksheet. Refer to TF-77. BR

ST

RS

BT

HA

SC

EL

IDX

TF-79
 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A
Road Test (Cont’d)
1. CHECK BEFORE ENGINE IS STARTED =NATF0017S02

1 CHECK 4WD SHIFT INDICATOR LAMP

1. Park vehicle on flat surface.
2. Turn ignition switch to “OFF” position.
3. Move A/T selector lever to “P” position.
4. Set 4WD shift switch to “4H” position.

SMT849D
5. Set 4WD shift switch to “2WD” position.
6. Turn ignition switch to “ON” position. (Do not start engine.)
7. Does 4WD shift indicator lamp turn ON for approx. 1 second?

SMT994D

Yes or No
Yes © GO TO 2.
No © Go to Symptom 1. Refer to TF-134.

2 CHECK 4WD WARNING LAMP

Is 4WD warning lamp turned ON?

SMT994D

Yes or No
Yes © 1. Turn ignition switch to “OFF” position.
2. Perform self-diagnosis.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.
3. Go to “2. CHECK AT IDLE”. Refer to TF-81.
No © Go to Symptom 2. Refer to TF-136.

TF-80
 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A
Road Test (Cont’d)
2. CHECK AT IDLE =NATF0017S03
GI
1 CHECK 4WD SHIFT INDICATOR LAMP
1. Park vehicle on flat surface. MA
2. Turn ignition switch to “OFF” position.
3. Move A/T selector lever to “P” or “N” position.
4. Set 4WD shift switch to “4H” position. EM
5. Set 4WD shift switch to “2WD” position.
6. Start engine.
7. Is 4WD shift indicator lamp turned OFF? LC

EC

FE

CL

SMT994D
MT
Yes or No
Yes © Go to “ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH”. Refer
to TF-112.
AT
No © GO TO 2.

2 CHECK 4WD WARNING LAMP

Is 4WD warning lamp turned OFF? PD
Yes or No
Yes © GO TO 3. AX
No © Perform self-diagnosis. Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-81
 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A
Road Test (Cont’d)

3 CHECK 4WD SHIFT INDICATOR LAMP

1. Set 4WD shift switch to “2WD”, “AUTO”, “4H”, “4LO”, “4H” and “2WD” in order.
(Stay at each switch position for at least 1 second.)
2. Does 4WD shift indicator lamp change properly and does buzzer sound?

SMT851D

SMT971D

Yes or No
Yes © GO TO 4.
No © Go to “2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH”. Refer to TF-102.

4 CHECK 4WD WARNING LAMP

Is 4WD warning lamp turned ON?
Yes or No
Yes © Perform self-diagnosis. (Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.)
No © GO TO 5.

TF-82
 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A
Road Test (Cont’d)

5 CHECK 4WD SHIFT INDICATOR LAMP GI

1. Move A/T selector lever to “P” position.
2. Set 4WD shift switch from “4H” to “4LO”. MA

EM

LC

EC

SMT849D FE
3. While shifting from “4H” to “4LO”, does 4WD shift indicator lamp turn OFF and ATP warning lamp turn ON?

CL

MT

AT

SMT994D

Yes or No
Yes © GO TO 6.
PD
No © Go to Symptoms 3 and 4. Refer to TF-138.
AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-83
 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A
Road Test (Cont’d)

6 CHECK 4WD SHIFT INDICATOR LAMP

Does 4WD shift indicator lamp indicate 4LO indicator lamp turn ON when 4WD shift switch is set in “4LO”?

SMT849D

SMT770D

Yes or No
Yes © GO TO 7.
No © Go to Symptom 5. Refer to TF-140.

7 CHECK 4WD SHIFT INDICATOR LAMP (*1)

1. Set 4WD shift switch from “4LO” to “4H”.
2. Does 4LO indicator lamp flicker? (*1)
*1: While “Wait” function is operating, 4LO indicator lamp flashes.
Yes or No
Yes © Go to Symptoms 6 and 7. Refer to TF-142 and TF-143.
No © Go to “3. CRUISE TEST”. Refer to TF-85.

TF-84
 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A
Road Test (Cont’d)
3. CRUISE TEST =NATF0017S04
GI
1 INSPECTION START
MA

EM

LC

EC
SMT849D
FE

CL

MT

AT
SMT994D

WITH CONSULT-II © GO TO 2.
WITHOUT CONSULT-II © GO TO 3.
PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-85
 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A
Road Test (Cont’d)

2 CHECK INPUT SIGNAL

With CONSULT-II
1. Warm up engine to normal operating temperature.
2. Park vehicle on flat surface.
3. Move A/T selector lever to “P” position.
4. Set 4WD shift switch to “4H” position.
5. Set 4WD shift switch to “AUTO” position.
6. Start engine.
7. Drive for at least 30 seconds at a speed higher than 20 km/h (12 MPH).
(Drive vehicle until “FLUID TEMP SE” exceeds 0.9V.)
8. Park vehicle on flat surface.
9. Move A/T selector lever to “P” position.
10. Set 4WD shift switch to “2WD” position.
11. Leave vehicle for at least 80 seconds with “FLUID TEMP SE” at 0.9V or less.

SMT972D
12. Is 4WD warning lamp turned ON?
Yes or No
Yes © Perform self-diagnosis. Refer to “Trouble Diagnosis with CONSULT-II”, TF-64.
No © GO TO 4.

3 CHECK INPUT SIGNAL

Without CONSULT-II
1. Warm up engine to normal operating temperature.
2. Park vehicle on flat surface.
3. Move A/T selector lever to “P” position.
4. Set 4WD shift switch to “4H” position.
5. Set 4WD shift switch to “AUTO” position.
6. Start engine.
7. Drive vehicle for at least 30 seconds at a speed higher than 20 km/h (12 MPH).
8. Park vehicle on flat surface.
9. Move A/T selector lever to “P” position.
10. Set 4WD shift switch to “2WD” position.
11. Is 4WD warning lamp turned ON?
Yes or No
Yes © Perform self-diagnosis. Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.
No © GO TO 4.

4 (1) CHECK TIGHT CORNER BRAKING SYMPTOM

1. Set 4WD shift switch to “AUTO” position.
2. Drive vehicle at speed lower than 20 km/h (12 MPH) with steering wheel fully turned.
3. Does tight corner braking symptom occur?
Yes or No
Yes © GO TO 5.
No © GO TO 6.

TF-86
 TROUBLE DIAGNOSIS — BASIC INSPECTION ATX14A
Road Test (Cont’d)

5 CONFIRM SYMPTOM AGAIN GI

Confirm symptom and self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61 and “Trouble Diagnosis with CONSULT-II”, TF-64. MA
OK or NG
OK © GO TO 6.
EM
NG © Go to Symptoms 8 and 9. Refer to TF-144, 145.

LC
6 (2) CHECK TIGHT CORNER BRAKING SYMPTOM
1. Set 4WD shift switch to “4H” position.
2. Drive vehicle at speed lower than 20 km/h (12 MPH) with steering wheel fully turned. EC
3. Does tight corner braking symptom occur?
Yes or No
FE
Yes © INSPECTION END
No © GO TO 7.
CL
7 CONFIRM SYMPTOM AGAIN
MT
Confirm symptom and self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61 and “Trouble Diagnosis with CONSULT-II”, TF-64.
OK or NG AT
OK © INSPECTION END
NG © Go to Symptoms 8 and 9. Refer to TF-144, 145.

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-87
 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A
Transfer Control Unit Terminals and Reference Value

Transfer Control Unit Terminals and Reference

Value NATF0018
REMOVAL AND INSTALLATION OF TRANSFER
CONTROL UNIT NATF0018S03
Removal NATF0018S0301
1. Turn ignition switch OFF and disconnect negative battery ter-
minal.
2. Remove console box.
3. Remove cluster lid C.
SMT862D 4. Remove audio assembly and A/C control unit.
5. Remove instrument lower panel on driver side.
6. Remove glove box.
7. Remove instrument lower panel on passenger side.
8. Remove instrument lower center panel.
9. Remove transfer control unit.
I For steps 2 through 8 above, refer to BT-24, “Instrument Panel
Assembly”.
Installation NATF0018S0302
I Installation is in the reverse order of removal.
When installing transfer control unit, tighten transfer control unit
lock nut.
Tightening torque:
: 4.3 - 5.8 N·m (0.44 - 0.59 kg-m, 38 - 51 in-lb)

INSPECTION OF TRANSFER CONTROL UNIT NATF0018S01

I Measure voltage between each terminal and terminal 6 or 45
by following “TRANSFER CONTROL UNIT INSPECTION
TABLE”, TF-89.

SMT771D

I Pin connector terminal layout

TF-88
 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A
Transfer Control Unit Terminals and Reference Value (Cont’d)

GI

MA

EM

LC
SMT772D

EC
TRANSFER CONTROL UNIT INSPECTION TABLE NATF0018S02
(Data are reference values.)
Terminal
FE
Item Condition Judgement standard
No.

4WD shift switch is set to “2WD” CL

Less than 1V
position.
2-4WD shift solenoid
1 &
valve MT
4WD shift switch is set to any posi-
Battery voltage
tion other than “2WD”.
AT
Lamp lights while system is operat-
Less than 1V
4WD shift indicator lamp ing properly.
2
(2WD)
2WD indicator lamp does not come
Battery voltage
on.

3 Ground — — PD
While actuator is operating
Transfer shift relay Battery voltage
4
(High)
(4H , 4LO) AX
Actuator does not operate. Less than 1V

& Lamp comes ON. (when engine is SU

stopped.)
(Fail-safe condition appears on
display, engine is stopped, actuator
Less than 1V BR
5 4WD warning lamp position detection switch is
inoperative, oil temperature is too
high and/or tires of different size are
installed.)
ST
Except above Battery voltage
RS
6 Ground — — —

7
CAN H — — — BT
(With VDC)

A/T selector lever is set to “reverse”

Battery voltage
7 position. HA
(Without PNP switch (R position) &
VDC) A/T selector lever is set to any posi-
tion other than “reverse”.
Less than 1V SC
8
CAN L — — — EL
(With VDC)

8
(Without — — — — IDX
VDC)

TF-89
 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A
Transfer Control Unit Terminals and Reference Value (Cont’d)

Terminal
Item Condition Judgement standard
No.

4WD shift switch is set to “2WD”

Battery voltage
position.
9 4WD shift switch (2WD)
4WD shift switch is set to any posi-
Less than 1V
tion other than “2WD”.
&
4WD shift switch is set to “AUTO”
Approx. 4 - 14V
Transfer dropping resis- position.
10
tor 4WD shift switch is set to any posi-
Less than 1V
tion other than “2WD”.

“4H” indicator lamp comes ON. Less than 1V

4WD shift indicator lamp
11 4WD shift switch is set to any posi-
(4H) Battery voltage
tion other than “4H”.

“4LO” indicator lamp comes ON. Approx. 0V

4WD shift indicator lamp
12 4WD shift switch is set to any posi-
(4LO) Battery voltage
tion other than “4LO”.

While actuator is operating

Battery voltage
13 Transfer shift relay (Low) (4LO , 4H)

Actuator does not operate. Approx. 0V

Transfer motor relay is ON. Battery voltage

14 Transfer motor relay
Transfer motor relay is OFF. Less than 1V

AT selector lever is set to “P” posi-

& Battery voltage
15 tion.
ATP lamp
(With VDC) AT selector lever is set to any posi-
Approx. 0V
tion other than “P”.

A/T selector lever is set to “N” posi-

15 Battery voltage
tion.
(Without PNP switch (N position)
VDC) A/T selector lever is set to any posi-
Less than 1V
tion other than “N” position.

Ignition key is set to “ON” position. Battery voltage

16 Power supply —
Ignition key is set to “OFF” position. Approx. 0V

17
Do not use.
(With VDC)

A/T selector lever is set to “P” posi-

17 Battery voltage
tion.
(Without PNP switch (P position)
VDC) A/T selector lever is set to any posi-
Less than 1V
tion other than “P”.

4WD shift switch is set to “4H” posi-

Battery voltage
tion.
18 4WD shift switch (4H) &
4WD shift switch is set to any posi-
Less than 1V
tion other than “4H”.

4WD shift switch is set to “AUTO”

Approx. 1.5 - 3V
position.
19 4WD solenoid valve
4WD shift switch is set to any posi-
Less than 1V
tion other than “2WD”.

20 — — — —

TF-90
 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A
Transfer Control Unit Terminals and Reference Value (Cont’d)

Terminal GI
Item Condition Judgement standard
No.

“AUTO” indicator lamp comes ON. Approx. 0V MA

4WD shift indicator lamp
21 4WD shift switch is set to any posi-
(AUTO) Battery voltage
tion other than “AUTO”.
EM
Ignition key is set to “ON” position. Battery voltage
22 Power supply —
Ignition key is set to “OFF” position. Approx. 0V
LC
4WD shift switch is set to “4LO”
Battery voltage
position.
23 4WD shift switch (4LO)
4WD shift switch is set to any posi-
EC
Less than 1V
tion other than “4LO”.

4WD shift switch is set to “AUTO”

Battery voltage
FE
position.
24 4WD shift switch (AUTO)
4WD shift switch is set to any posi-
tion other than “AUTO”.
Less than 1V CL

& Transfer is set to “4LO” position. Approx. 0V

25 Neutral-4LO switch MT
Transfer is set to any position other
Power supply
than “4LO”.

4WD shift switch is set to “4H” posi- AT

Less than 1V
Transfer 4H actuator tion.
27
switch 4WD shift switch is set to any posi-
Battery voltage
tion other than “4H”.

Throttle position sensor Throttle valve is closed.

28
(Ground)
Less than 1V PD
Throttle valve is fully open.

When moving at 20 km/h (12 MPH),

use the CONSULT-II pulse fre- AX
quency measuring function.*1
CAUTION:
TCM signal (Vehicle
29
speed signal)
& Connect the diagnosis data link Approximately 225 Hz SU
cable to the vehicle diagnosis
connector.
*1: A circuit tester cannot be used to BR
test this item.

Ignition key is set to “ON” position. Approx. 4.5 - 5.5V ST

Throttle position sensor
30 (Power supply for &
throttle position sensor)
Ignition key is set to “OFF” position. Approx. 0V
RS

BT
At 20°C (68°F) Approx. 1.5V
Transfer fluid tempera-
31 &
ture sensor HA
At 80°C (176°F) Approx. 0.5V

32 SC
Do not use.
(With VDC)

EL

IDX

TF-91
 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A
Transfer Control Unit Terminals and Reference Value (Cont’d)

Terminal
Item Condition Judgement standard
No.

When moving, use the CONSULT-II

pulse frequency measuirng func-
tion.*2
32 CAUTION: Refer to the illustration
(Without ABS signal & Connect the diagnosis data link (SMT973D) at the end of
VDC) cable to the vehicle diagnosis this section.
connector.
*2: A circuit tester cannot be used to
test this item.

While actuator is operating from

Transfer shift relay Battery voltage
33 “4H” to “4LO”
(High)
Actuator does not operate. Approx. 0V

4WD shift switch is set to “AUTO” or

“4H”, then A/T selector lever is set to
Battery voltage
“D” position. (wait detection system:
OFF)
34 Clutch pressure switch
& 4WD shift switch is set to “2WD”,
“AUTO” or “4H”, then A/T selector
Approx. 0V
lever is set to “D” position. (wait
detection system: ON)

4WD shift switch is set to “2WD”,

“AUTO” or “4H”, then A/T selector Battery voltage
35 Line pressure switch lever is set to “D” position.

— Approx. 0V

36 CONSULT-II (RX) — — —

37
Do not use.
(With VDC)

37
Refer to EC-141, “ECM
(Without Tachometer —
Inspection Table”.
VDC)

38 Sensor is installed, but do not use. (Wheel speed is sent from VDC C/U via CAN commu-
Front revolution sensor
(With VDC) nication.)

Approx. 1V [30 km/h (19

38 4WD shift switch is set to “4H” posi- MPH)]
(Without Front revolution sensor tion. A/T selector lever is set to “D” Voltage rises in
VDC) position. response to vehicle
speed.

39
Do not use.
(With VDC)

TF-92
 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A
Transfer Control Unit Terminals and Reference Value (Cont’d)

Terminal GI
Item Condition Judgement standard
No.

39
ECM (Throttle position
Throttle valve is fully open. Approx. 0.5V MA
(Without
sensor)
VDC) Throttle valve is closed. Approx. 4.2V

A/T selector lever is set to “P” posi- EM

Battery voltage
tion.
40 ATP switch
A/T selector lever is set to any posi-
Less than 1V LC
tion other than “P”.

Transfer motor relay Transfer motor relay is ON. Battery voltage

41
monitor
EC
Transfer motor relay is OFF. Less than 1V

While actuator is operating from

Transfer shift relay & “4LO” to “4H” position
Battery voltage FE
42
(LOW)
Actuator does not operate. Approx. 0V

4WD shift switch is set to any posi-

CL
Battery voltage
tion other than “4LO”.
43 Wait detection switch
4WD shift switch is set to “4LO”
Less than 1V
MT
position.*3

4WD shift switch is set to any posi-

tion other than “4LO”. (Actuator: Battery voltage
AT
Transfer 4LO actuator High position)
44
switch
4WD shift switch is set to “4LO”
Less than 1V
position. (Actuator: Low position)

45 Ground — — —
PD
46 — — — —

AX
Power supply (memory
47 & — Battery voltage
back up)
SU

48 CONSULT-II (TX) — — — BR
*3: While wait detection system is operating, terminal 43 exists battery voltage.
ST

RS

BT

HA

SC

EL

IDX

TF-93
 TROUBLE DIAGNOSIS — GENERAL DESCRIPTION ATX14A
Transfer Control Unit Terminals and Reference Value (Cont’d)

SMT172E

TF-94
 DTC U1000 CAN COMMUNICATION LINE (WITH VDC) ATX14A
Description

Description NATF0135
GI
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many
electronic control units are equipped onto a vehicle, and each control unit shares information and links with MA
other control units during operation (not independent). In CAN communication, control units are connected with
2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wir-
ing. Each control unit transmits/receives data but selectively reads required data only. EM
On Board Diagnosis Logic
I This is an OBD-II self-diagnostic item.
NATF0136
LC
I Diagnostic trouble code “CAN COMM CIRCUIT” with CONSULT-II or U1000 without CONSULT-II is
detected when TCM cannot communicate to other control unit. EC
Possible Cause NATF0137
Harness or connectors FE
(CAN communication line is open or shorted.)

CL

MT

AT
DTC Confirmation Procedure NATF0138
NOTE:
If “DTC Confirmation Procedure” has been previously
conducted, always turn ignition switch “OFF” and wait at least
10 seconds before conducting the next test.
After the repair, perform the following procedure to confirm the
PD
malfunction is eliminated.
AX

SU
WITH CONSULT-II NATF0138S01
1. Turn ignition switch to “ON” position. (Do not start engine.)
BR
2. Select “DATA MONITOR” mode for “ALL MODE AWD/4WD”
with CONSULT-II.
3. Start engine and wait for at least 6 seconds. ST
4. If DTC is detected, go to TF-96, “Diagnostic Procedure”.
RS

SDIA2216E BT
WITH GST NATF0138S02
Follow the procedure “WITH CONSULT-II”. HA

SC

EL

IDX

TF-95
 DTC U1000 CAN COMMUNICATION LINE (WITH VDC) ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0139

1 CHECK CAN COMMUNICATION CIRCUIT

With CONSULT-II
1. Turn ignition switch to “ON” position. (Do not start engine.)
2. Select “DATA MONITOR” mode for “ALL MODE AWD/4WD” with CONSULT-II.
3. The “CAN COMM CIRCUIT” is detected.

PCIA0061E

Yes or No
Yes © Go to EL-409, “CAN Communication Unit”.
No © INSPECTION END

TF-96
 VEHICLE SPEED SENSOR (FRONT REVOLUTION SENSOR)
(WITHOUT VDC) ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0019

GI
1 FRONT REVOLUTION SENSOR
Refer to “Front Revolution Sensor”, “COMPONENT INSPECTION”, TF-148. MA
OK or NG
OK © GO TO 3. EM
NG © GO TO 2.
LC
2 CHECK CONTINUITY
Check the following. EC
I Continuity of transfer sub-harness
Refer to “Transfer Sub-harness”, “COMPONENT INSPECTION”, TF-149.
OK or NG FE
OK © Repair or replace front revolution sensor.
NG © Repair or replace front revolution sensor and transfer sub-harness. CL

3 CHECK INPUT SIGNAL MT

WITH CONSULT-II © GO TO 4.
AT
WITHOUT CONSULT-II © GO TO 5.

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-97
 VEHICLE SPEED SENSOR (FRONT REVOLUTION SENSOR)
(WITHOUT VDC) ATX14A
Diagnostic Procedure (Cont’d)

4 CHECK INPUT SIGNAL

With CONSULT-II
1. Start engine.
2. Select “ECU INPUT SIGNALS” in Data Monitor.
3. Read out the value of “VEHICLE SPEED SENSOR (FRONT)” while driving.

SMT773D

SMT974D
4. Check if the value changes according to accelerating and decelerating the vehicle.
OK or NG
OK © GO TO 6.
NG © GO TO 7.

TF-98
 VEHICLE SPEED SENSOR (FRONT REVOLUTION SENSOR)
(WITHOUT VDC) ATX14A
Diagnostic Procedure (Cont’d)

5 CHECK INPUT SIGNAL GI

Without CONSULT-II
1. Start engine. MA
2. Check voltage between transfer control unit harness connector terminals 38 and 28.
(Measure it in AC range.)
Voltage:
0 km/h (0 MPH): 0V
EM
30 km/h (19 MPH): More than 1V
(Voltage rises gradually in response to vehicle speed.)
LC

EC

FE

CL

MT

AT

PD

SMT774D AX
OK or NG
OK © GO TO 6. SU
NG © GO TO 7.

BR
6 PERFORM SELF-DIAGNOSIS AGAIN
After driving for a while, perform self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61. ST
OK or NG
OK © INSPECTION END RS
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89.
BT
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.
HA
7 CHECK HARNESS CONTINUITY BETWEEN TRANSFER CONTROL UNIT AND FRONT REVOLUTION
SENSOR SUB-HARNESS CONNECTOR SC
OK or NG
OK © GO TO 6.
EL
NG © Repair or replace sub-harness connector between transfer control unit and front revolu-
tion sensor. IDX

TF-99
 4WD SOLENOID VALVE ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0020

1 CHECK 4WD SOLENOID VALVE

SMT775D
Refer to “4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch”, “COMPONENT INSPECTION”, TF-147.
OK or NG
OK © GO TO 2.
NG © Check the following. If OK, repair or replace 4WD solenoid valve.
I Continuity of transfer sub-harness
Refer to “TRANSFER TERMINAL CORD ASSEMBLY SUB-HARNESS CONNECTOR”,
“COMPONENT INSPECTION”, TF-150.

2 CHECK POWER SOURCE CIRCUIT

1. Turn ignition switch to “OFF” position.
2. Disconnect transfer control unit harness connector.
3. Check resistance between transfer terminal cord assembly sub-harness connector terminal 6 and transfer control unit
harness connector terminal 10.
Resistance: 11.2 - 12.8Ω

SMT150E

OK or NG
OK © GO TO 3.
NG © Check the following.
I Transfer dropping resistor
Refer to “Transfer Dropping Resistor”, “COMPONENT INSPECTION”, TF-148.
I Continuity between transfer terminal cord assembly sub-harness connector terminal 6
and transfer control unit harness connector terminal 10.

TF-100
 4WD SOLENOID VALVE ATX14A
Diagnostic Procedure (Cont’d)

3 CHECK POWER SOURCE CIRCUIT GI

1. Turn ignition switch to “OFF” position.
2. Check continuity between transfer terminal cord assembly sub-harness connector terminal 6 and transfer control unit MA
harness connector terminal 19.
Continuity should exist.
EM

LC

EC

FE
SMT777D

OK or NG CL
OK © GO TO 4.
NG © Repair or replace harness between transfer terminal cord assembly sub-harness connec- MT
tor terminal 6 and transfer control unit harness connector terminal 19.

AT
4 PERFORM SELF-DIAGNOSIS
After driving for a while, perform self-diagnosis.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61 and “Trouble Diagnosis with CONSULT-II”, TF-64.
OK or NG
OK © INSPECTION END PD
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER
CONTROL UNIT INSPECTION TABLE”, TF-89. AX
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.
SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-101
 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0021

1 CHECK 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH

Refer to “2-4WD Shift Solenoid Valve and Transfer Fluid Temperature Sensor”, “COMPONENT INSPECTION”, TF-147.

SMT778D

OK or NG
OK © GO TO 2.
NG © Check the following. If OK, repair or replace 2-4WD shift solenoid valve and 4WD
shift switch.
I Continuity of transfer sub-harness
Refer to “TRANSFER TERMINAL CORD ASSEMBLY SUB-HARNESS CONNECTOR”,
“COMPONENT INSPECTION”, TF-150.

TF-102
 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH ATX14A
Diagnostic Procedure (Cont’d)

2 CHECK INPUT SIGNAL GI

With CONSULT-II
1. Select “ECU INPUT SIGNALS” in Data Monitor. MA
2. Read out ON/OFF status of “2WD SW” and “LOCK SWITCH”.

EM

LC

EC

FE

CL

MT

AT

SMT974D

OK or NG
PD
OK © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89. AX
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.
NG © GO TO 3. SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-103
 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH ATX14A
Diagnostic Procedure (Cont’d)

3 CHECK 4WD SHIFT SWITCH POWER SOURCE

1. Disconnect 4WD shift switch harness connector.
2. Turn ignition switch to “ON” position.
3. Check voltage between 4WD shift switch harness connector terminal 1 and body ground.
Voltage: Battery voltage

SMT852D

OK or NG
OK © GO TO 4.
NG © Check the following.
I No. 18 fuse (10A)
I Continuity between ignition switch and 4WD shift switch

TF-104
 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH ATX14A
Diagnostic Procedure (Cont’d)

4 CHECK HARNESS CONTINUITY GI

1. Turn ignition switch to “OFF” position.
2. Check continuity between the following terminals: MA
I Transfer control unit 9 and 4WD shift switch 2 (2WD)
I Transfer control unit 18 and 4WD shift switch 5 (4H)
I Transfer control unit 24 and 4WD shift switch 3 (AUTO)
I Transfer control unit 23 and 4WD shift switch 6 (4LO)
EM
I Transfer control unit 1 and Transfer terminal cord assembly sub-harness connector 4
I 4WD shift switch 4 and Transfer terminal cord assembly sub-harness connector 5
Continuity should exist.
LC

EC

FE

CL

MT

AT

PD

AX
SMT853D

OK or NG SU
OK © GO TO 5.
NG © Repair harness or connector. BR

5 PERFORM SELF-DIAGNOSIS AGAIN

ST
After driving for a while, perform self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.
OK or NG RS
OK © INSPECTION END
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER BT
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89.
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with HA
harness connector.

SC

EL

IDX

TF-105
 TRANSFER MOTOR AND TRANSFER MOTOR RELAY ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0022

1 CHECK TRANSFER MOTOR AND TRANSFER MOTOR RELAY

SMT151E
Refer to “Transfer Motor” and “Transfer Motor Relay”, “COMPONENT INSPECTION”, TF-149.
OK or NG
OK © GO TO 2.
NG © Repair or replace transfer motor and transfer motor relay.

2 CHECK CONTINUITY
Check the following.
I Continuity of transfer sub-harness
Refer to “TRANSFER SWITCH ASSEMBLY SUB-HARNESS CONNECTOR”, “COMPONENT INSPECTION”, TF-150.
OK or NG
OK © GO TO 3.
NG © Repair or replace transfer sub-harness.

3 CHECK INPUT SIGNAL

With CONSULT-II
1. Select “MAIN SIGNALS” in Data Monitor.
2. Read out ON/OFF status of “MOTOR RELAY”.

SMT975D
3. When the value is different from standard value although ON/OFF switching occurs, check the following items.
I PNP switch, throttle position sensor and closed throttle position switch circuits
Refer to AT-102, “DTC P0705 Park/Neutral Position Switch”, AT-179, “DTC P1705 Throttle Position Sensor”.
OK or NG
OK © GO TO 4.
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89.
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.

TF-106
 TRANSFER MOTOR AND TRANSFER MOTOR RELAY ATX14A
Diagnostic Procedure (Cont’d)

4 CHECK TRANSFER MOTOR RELAY POWER SOURCE GI

1. Disconnect transfer motor relay harness connector.
2. Turn ignition switch to “ON” position. MA
3. Check voltage between transfer motor relay harness connector terminals 1, 3 and body ground.
Voltage: Battery voltage
EM

LC

EC

FE
SMT854DA

OK or NG CL
OK © GO TO 5.
NG © Check the following. MT
I No. 55 fuse (20A)
I No. 8 fuse (10A)
I Harness continuity between fuse and transfer motor relay AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-107
 TRANSFER MOTOR AND TRANSFER MOTOR RELAY ATX14A
Diagnostic Procedure (Cont’d)

5 CHECK HARNESS CONTINUITY

1. Turn ignition switch to “OFF” position.
2. Check continuity between the following terminals.
I Transfer control unit 41 and Transfer motor 14
I Transfer control unit 41 and Transfer motor relay 2
I Transfer control unit 14 and Transfer motor relay 4
I Transfer motor 15 and body ground
Continuity should exist.

SMT855DA

OK or NG
OK © GO TO 6.
NG © Repair or replace harness or connector.

6 PERFORM SELF-DIAGNOSIS AGAIN

After driving for a while, perform self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61 and “Trouble Diagnosis with CONSULT-II”, TF-64.
OK or NG
OK © INSPECTION END
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89.
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.

TF-108
 TRANSFER FLUID TEMPERATURE SENSOR ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0023

GI
1 CHECK TRANSFER FLUID TEMPERATURE SENSOR
Refer to “2-4WD Shift Solenoid Valve and Transfer Fluid Temperature Sensor”, “COMPONENT INSPECTION”, TF-147. MA
OK or NG
OK © GO TO 2. EM
NG © Repair or replace fluid temperature sensor.
LC
2 CHECK CONTINUITY
Check the following. EC
I Continuity of transfer sub-harness
Refer to “TRANSFER TERMINAL CORD ASSEMBLY SUB-HARNESS CONNECTOR”, “COMPONENT INSPECTION”,
TF-150.
FE
OK or NG
OK © GO TO 3.
CL
NG © Repair or replace transfer sub-harness.

MT
3 CHECK INPUT SIGNAL

WITH CONSULT-II © GO TO 4.
AT
WITHOUT CONSULT-II © GO TO 5.

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-109
 TRANSFER FLUID TEMPERATURE SENSOR ATX14A
Diagnostic Procedure (Cont’d)

4 CHECK INPUT SIGNAL

SMT784D
With CONSULT-II
1. Start engine.
2. Select “ECU INPUT SIGNALS” in Data Monitor.
3. Read out the value of “FLUID TEMP SE”.
Voltage:
20°C (68°F): Approx. 1.5V
80°C (176°F): Approx. 0.5V

SMT974D

OK or NG
OK © GO TO 6.
NG © Check the following.
I Continuity between transfer control unit and transfer terminal cord assembly sub-har-
ness connector

TF-110
 TRANSFER FLUID TEMPERATURE SENSOR ATX14A
Diagnostic Procedure (Cont’d)

5 CHECK INPUT SIGNAL GI

Without CONSULT-II
1. Turn ignition switch to “ON” position. MA
2. Check voltage between transfer control unit harness connector terminals 28 and 31.
Voltage:
20°C (68°F): Approx. 1.5V
80°C (176°F): Approx. 0.5V
EM

LC

EC

FE
SMT785D

OK or NG
CL
OK © GO TO 6.
NG © Check the following. MT
I Continuity between transfer control unit and transfer terminal cord assembly sub-har-
ness connector
AT
6 PERFORM SELF-DIAGNOSIS AGAIN
After driving for a while, perform self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.
OK or NG PD
OK © INSPECTION END
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER AX
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89.
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with SU
harness connector.

BR

ST

RS

BT

HA

SC

EL

IDX

TF-111
 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO
SWITCH ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0024

1 CHECK ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH

SMT786D
Refer to “ATP Switch, Neutral-4LO Switch and Wait Detection Switch”, “COMPONENT INSPECTION”, TF-148.
OK or NG
OK © GO TO 3.
NG © GO TO 2.

2 CHECK CONTINUITY OF TRANSFER SUB-HARNESS

Check the following.
I Continuity of transfer sub-harness
Refer to “TRANSFER SWITCH ASSEMBLY SUB-HARNESS CONNECTOR”, “COMPONENT INSPECTION”, TF-150.
OK or NG
OK © Repair or replace ATP switch, wait detection switch or neutral-4LO switch.
NG © Repair or replace transfer sub-harness.

3 CHECK INPUT SIGNAL

WITH CONSULT-II © GO TO 4.
WITHOUT CONSULT-II © GO TO 5.

TF-112
 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO
SWITCH ATX14A
Diagnostic Procedure (Cont’d)

4 CHECK INPUT SIGNAL GI

With CONSULT-II
1. Select “ECU INPUT SIGNALS” in Data Monitor. MA
2. Read out the ON/OFF status of “ATP SW”, “NEUTRAL SW” and “WAIT DETCT SW”.

EM

LC

EC

FE
SMT976D

OK or NG
OK © GO TO 6.
CL
NG © Check the following.
I Harness continuity between transfer switch assembly sub-harness connector and MT
transfer control unit
I Continuity between transfer switch assembly sub-harness connector and body ground
AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-113
 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO
SWITCH ATX14A
Diagnostic Procedure (Cont’d)

5 CHECK INPUT SIGNAL

Without CONSULT-II
1. Turn ignition switch to “OFF” position.
2. Operate 4WD shift switch and check continuity between the following terminals.
Continuity:
Terminal 40 (ATP switch) and body ground
“4H” position: No continuity should exist.
Between “4H” and “4LO”: Continuity should exist.
“4LO” position: No continuity should exist.
Terminal 25 (Neutral-4LO switch) and body ground
“4H” position: No continuity should exist.
“4LO” position: Continuity should exist.
Terminal 43 (Wait detection switch) and body ground
“4H” position: No continuity should exist. (*1)
“4LO” position: Continuity should exist.
*1: After setting from “4LO” to “4H”, continuity exists while “Wait” function is operating in “4H” position.
(No continuity exists when “Wait” function is canceled.)

SMT787D

SMT849D

OK or NG
OK © GO TO 6.
NG © Check the following.
I Harness continuity between transfer switch assembly sub-harness connector and
transfer control unit
I Continuity between transfer switch assembly sub-harness connector and body ground

TF-114
 ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO
SWITCH ATX14A
Diagnostic Procedure (Cont’d)

6 PERFORM SELF-DIAGNOSIS AGAIN GI

After driving for a while, perform self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61. MA
OK or NG
OK © INSPECTION END
EM
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89. LC
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.
EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-115
 CLUTCH PRESSURE SWITCH ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0025

1 CHECK MALFUNCTION
Is this malfunction detected only while driving in reverse?
Yes or No
Yes © CHECK A/T PNP SWITCH “R” POSITION.
Refer to AT-102, “DTC P0705 Park/Neutral Position Switch”.
No © GO TO 2.

2 CHECK OTHER MALFUNCTION

Are other malfunctions also detected by self-diagnosis and CONSULT-II?
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61 and “Trouble Diagnosis with CONSULT-II”, TF-64.
Yes or No
Yes © CHECK FOR OTHER MALFUNCTIONS.
(When other malfunctions are eliminated, clutch pressure switch malfunction display may
disappear.)
No © GO TO 3.

3 CHECK 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH CIRCUITS
Check 2-4WD shift solenoid valve and 4WD shift switch circuits.
OK or NG
OK © GO TO 4.
NG © Check, repair or replace faulty parts.

4 CHECK INPUT SIGNAL

WITH CONSULT-II © GO TO 5.
WITHOUT CONSULT-II © GO TO 6.

TF-116
 CLUTCH PRESSURE SWITCH ATX14A
Diagnostic Procedure (Cont’d)

5 CHECK INPUT SIGNAL GI

With CONSULT-II
1. Turn ignition switch to “ON” position. MA
2. Select “ECU INPUT SIGNALS” in Data Monitor.
3. Read out ON/OFF status of “CL PRES SW”.
EM

LC

EC

FE
SMT788D
CL

MT

AT

SMT977D

OK or NG PD
OK © GO TO 7.
NG © Check the following. AX
I Continuity between transfer control unit and transfer terminal cord assembly sub-har-
ness connector
I Transfer sub-harness SU
I Clutch pressure switch
Refer to “4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch”,
“COMPONENT INSPECTION”, TF-147. BR

ST

RS

BT

HA

SC

EL

IDX

TF-117
 CLUTCH PRESSURE SWITCH ATX14A
Diagnostic Procedure (Cont’d)

6 CHECK INPUT SIGNAL

Without CONSULT-II
1. Turn ignition switch to “ON” position and set 4WD shift switch to “4H” position.
2. Check voltage between transfer control unit harness connector terminal 34 and body ground.
When 4WD shift switch is in “2WD”:
Battery voltage should exist.
When 4WD shift switch is in “AUTO” or “4H” and A/T selector lever is in “D”:
“Wait” operating: Battery voltage should exist.
“Wait” not operating: Approx. 0 volts should exist.

SMT789D

SMT849D

OK or NG
OK © GO TO 7.
NG © Check the following.
I Continuity between transfer control unit and transfer terminal cord assembly sub-har-
ness connector
I Transfer sub-harness
I Clutch pressure switch
Refer to “4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch”,
“COMPONENT INSPECTION”, TF-147.

7 PERFORM SELF-DIAGNOSIS AGAIN

1. Check hydraulic parts.
2. After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.
OK or NG
OK © INSPECTION END
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER
CONTROL UNIT INSPECTION TABLE”, TF-89.
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.

TF-118
 LINE PRESSURE SWITCH ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0026

GI
1 CHECK MALFUNCTION
Is this malfunction detected only while driving in reverse? MA
Yes or No
Yes © CHECK A/T PNP SWITCH “R” POSITION. EM
Refer to AT-102, “DTC P0705 Park/Neutral Position Switch”.
No © GO TO 2.
LC
2 CHECK OTHER MALFUNCTIONS
EC
Are other malfunctions also detected by self-diagnosis and CONSULT-II?
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61 and “Trouble Diagnosis with CONSULT-II”, TF-64.
Yes or No FE
Yes © CHECK FOR OTHER MALFUNCTIONS.
(When other malfunctions are eliminated, line pressure switch malfunction display may
disappear.)
CL
No © GO TO 3.
MT
3 CHECK INPUT SIGNAL
AT
WITH CONSULT-II © GO TO 4.
WITHOUT CONSULT-II © GO TO 5.

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-119
 LINE PRESSURE SWITCH ATX14A
Diagnostic Procedure (Cont’d)

4 CHECK INPUT SIGNAL

SMT790D
With CONSULT-II
1. Select “ECU INPUT SIGNALS” in Data Monitor.
2. Read out the ON/OFF status of “LINE PRES SW”.

SMT977D

OK or NG
OK © GO TO 6.
NG © Check the following.
I Continuity between transfer control unit and transfer terminal cord assembly sub-har-
ness connector
I Transfer sub-harness
I Line pressure switch
Refer to “4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch”,
“COMPONENT INSPECTION”, TF-147.

TF-120
 LINE PRESSURE SWITCH ATX14A
Diagnostic Procedure (Cont’d)

5 CHECK INPUT SIGNAL GI

Without CONSULT-II
1. Turn ignition switch to “OFF” position. MA
2. Disconnect transfer control unit harness connector.
3. Check continuity between transfer control unit harness connector terminal 35 and body ground.
After the vehicle has been left for at least 5 minutes in a room temperature with ignition switch “OFF”:
No continuity should exist.
EM
With ignition switch in “ON”, 4WD shift switch in “AUTO” or “4H” and A/T selector lever in “D”:
Continuity should exist.
LC

EC

FE

CL

SMT152E
MT

AT

PD

SMT849D AX
OK or NG
OK © GO TO 6. SU
NG © Check the following.
I Continuity between transfer control unit and transfer terminal cord assembly sub-har-
ness connector BR
I Transfer sub-harness
I Line pressure switch
Refer to “4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch”, ST
“COMPONENT INSPECTION”, TF-147.

RS
6 PERFORM SELF-DIAGNOSIS AGAIN
1. Check hydraulic parts.
2. After driving for a while, perform self-diagnosis again. Refer to “Trouble Diagnosis without CONSULT-II”, TF-61. BT
OK or NG
OK © INSPECTION END HA
NG © 1. Perform transfer control unit input/output signal inspection. Refer to TF-89.
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector. SC

EL

IDX

TF-121
 ABS OPERATION SIGNAL (WITHOUT VDC) ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0027

1 CHECK INPUT SIGNAL

WITHOUT CONSULT-II © GO TO 2.

2 CHECK INPUT SIGNAL

Without CONSULT-II
1. Turn ignition switch to “OFF” position.
2. Disconnect ABS actuator and electric unit (control unit) harness connector.
3. Disconnect ABS actuator and electric unit (control unit) and transfer control unit harness connectors.
4. Check continuity between transfer control unit harness connector terminal 32 and ABS actuator and electric unit (con-
trol unit) harness connector terminal 9.
Continuity should exist.
5. Check continuity between transfer control unit harness connector terminal 32, ABS actuator and electric unit (control
unit) harness connector terminal 9 and body ground.
Continuity should not exist.

SMT793DC

OK or NG
OK © GO TO 3.
NG © Repair or replace harness or connector between ABS actuator and electric unit (control
unit) and transfer control unit.

3 CHECK COMMUNICATION LINE

Check communication line between ABS actuator and electric unit (control unit) and transfer control unit.
(Refer to BR-144, “8. Vehicle vibrates excessively when ABS is operating”.)
OK or NG
OK © GO TO 4.
NG © Check, repair or replace faulty parts.

TF-122
 ABS OPERATION SIGNAL (WITHOUT VDC) ATX14A
Diagnostic Procedure (Cont’d)

4 PERFORM SELF-DIAGNOSIS AGAIN GI

After driving for a while, perform self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61. MA
OK or NG
OK © INSPECTION END
EM
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89. LC
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.
EC

FE

CL

MT

AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-123
 DATA ERASE/DISPLAY ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0028

1 CHECK TRANSFER CONTROL UNIT POWER SOURCE

1. Turn ignition switch to “OFF” position and perform self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61 and “Trouble Diagnosis with CONSULT-II”, TF-64.
2. Turn ignition switch to “OFF” position.
3. Disconnect transfer control unit harness connector.
4. Check voltage between transfer control unit harness connector terminal 47 and body ground.
Voltage: Battery voltage

SMT794D

OK or NG
OK © GO TO 2.
NG © Check the following.
I No. 24 fuse (7.5A)
I Harness continuity between fuse and transfer control unit

2 PERFORM SELF-DIAGNOSIS AGAIN

After driving for a while, perform self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61 and “Trouble Diagnosis with CONSULT-II”, TF-64.
OK or NG
OK © INSPECTION END
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89.
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.

TF-124
 SHIFT ACTUATOR ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0064

GI
1 SHIFT ACTUATOR
Refer to “Actuator & Actuator Position Switch”, “COMPONENT INSPECTION”, TF-151. MA
OK or NG
OK © GO TO 3. EM
NG © GO TO 2.
LC
2 CHECK POWER SOURCE

EC

FE

CL

MT
SMT825DA
1. Disconnect transfer control device terminal.
2. Turn ignition switch to “ON”. (Do not start engine.) AT
3. Check voltage between transfer control device harness connector 3 (or 4) and body ground while 4WD shift switch is
set from 4H to 4LO (or from 4LO to 4H).
Voltage: Battery voltage
OK or NG
OK © Repair or replace actuator. PD
NG © 1. Recheck the following.
I Continuity between ignition switch and transfer HI & LOW relays
I Ignition switch and No. 3 fuse (20A)
AX
I Continuity between transfer shift HI & LOW relays and transfer control device
2. If NG, repair or replace damaged part.
SU
3 CHECK INPUT SIGNAL
BR
WITH CONSULT-II © GO TO 4.
WITHOUT CONSULT-II © GO TO 5.
ST

RS

BT

HA

SC

EL

IDX

TF-125
 SHIFT ACTUATOR ATX14A
Diagnostic Procedure (Cont’d)

4 CHECK INPUT SIGNAL

With CONSULT-II
1. Start engine (idling).
2. Select “SELF-DIAG RESULTS” in Select Diag Mode.
3. Read out self-diagnostic result.

SMT826D

SMT978D

OK or NG
OK © GO TO 7.
NG © GO TO 6.

TF-126
 SHIFT ACTUATOR ATX14A
Diagnostic Procedure (Cont’d)

5 CHECK INPUT SIGNAL GI

Without CONSULT-II
1. Start engine (idling). MA
2. Check voltage between transfer control unit harness connector terminal 33 (or 42) and body ground while 4WD shift
switch is set from 4H to 4LO (or from 4LO to 4H).
EM

LC

EC

FE
SMT828D
3. Result CL

MT

AT

MTBL0202

OK or NG
OK © GO TO 7. PD
NG © GO TO 6.

AX
6 CHECK HARNESS CONTINUITY BETWEEN TRANSFER CONTROL UNIT AND TRANSFER CONTROL
DEVICE
SU
OK or NG
OK © GO TO 7.
BR
NG © Repair and replace harness connector between transfer control unit and transfer control
device.
ST
7 PERFORM SELF-DIAGNOSIS AGAIN
After driving for a while, perform self-diagnosis again. RS
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.
OK or NG
BT
OK © INSPECTION END
NG © 1. Perform transfer control unit/output signal inspection. Refer to “TRANSFER CON-
TROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL HA
DESCRIPTION”, TF-89.
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector. SC

EL

IDX

TF-127
 SHIFT ACTUATOR POSITION SWITCH ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0065

1 SHIFT ACTUATOR POSITION SWITCH

Refer to “Actuator & Actuator Position Switch”, “COMPONENT INSPECTION”, TF-151.
OK or NG
OK © GO TO 3.
NG © GO TO 2.

2 CHECK POSITION SWITCH

1. Recheck continuity of shift actuator position switch.
Refer to “Actuator & Actuator Position Switch”, “COMPONENT INSPECTION”, TF-151.
Continuity should exist.
OK or NG
OK © GO TO 3.
NG © Repair or replace position switch.

3 CHECK INPUT SIGNAL

WITH CONSULT-II © GO TO 4.
WITHOUT CONSULT-II © GO TO 5.

4 CHECK INPUT SIGNAL

With CONSULT-II
1. Start engine (idling).
2. Select “SELF-DIAG RESULTS” in Select Diag Mode.
3. Read out self-diagnostic result.

SMT829DA

SMT978D

OK or NG
OK © GO TO 7.
NG © GO TO 6.

TF-128
 SHIFT ACTUATOR POSITION SWITCH ATX14A
Diagnostic Procedure (Cont’d)

5 CHECK INPUT SIGNAL GI

Without CONSULT-II
1. Start engine (idling). MA
2. Check voltage transfer control unit harness connector terminal 27 (or 44) and body ground while 4WD shift switch is
set from 4H to 4LO (or from 4LO to 4H).
EM

LC

EC

FE
SMT830D
3. Result CL

MT

AT
MTBL0203

OK or NG
OK © GO TO 7.
NG © GO TO 6. PD

6 CHECK HARNESS CONTINUITY BETWEEN TRANSFER CONTROL UNIT AND TRANSFER CONTROL AX
DEVICE

OK or NG
SU
OK © GO TO 7.
NG © Repair and replace harness connector between transfer control unit and transfer control
device. BR

7 PERFORM SELF-DIAGNOSIS AGAIN ST

After driving for a while, perform self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.
RS
OK or NG
OK © INSPECTION END
BT
NG © 1. Perform transfer control unit/output signal inspection. Refer to “TRANSFER CON-
TROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89. HA
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.
SC

EL

IDX

TF-129
 SHIFT ACTUATOR CIRCUIT ATX14A
Diagnostic Procedure

Diagnostic Procedure NATF0066

1 SHIFT ACTUATOR CIRCUIT

Refer to “Transfer Shift Relay (High & Low)”, “COMPONENT INSPECTION” and “Actuator & Actuator Position Switch”,
“COMPONENT INSPECTION”, TF-150, 151.
OK or NG
OK © GO TO 2.
NG © Repair or replace transfer shift relay and actuator and actuator position switch.

2 CHECK POWER SOURCE OF TRANSFER SHIFT (HI & LOW) RELAY

SMT825DA
1. Disconnect transfer control device terminal.
2. Turn ignition switch to “ON” (Do not start engine).
3. Check voltage between transfer shift HI and LOW relay terminal 5 and body ground.
Voltage: Battery voltage

SMT153E

OK or NG
OK © GO TO 3.
NG © Check the following.
I Continuity between ignition switch and transfer shift HI & LOW relays
I Check ground circuit between transfer shift HI & LOW relays and body ground.
I Ignition switch and No. 3 fuse (20A)

TF-130
 SHIFT ACTUATOR CIRCUIT ATX14A
Diagnostic Procedure (Cont’d)

3 CHECK POWER SOURCE OF TRANSFER CONTROL DEVICE GI

1. Disconnect transfer control device terminal.
2. Turn ignition switch to “ON”. (Do not start engine.) MA
3. Turn 4WD shift switch from “4H” to “4LO” (or from “4LO” to “4H”).
4. Check voltage between transfer control device terminal 3 (or 4) and body ground.
Voltage: Battery voltage
EM

LC

EC

FE

SMT832D CL
OK or NG
OK © GO TO 4. MT
NG © Check the following.
I Harness and connector from transfer shift HI and LOW relays to transfer control
device harness terminal AT
I Ground circuit between transfer control device and body ground.

4 CHECK INPUT SIGNAL

WITH CONSULT-II © GO TO 5.
PD
WITHOUT CONSULT-II © GO TO 6.
AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-131
 SHIFT ACTUATOR CIRCUIT ATX14A
Diagnostic Procedure (Cont’d)

5 CHECK INPUT SIGNAL

With CONSULT-II
1. Start engine (idling).
2. Select “SELF-DIAG RESULTS” in Select Diag Mode.
3. Read out self-diagnostic result.

SMT835D

SMT978D

OK or NG
OK © GO TO 8.
NG © GO TO 7.

TF-132
 SHIFT ACTUATOR CIRCUIT ATX14A
Diagnostic Procedure (Cont’d)

6 CHECK INPUT SIGNAL GI

Without CONSULT-II
1. Start engine (idling). MA
2. Check voltage between transfer control unit harness connector terminal 4 (or 13) and body ground while 4WD shift
switch is set from 4H to 4LO (or from 4LO to 4H).
EM

LC

EC

FE
SMT154E
3. Result
CL

MT

AT

MTBL0516

OK or NG
OK © GO TO 8. PD
NG © GO TO 7.

AX
7 CHECK HARNESS CONTINUITY BETWEEN TRANSFER CONTROL UNIT AND TRANSFER CONTROL
DEVICE

OK or NG
SU
OK © GO TO 8.
NG © Repair and replace harness connector between transfer control unit and transfer control BR
device.

ST
8 PERFORM SELF-DIAGNOSIS AGAIN
After driving for a while, perform self-diagnosis again.
Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.
RS
OK or NG
OK © INSPECTION END
BT
NG © 1. Perform transfer control unit/output signal inspection. Refer to “TRANSFER CON-
TROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL HA
DESCRIPTION”, TF-89.
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector. SC

EL

IDX

TF-133
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 1. 4WD Shift Indicator Lamp Does Not Turn ON

Symptom 1. 4WD Shift Indicator Lamp Does

Not Turn ON NATF0029
SYMPTOM: Although ignition switch is turned “ON”, all the
4WD shift indicator lamps do not turn ON for 1 second.
1 CHECK TRANSFER CONTROL UNIT POWER SOURCE

SMT994D

SMT860D
1. Turn ignition switch to “OFF” position and disconnect transfer control unit harness connector.
2. Turn ignition switch to “ON” position. (Do not start engine.)
3. Check voltage between transfer control unit harness connector terminals 16, 22 and body ground.
Voltage: Battery voltage

SMT796D

OK or NG
OK © GO TO 2.
NG © Check the following.
I Continuity between ignition switch and transfer control unit
I Ignition switch and No. 18 fuse (10A)

TF-134
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 1. 4WD Shift Indicator Lamp Does Not Turn ON (Cont’d)

2 CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT GI

1. Turn ignition switch to “OFF” position.
2. Disconnect transfer control unit harness connector. MA
3. Measure resistance between transfer control unit harness connector terminals 6, 45 and body ground.
Resistance: 0Ω
EM

LC

EC

SMT797D
FE
OK or NG
OK © GO TO 3. CL
NG © Check continuity between transfer control unit and body ground.
MT
3 CHECK PROCEDURES FROM THE BEGINNING AGAIN
Check again. AT
OK or NG
OK © INSPECTION END
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89. PD
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.
AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-135
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 2. 4WD Warning Lamp Does Not Turn ON

Symptom 2. 4WD Warning Lamp Does Not Turn

ON =NATF0030
SYMPTOM: Although ignition switch is turned “ON”, 4WD
warning lamp does not turn ON.
1 CHECK TRANSFER CONTROL UNIT POWER SOURCE

SMT799D
1. Turn ignition switch to “OFF” position and disconnect transfer control unit harness connector.
2. Turn ignition switch to “ON” position.
(Do not start engine.)
3. Check voltage between transfer control unit harness connector terminals 16, 22 and body ground.
Voltage: Battery voltage

SMT800D

OK or NG
OK © GO TO 2.
NG © Check the following.
I Continuity between ignition switch and transfer control unit
I Ignition switch and No. 18 fuse (10A)

TF-136
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 2. 4WD Warning Lamp Does Not Turn ON (Cont’d)

2 CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT GI

1. Turn ignition switch to “OFF” position.
2. Disconnect transfer control unit harness connector. MA
3. Measure resistance between transfer control unit harness connector terminals 6, 45 and body ground.
Resistance: 0Ω
EM

LC

EC

SMT803D
FE
OK or NG
OK © GO TO 3. CL
NG © Check continuity between transfer control unit and body ground.
MT
3 CHECK 4WD WARNING LAMP CIRCUIT
Check the following. AT
I 4WD warning lamp
I Continuity between ignition switch and 4WD warning lamp
I Continuity between 4WD warning lamp and transfer control unit
OK or NG
OK © GO TO 4. PD
NG © I Repair or replace harness or connector.
I Replace 4WD warning lamp.
AX
4 CHECK PROCEDURES FROM THE BEGINNING AGAIN
Check again. SU
OK or NG
OK © INSPECTION END BR
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89.
ST
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with
harness connector.
RS

BT

HA

SC

EL

IDX

TF-137
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 3. 4WD Shift Indicator Lamp Does Not Turn OFF

Symptom 3. 4WD Shift Indicator Lamp Does

Not Turn OFF NATF0031
SYMPTOM: When 4WD shift switch is set from “4H” to
“4LO”, all the 4WD shift indicator lamps do not turn OFF.
1 CHECK ATP SWITCH CIRCUIT

SMT994D
Check ATP switch circuit.
Refer to “Diagnostic Procedure”, “ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH”, TF-148.
OK or NG
OK © GO TO 2.
NG © Check, repair or replace faulty parts.

2 CHECK PROCEDURE FROM THE BEGINNING AGAIN

Check again.
OK or NG
OK © INSPECTION END
NG © Recheck each connector’s pin terminals for damage or loose connection.

Symptom 4. ATP Warning Lamp Does Not Turn

ON NATF0032
SYMPTOM: When 4WD shift switch is set from “4H” to
“4LO” with A/T selector lever in “P” position, ATP warning
lamp does not turn ON.

SMT173E

1 CHECK ATP SWITCH CIRCUIT

Check ATP switch circuit.
Refer to “Diagnostic Procedure”, “ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH”, TF-148.
OK or NG
OK © GO TO 2.
NG © Check, repair or replace faulty parts.

TF-138
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 4. ATP Warning Lamp Does Not Turn ON (Cont’d)

2 CHECK FOLLOWING ITEMS GI

Check the following.
I ATP warning lamp MA
I Continuity between “TFCU” terminal 15 and ATP warning lamp (With VDC)
I Continuity between PNP (“P” position) switch terminal 7 and ATP warning lamp (Without VDC)
I Continuity between ATP warning lamp and ATP switch
EM
OK or NG
OK © GO TO 4. (With VDC)/GO TO 3. (Without VDC)
LC
NG © Repair or replace ATP warning lamp, harness or connector.

EC
3 CHECK PNP SWITCH CIRCUIT (Without VDC)
Check PNP switch circuit.
Refer to AT-102, “DTC P0705 Park/Neutral Position Switch”. FE
OK or NG
OK © GO TO 4. CL
NG © Check, repair or replace faulty parts.

MT
4 CHECK PROCEDURES FROM THE BEGINNING AGAIN
Check again.
AT
OK or NG
OK © INSPECTION END
NG © Recheck each connector’s pin terminals for damage or loose connection.

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-139
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 5. 4LO Indicator Lamp Does Not Turn ON

Symptom 5. 4LO Indicator Lamp Does Not Turn

ON =NATF0033
SYMPTOM: When 4WD shift switch is set from “4H” to
“4LO” position, 4LO indicator lamp does not turn ON.
1 CHECK TRANSFER CONTROL UNIT POWER SUPPLY CIRCUIT

SMT994D

SMT851D

SMT979D
1. Disconnect battery negative terminal (−), then transfer control unit connector.
2. Connect battery negative terminal (−) and turn ignition switch “ON” (with engine stopped).
3. Check voltage across transfer control unit body-side connector terminals 47, 16 and body ground.
Voltage: Battery voltage
OK or NG
OK © GO TO 2.
NG © Check the following.
I Continuity between battery and transfer control unit
I Ignition switch (Refer to EL-11, “Power Supply Routing”.)
I No. 24 fuse (7.5A), No. 8 fuse (10A) and No. 18 fuse (10A)

TF-140
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 5. 4LO Indicator Lamp Does Not Turn ON (Cont’d)

2 CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT GI

1. Turn ignition switch “OFF”, and disconnect transfer control unit connector.
2. Check for continuity between transfer control unit body-side connector terminals 6, 45 and body ground. MA
Continuity should exist.
OK or NG
OK © GO TO 3.
EM
NG © Check the following.
I Continuity between transfer control unit and body ground LC

3 CHECK 4LO INDICATOR LAMP CIRCUIT EC

Disconnect battery negative terminal (−) and check the following items:
1. Check condition of 4LO indicator lamp.
2. Check continuity between battery and 4LO indicator lamp. FE
3. Check continuity between 4LO indicator lamp and transfer control unit connector terminal 12.
4. Check condition of ATP switch.
5. Check condition of neutral-4LO switch. CL
6. Check continuity between neutral-4LO switch ground terminal 6 and body ground.
OK or NG
MT
OK © GO TO 4.
NG © Check the following.
I 4LO indicator lamp AT
I Neutral-4LO switch
Refer to “ATP Switch, Neutral-4LO Switch and Wait Detection Switch”, “COMPONENT
INSPECTION”, TF-148.

4 CHECK PROCEDURES FROM THE BEGINNING PD

Check again.
OK or NG AX
OK © INSPECTION END
NG © 1. Perform transfer control unit input/output signal inspection. Refer to “TRANSFER SU
CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL
DESCRIPTION”, TF-89.
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with BR
harness connector.

ST

RS

BT

HA

SC

EL

IDX

TF-141
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 6. 4WD Shift Indicator Lamp Does Not Indicate “4H”

Symptom 6. 4WD Shift Indicator Lamp Does

Not Indicate “4H” NATF0034
SYMPTOM: When 4WD shift switch is set to “4H”, 4WD shift
indicator lamp does not indicate “4H”.
1 CHECk 4WD WARNING LAMP

SMT994D
Is 4WD warning lamp turned ON?
Yes or No
Yes © Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.
No © GO TO 2.

2 CHECK FOLLOWING ITEMS

Check the following.
I Neutral-4LO switch circuit. Refer to TF-112.
I Wait detection switch circuit. Refer to TF-112.
I ATP switch circuit. Refer to TF-112.
OK or NG
OK © GO TO 3.
NG © Check, repair or replace faulty parts.

3 CHECK PROCEDURES FROM THE BEGINNING AGAIN

Check again.
OK or NG
OK © INSPECTION END
NG © Recheck each connector’s pin terminals for damage or loose connection.

TF-142
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 7. 4WD Shift Indicator Lamp Repeats Flickering

Symptom 7. 4WD Shift Indicator Lamp Repeats GI

Flickering =NATF0035
SYMPTOM: 4WD shift indicator lamp keeps flickering.
MA
1 CHECK 4WD SHIFT INDICATOR LAMP

EM

LC

EC

FE
SMT994D
1. Set 4WD shift switch to “2WD” position.
2. Move vehicle forward and backward. Or drive straight increasing or decreasing speed under 20 km/h (12 MPH). CL
3. Does 4WD shift indicator lamp keep flickering?
Yes or No MT
Yes © GO TO 2.
No © INSPECTION END
AT
2 CHECK TIGHT CORNER BRAKING SYMPTOM
Drive vehicle at speed under 20 km/h (12 MPH), turning steering wheel to the limit. Does tight corner braking symptom
occur?
Yes or No PD
Yes © GO TO 3.
No © GO TO 4. AX

3 CHECK 4WD SHIFT INDICATOR LAMP SU

Does the 4WD shift indicator lamp keep flickering when the front wheels are jacked up?
Yes or No BR
Yes © Check transfer unit operating system.
No © Check tires.
ST
4 CHECK 4WD WARNING LAMP
RS
Does 4WD warning lamp flicker? (4WD shift indicator lamp is turned OFF.)
Yes or No
Yes © Perform self-diagnoses. Refer to “Trouble Diagnosis without CONSULT-II”, TF-61.
BT
No © GO TO 5.
HA
5 CHECK 4WD SHIFT INDICATOR LAMP
Does 4WD shift indicator lamp keep flickering? SC
Yes or No
Yes © Check again. EL
No © INSPECTION END
IDX

TF-143
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 8. Tight Corner Braking Symptom

Symptom 8. Tight Corner Braking Symptom NATF0036

SYMPTOM: Tight corner braking symptom occurs. (Hydraulic
system failure)
1 CHECK INPUT SIGNAL
With CONSULT-II
1. Select “ECU INPUT SIGNALS” in Data Monitor.
2. Read out the ON/OFF status of “CLUTCH PRES SW”.

SMT977D

Without CONSULT-II
Check voltage between transfer control unit harness connector terminal 34 and body ground.
Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”,
TF-89.
OK or NG
OK © Disassemble transfer unit and check the following.
I Control valve assembly
I 4WD solenoid valve
I 2-4WD shift solenoid valve
I Clutch piston
I Clutch assembly
NG © GO TO 2.

2 CHECK CLUTCH PRESSURE SWITCH CIRCUIT

Check clutch pressure switch circuit.
Refer to “Diagnostic Procedure”, “CLUTCH PRESSURE SWITCH”, TF-116.
OK or NG
OK © GO TO 3.
NG © Check, repair or replace faulty parts.

3 CHECK PROCEDURES FROM THE BEGINNING AGAIN

Check again.
OK or NG
OK © INSPECTION END
NG © Recheck each connector’s pin terminals for damage or loose connection.

TF-144
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 9. 4WD System Does Not Operate

Symptom 9. 4WD System Does Not Operate =NATF0037

GI
SYMPTOM: The vehicle cannot be put into 4WD mode.
(Hydraulic system failure)
MA
1 CHECK INPUT SIGNAL
With CONSULT-II
1. Select “ECU INPUT SIGNALS” in Data Monitor. EM
2. Read out the ON/OFF status of “CLUTCH PRES SW”.

LC

EC

FE

CL
SMT977D

Without CONSULT-II
MT
Check voltage between transfer control unit harness connector terminal 34 and body ground.
Refer to “TRANSFER CONTROL UNIT INSPECTION TABLE”, “TROUBLE DIAGNOSIS — GENERAL DESCRIPTION”,
TF-89.
AT
OK or NG
OK © 1. Check transfer fluid level.
2. Disassemble transfer unit and check the following.
I Transfer motor
I Main oil pump assembly PD
I Sub-oil pump assembly
I Oil strainer
I Control valve assembly AX
I 2-4WD shift solenoid valve
I Oil filter element
I Lip seal SU
I Strainer O-ring
I Main oil pump drive gear
I Seal ring BR
I D-ring
I Clutch piston
I Clutch assembly ST
NG © GO TO 2.
RS
2 CHECK CLUTCH PRESSURE CIRCUIT
Check clutch pressure switch circuit. BT
Refer to “Diagnostic Procedure”, “CLUTCH PRESSURE SWITCH”, TF-116.
OK or NG
OK © GO TO 3.
HA
NG © Check, repair or replace faulty parts.
SC

EL

IDX

TF-145
 TROUBLE DIAGNOSES FOR SYMPTOMS ATX14A
Symptom 9. 4WD System Does Not Operate (Cont’d)

3 CHECK PROCEDURES FROM THE BEGINNING

Check again.
OK or NG
OK © INSPECTION END
NG © Recheck each connector’s pin terminals for damage or loose connection.

TF-146
 NATF0038

COMPONENT INSPECTION ATX14A

4WD Shift Switch

4WD Shift Switch NATF0038S01

GI
Check continuity between each terminal.
Terminals Switch position Continuity MA
2WD Yes
1-2
Except 2WD No EM
AUTO Yes
1 - 3, 1 - 4
Except AUTO No LC
SMT858D 4H Yes
1 - 4, 1 - 5
Except 4H No EC
4LO Yes
1 - 4, 1 - 6 FE
Except 4LO No

CL

MT

AT
2-4WD Shift Solenoid Valve and Transfer Fluid
Temperature Sensor NATF0038S02
Measure resistance between terminals of transfer terminal cord
assembly sub-harness connector located on rear-right of transfer
unit.
PD
Component parts Terminals Resistance

2-4WD shift solenoid valve 4-5

Approx. 20°C (68°F): AX
Approx. 22.8 - 25.2Ω

Approx. 20°C (68°F): Approx. 2.5 kΩ

SMT079D Transfer fluid temperature
2-3 Approx. 80°C (176°F): Approx. 0.3 SU
sensor
kΩ

BR

ST

RS

BT
4WD Solenoid Valve, Clutch Pressure Switch
and Line Pressure Switch HA
NATF0038S03
Measure resistance between terminals of transfer terminal cord
assembly sub-harness connector located on rear-right of transfer
unit.
SC

EL

IDX
SMT080D

TF-147
 COMPONENT INSPECTION ATX14A
4WD Solenoid Valve, Clutch Pressure Switch and Line Pressure Switch (Cont’d)

Component
Terminals Remarks
parts

4WD solenoid
6 Approx. 20°C (68°F): Approx. 3.0 - 3.4Ω
valve

In room temperature
I 2-4WD shift solenoid valve “OFF”: No
Clutch pres-
7 continuity
sure switch
Ground I 2-4WD shift solenoid valve and transfer
terminal motor “ON”: Continuity exists

In room temperature
I Turn ignition switch to “OFF” position
Line pressure
1 and leave vehicle for more than 5 min-
switch
utes. (OFF): No continuity
I Transfer motor “ON”: Continuity exists

Front Revolution Sensor NATF0038S04

Measure resistance between terminals of front revolution sensor
sub-harness connector located on rear-right of transfer unit.
Terminals Resistance

16 - 17 500 - 650Ω

18 - 17 No continuity

18 - 16 No continuity

SMT081D

Transfer Dropping Resistor NATF0038S07

Check resistance between terminals.
Resistance: 11.2 - 12.8 Ω

SMT806D

ATP Switch, Neutral-4LO Switch and Wait

Detection Switch NATF0038S06
Measure resistance between terminals of transfer switch assembly
sub-harness connector located on rear-right of transfer unit.

SMT083D

TF-148
 COMPONENT INSPECTION ATX14A
ATP Switch, Neutral-4LO Switch and Wait Detection Switch (Cont’d)

4WD shift switch position GI

Switch Terminals
4H (N) 4LO

No conti- No conti-
MA
ATP switch 8-9 Continuity
nuity nuity

Neutral-4LO
12 - 13 No continuity Continuity
EM
switch

No continuity Continuity
Wait detection LC
10 - 11 (Note)
switch
+---------------------------
NOTE: EC
When shifting from “4LO” to “4H”, continuity exists while “Wait” function is operat-
ing. (No continuity exists when “Wait” function is canceled.)
FE

CL

MT

AT
Transfer Motor NATF0038S05
Apply battery voltage directly to transfer motor assembly sub-har-
ness connector located on rear-right of transfer unit. (Positive: Ter-
minal 14, Negative: Terminal 15)
Transfer motor should operate.
PD

AX

SMT082D SU
Transfer Motor Relay NATF0038S08
1. Apply battery voltage directly to terminals 3 and 4. BR
2. Check continuity between terminals 1 and 2.
Condition Continuity (1 - 2)
ST
Battery voltage is applied Yes

No voltage is applied No RS

SMT085D BT
Transfer Sub-harness NATF0038S09
FRONT REVOLUTION SENSOR SUB-HARNESS HA
CONNECTOR NATF0038S0901
Check continuity between terminals shown in the figure. SC

EL

IDX
SMT086DB

TF-149
 COMPONENT INSPECTION ATX14A
Transfer Sub-harness (Cont’d)
TRANSFER SWITCH ASSEMBLY SUB-HARNESS
CONNECTOR NATF0038S0902
Check continuity between terminals shown in the figure.

SMT087D

TRANSFER TERMINAL CORD ASSEMBLY

SUB-HARNESS CONNECTOR NATF0038S0903
Check continuity between terminals shown in the figure.
Terminals on solenoid valve
Terminals Components

6 4WD solenoid valve

4, 5 2-4WD shift solenoid valve

2, 3 Transfer fluid temperature sensor

SMT088D 7 Clutch pressure switch

1 Line pressure switch

Transfer Shift Relay (High & low) NATF0038S10

Check continuity between terminals 3 and 4.
Condition Continuity

12V direct current supply

No
between terminals 1 and 2

No current supply Yes

SMT197E

TF-150
 COMPONENT INSPECTION ATX14A
Actuator & Actuator Position Switch

Actuator & Actuator Position Switch NATF0038S11

GI
ACTUATOR NATF0038S1101
Operation & resistance check
MA
I Apply battery voltage directly to actuator assembly.
Operating check Battery positive terminal Battery negative terminal
EM
1 4 3

2 3 4
LC
Check Approx. 0.2Ω (When the motor is not operated.)
SMT812D

ACTUATOR POSITION SWITCH EC

NATF0038S1102
Continuity check
Battery positive Battery negative FE
Continuity check Continuity
terminal terminal

1 4 3 1-5 CL
2 3 4 2-5

MT
SMT838D
AT

PD

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

TF-151
 ON-VEHICLE SERVICE ATX14A
Replacing Oil Seal

Replacing Oil Seal NATF0068

FRONT CASE OIL SEAL NATF0068S01
1. Drain transfer fluid.
2. Remove exhaust front tube and heat insulator. Refer to
“Removal”, TF-155.
3. Remove front propeller shaft. Refer to PD-8, “Removal and
Installation”.
4. Remove companion flange lock nut.
I Do not reuse lock nut.
SMT844DB

5. Put a matchmark on top of drive pinion thread. The mark

should be in line with the mark on the companion flange.
I Always mark top of drive pinion screw using paint.

SMT112D

6. Remove companion flange.

SMT802C

7. Remove front case oil seal.

SMT803C

8. Install front case oil seal.

I Before installing, apply multi-purpose grease to seal lip.
9. Install companion flange.

SMT183E

TF-152
 ON-VEHICLE SERVICE ATX14A
Replacing Oil Seal (Cont’d)
10. Tighten nut to the specified torque. GI
Refer to TF-157.
11. Install front propeller shaft.
12. Install exhaust front tube and heat insulator. MA

EM

LC
SMT845DB

SHIFT SHAFT OIL SEAL EC

NATF0068S02
1. Remove front propeller shaft. Refer to PD-8, “Removal and
Installation”.
FE
2. Remove companion flange. Refer to “FRONT CASE OIL
SEAL”, TF-152.
3. Remove actuator lever from transfer outer shift lever. Then CL
remove outer shift lever.

MT
SMT808D
AT
4. Remove shift shaft oil seal.
I Be careful not to damage cross shaft.

PD

AX

SMT491A SU
5. Install shift shaft oil seal.
I Before installing, apply multi-purpose grease to seal lip.
BR
6. Install transfer control linkage.
7. Install companion flange. Refer to “FRONT CASE OIL SEAL”,
TF-152. ST
8. Install front propeller shaft.

RS

SMT805C BT
REAR OIL SEAL NATF0068S03
1. Remove rear propeller shaft. Refer to PD-8, “Removal and HA
Installation”.
2. Remove rear oil seal.
3. Install rear oil seal. SC
I Before installing, apply multi-purpose grease to seal lip.
4. Install rear propeller shaft. EL

IDX
SMT892C

TF-153
 ON-VEHICLE SERVICE ATX14A
Transfer Motor

Transfer Motor
REMOVAL NATF0069
1. Disconnect transfer motor harness connector.
2. Remove breather pipe from transfer motor.
3. Remove bolts to detach transfer motor.
I After removing transfer motor, be sure to replace O-ring
with new one.
INSTALLATION NATF0070
1. Apply petroleum jelly or ATF to O-ring.
SMT874C
2. Align width across flat-notch with oil pump groove, and install
transfer motor.
3. Tighten bolts.
: 41 - 48 N·m (4.2 - 4.9 kg-m, 30 - 35 ft-lb)
4. Install breather pipe to transfer motor.
5. Connect transfer motor harness connector.

Transfer Oil Filter

REMOVAL NATF0071
I Remove bolts to detach oil filter.
I When removing oil filter from transfer, avoid damaging it.
Be sure to loosen bolts evenly.
I When removing oil filter, be sure to replace O-ring with
new one.
INSTALLATION NATF0072
1. Apply petroleum jelly or ATF to O-ring.
SMT875C 2. Tighten bolts evenly to install oil filter.
: 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb)
I Be sure not to damage oil filter.

TF-154
REMOVAL AND INSTALLATION ATX14A
Removal

Removal NATF0073
GI
1. Remove exhaust front and rear tubes. Refer to FE-9,
“EXHAUST SYSTEM”.
2. Remove front and rear propeller shaft. Refer to PD-8, MA
“Removal and Installation”.
3. Insert plug into rear oil seal after removing propeller shaft. EM
I Be careful not to damage spline, sleeve yoke and rear oil
seal, when removing propeller shaft.
4. Disconnect neutral-4LO switch, front revolution sensor, ATP LC
switch, transfer motor and 4WD shift switch harness connec-
SMT897C tors.
5. Remove center console and A/T control device. EC
6. Remove floor panel for transfer.
7. Remove upper side fixing bolt for A/T and TF. FE
8. Remove actuator lever from transfer outer shift lever and
remove sub-oil pump from transfer.
9. Remove remaining fixing bolt for AT and TF. CL

MT
SMT808D
AT
10. Remove transfer from transmission.
WARNING:
Support transfer while removing it.

PD

AX

SMT899C SU

BR

ST

RS

SMT871C BT
Installation NATF0074
I Tighten bolts securing transfer. HA
Bolt length:
45 mm (1.77 in) SC
Tightening torque:
: 31 - 42 N·m (3.2 - 4.3 kg-m, 23 - 31 ft-lb)
EL

IDX
SMT872C

TF-155
 OVERHAUL ATX14A
Transfer Gear Control

Transfer Gear Control NATF0075

SMT809D

1. Actuator 2. Actuator lever 3. Outer shift lever

TF-156
 OVERHAUL ATX14A
Transfer Components

Transfer Components NATF0076

GI

MA

EM

LC

EC

FE

CL

MT

AT

PD

AX
SMT194EA

1. Oil seal 18. L-H sleeve 35. Mainshaft SU

2. Transfer cover 19. 2-4 sleeve 36. Drive chain
3. Snap ring 20. Radial needle bearing 37. Clutch drum
4. Washer 21. Front revolution sensor 38. Clutch hub BR
5. Snap ring 22. Retaining pin 39. Snap ring
6. Main gear bearing 23. L-H fork 40. Driven plate
7. Front case 24. 2-4 fork 41. Drive plate ST
8. Check plug 25. Shift fork spring 42. Retaining plate
9. Check spring 26. Fork guide 43. Return spring assembly
10. Check ball 27. Retaining pin 44. Press flange RS
11. Internal gear 28. Shift rod 45. Washer
12. Snap ring 29. Self-lock nut 46. Thrust needle bearing
13. Bearing race 30. Companion flange 47. Snap ring BT
14. Thrust needle bearing 31. Oil seal 48. Seal ring
15. Planetary carrier 32. Drain plug 49. Front bearing
16. Thrust needle bearing 33. Wait detection switch 50. Front drive shaft HA
17. Sun gear 34. Needle bearing 51. Rear bearing

SC

EL

IDX

TF-157
 OVERHAUL ATX14A
Transfer Components (Cont’d)

SMT207EA

55. Thrust needle bearing race 69. Oil seal 83. Oil pump gasket
56. Clutch piston 70. Magnet 84. Sub-oil pump housing
57. D-ring 71. Baffle plate 85. Outer gear
58. Lip seal 72. Oil strainer 86. Inner gear
59. Oil gutter 73. O-ring 87. O-ring
60. Center case 74. Control valve assembly 88. Sub-oil pump cover
61. Stem bleeder 75. Lip seal (7 pieces) 89. O-ring
62. Mainshaft rear bearing 76. Filler plug 90. Transfer motor
63. Thrust washer 77. Inner gear 91. O-ring
64. Speedometer drive gear 78. Outer gear 92. Oil filter stud
65. Snap ring 79. Oil pump housing 93. O-ring
66. Rear case 80. Bushing 94. O-ring
67. ATP switch 81. Oil pump shaft 95. Oil filter
68. Neutral-4LO switch 82. Oil pressure check plug

TF-158
 DISASSEMBLY ATX14A
Rear Case

Rear Case GI
DISASSEMBLY NATF0077
1. Remove neutral-4LO switch and ATP switch.
MA
2. Remove bolts.

EM

LC
SMT877C

3. Remove rear case from center case by tapping it lightly with a EC

plastic hammer.
FE

CL

MT
SMT878C
AT
Center Case
DISASSEMBLY NATF0078
1. Remove oil pump shaft from main oil pump.

PD

AX

SMT883C SU
2. Remove stem bleeder from bleeder hole.
BR

ST

RS

SMT884C BT
3. Remove lock nut from companion flange.
I Do not reuse lock nut. HA

SC

EL

IDX
SMT844DB

TF-159
 DISASSEMBLY ATX14A
Center Case (Cont’d)
4. Remove companion flange.

SMT886CA

5. Remove bolts.

SMT887C

6. Insert screwdrivers as shown in the figure, and separate cen-

ter case from front case. Then, remove center case by lever-
ing it up with a tire lever or the like.
I Be careful not to damage the mating surface.

SMT888C

7. Remove snap ring from mainshaft.

I Do not reuse snap ring.

SMT889C

8. Remove C-rings from mainshaft bearing.

SMT890C

TF-160
 DISASSEMBLY ATX14A
Center Case (Cont’d)
Front Drive Shaft and Drive Chain NATF0078S01 GI
1. Remove oil gutter from center case.
2. With front drive shaft held by one hand as shown in the figure,
tap center case with a plastic hammer to remove it with drive MA
chain.
I Do not tap drive chain with a plastic hammer.
EM

LC
SMT900C

3. Set a puller (ST30031000) and an adapter (ST33052000). EC

Remove front drive shaft front bearing.
FE

CL

MT
SMT175E
AT
4. Set the puller (ST30031000) and the adapter (ST33052000).
Remove front drive shaft rear bearing.

PD

AX

SMT176E SU
Mainshaft and Clutch Drum NATF0078S02
1. Remove mounting bolts to detach baffle plate.
BR

ST

RS

SMT903CA BT
2. Set center case to press stand. Remove mainshaft from cen-
ter case. HA

SC

EL

IDX
SMT904C

TF-161
 DISASSEMBLY ATX14A
Center Case (Cont’d)
3. Remove thrust needle bearing from press flange.

SMT905C

4. Remove seal ring from mainshaft.

I Do not reuse seal ring.

SMT906C

5. Set a drift (KV31103300), a support ring (KV40104710), a sup-

port ring (ST27863000) and a drift (ST35271000) to press
flange as shown in the figure. Press drift until snap ring is out
of place.

SMT907C

6. Remove snap ring from mainshaft.

I Do not reuse snap ring.

SMT908C

7. Remove washer.

SMT909C

TF-162
 DISASSEMBLY ATX14A
Center Case (Cont’d)
8. Remove press flange from mainshaft. GI

MA

EM

LC
SMT910C

9. Remove return spring assembly from clutch hub. EC

FE

CL

MT
SMT911C
AT
10. Remove each plate from clutch drum.

PD

AX

SMT912C SU
11. Remove snap ring from mainshaft.
I Do not reuse snap ring.
BR

ST

RS

SMT913C BT
12. Tap mainshaft with a plastic hammer to remove it from clutch
drum and clutch hub. HA
13. Remove needle bearing from mainshaft.

SC

EL

IDX
SMT914C

TF-163
 DISASSEMBLY ATX14A
Center Case (Cont’d)
Clutch Piston NATF0078S03
1. Remove oil pressure check plug from oil pressure check port.

SMT915C

2. Apply air gradually from oil pressure check port, and remove
clutch piston from center case.

SMT916C

3. Remove lip seal and D-ring from clutch piston.

I Do not reuse lip seal and D-ring.
4. Remove thrust needle bearing race from clutch piston by hook-
ing a screwdriver edge into 4 notches of thrust needle bearing
race.

SMT917C

Control Valve NATF0078S04

CAUTION:
I Do not reuse any part that has been dropped or damaged.
I Make sure valve is assembled in the proper direction.
I Do not use a magnet because residual magnetism stays
during disassembly.

1. Remove bolts, and detach oil strainer.

SMT918C

TF-164
 DISASSEMBLY ATX14A
Center Case (Cont’d)
2. Remove O-rings from oil strainer. GI
I Do not reuse O-rings.

MA

EM

LC
SMT919C

3. Remove bolts for control valve. EC

FE

CL

MT
SMT920C
AT
4. Remove snap ring. Then push terminal assembly into center
case to remove control valve assembly.

PD

AX

SMT921C SU
5. Remove lip seals from center case.
I Do not reuse lip seals.
BR
I There are two kinds of lip seals (lip seal of large inner
diameter: 5 pieces, lip seal of small inner diameter: 2
pieces). Confirm the position before disassembly. ST

RS

SMT922CA BT
6. Remove all bolts except for two.
HA

SC

EL

IDX
SMT923C

TF-165
 DISASSEMBLY ATX14A
Center Case (Cont’d)
7. Remove 4WD solenoid valve, clutch pressure switch, 2-4WD
shift solenoid valve, line pressure switch, and transfer fluid
temperature sensor from control valve assembly.
8. Remove O-rings from each solenoid valve, switch and termi-
nal body.
I Do not reuse O-rings.

SMT924C

9. Place control valve with lower body facing up, remove two
mounting bolts, and then remove lower body and separator
plate from upper body.
CAUTION:
I Be careful not to drop relief balls. Detach lower body care-
fully.
I Do not reuse separator plate.

SMT925C

10. Make sure reverse balls, relief balls and relief springs, accu-
mulator pistons and valve springs are securely installed as
shown in the figure, and remove them.

SMT177E

11. Remove retainer plates.

SMT927C

12. Remove each control valve, spring and plug.

SMT928CA

TF-166
 DISASSEMBLY ATX14A
Center Case (Cont’d)
Mainshaft Rear Bearing NATF0078S05 GI
1. Remove mainshaft rear bearing from center case using a
remover (ST35291000) and a remover (ST30090010).
MA

EM

LC
SMT929C

Main Oil Pump EC

NATF0078S06
1. Remove bolts as shown in figure to detach main oil pump.
FE

CL

MT
SMT930C
AT
2. Remove outer gear and inner gear.

PD

AX

SMT931C SU
Sub-oil Pump NATF0078S07
1. Remove bolts to detach transfer motor from center case. Then
remove O-ring from the transfer motor.
BR
I Do not reuse O-ring.
ST

RS

SMT932C BT
2. Remove sub-oil pump mounting bolts.
HA

SC

EL

IDX
SMT933C

TF-167
 DISASSEMBLY ATX14A
Center Case (Cont’d)
3. Thread two bolts (M4 x 0.8) into the holes of sub-oil pump as
shown in the figure, and pull out to remove sub-oil pump.

SMT934C

4. Remove oil pump gasket.

I Do not reuse gasket.

SMT935C

5. Remove sub-oil pump cover, outer gear, inner gear and O-ring
from sub-oil pump housing.
I Do not reuse O-ring.

SMT936C

Oil Filter NATF0078S08

1. Remove bolts for oil filter.

SMT937C

2. Insert a screwdriver as shown in the figure to remove oil filter.

SMT938C

TF-168
 DISASSEMBLY ATX14A
Center Case (Cont’d)
3. Remove O-rings from oil filter. GI
I Do not reuse O-rings.

MA

EM

LC
SMT939C

4. Remove oil filter stud. EC

FE

CL

MT
SMT940C
AT
5. Remove O-ring from oil filter stud.
I Do not reuse O-ring.

PD

AX

SMT941C SU
Front Case
DISASSEMBLY NATF0079 BR
1. Remove rear case from center case. Refer to TF-159.
2. Remove front case from center case.
ST

RS

SMT895C BT
Shift Rod Components NATF0079S01
1. Remove check plug, then check spring and check ball. HA
2. Remove wait detection switch.
SC

EL

IDX
SMT990C

TF-169
 DISASSEMBLY ATX14A
Front Case (Cont’d)
3. Remove shift rod components together with 2-4 sleeve and
L-H sleeve.

SMT991C

4. Remove 2-4 sleeve and L-H sleeve from 2-4 fork and L-H fork
respectively.

SMT992C

5. Drive out retaining pin from shift rod.

I Do not reuse retaining pin.

SMT993C

6. Remove L-H fork, 2-4 fork, shift fork spring and fork guide from
shift rod.

SMT195E

Planetary Carrier, Sun Gear and Internal Gear NATF0079S02

1. Remove radial needle bearing from sun gear.

SMT995C

TF-170
 DISASSEMBLY ATX14A
Front Case (Cont’d)
2. Remove bolts to detach transfer cover. GI
I Do not reuse bolts.

MA

EM

LC
SMT996C

3. Remove oil seal from transfer cover. EC

I Do not reuse oil seal.
FE

CL

MT
SMT997C
AT
4. Remove snap ring from main gear bearing.
I Do not reuse snap ring.

PD

AX

SMT998C SU
5. Remove sun gear by tapping it lightly.
BR

ST

RS

SMT999C BT
6. Remove snap ring from sun gear.
I Do not reuse snap ring as it is a selective part. HA
7. Remove washer from sun gear.
SC

EL

IDX
SMT001D

TF-171
 DISASSEMBLY ATX14A
Front Case (Cont’d)
8. Set an adapter to sun gear as shown in the figure. Remove sun
gear from planetary carrier. Remove main gear bearing, bear-
ing race and thrust needle bearing (front and rear of planetary
carrier) from sun gear.

SMT002DA

9. Remove snap ring, and remove internal gear.

I Do not reuse snap ring.

SMT004D

10. Remove front oil seal.

I Do not reuse oil seal.
11. Loosen nut of outer lever assembly to pull out cotter pin, and
remove outer lever.
12. Remove inner lever assembly.

SMT198E

TF-172
REPAIR FOR COMPONENT PARTS ATX14A
Front Case

Front Case GI
INSPECTION NATF0080
Planetary Carrier NATF0080S01 MA
I Measure end play of each pinion gear, and make sure the
measurement is within specification shown below. If out of
specification, replace planetary carrier with new one. EM
Pinion gear end play:
0.1 - 0.7 mm (0.004 - 0.028 in)
I Check working face of each gear, bearing and others for LC
SMT006D
damage, burrs, partial wear, dents and other abnormality. If
any is found, replace planetary carrier with new one.
EC

FE

CL

MT

AT
Sun Gear NATF0080S02
I Check if oil passage of sun gear is clogged. For this, try to pass
a 3.6 mm (0.142 in) dia. wire through oil passage as shown in
the figure.
I Check sliding/contact surface of each gear, bearing and others
for damage, burrs, partial wear, dents, and other abnormality. PD
If any is found, replace sun gear with new one.
AX

SMT007D SU
Internal Gear NATF0080S03
I Check internal gear teeth for damage, partial wear, dents and
other abnormality. If any is found, replace internal gear with
BR
new one.
ST

RS

SMT008D BT
Shift Rod Components NATF0080S04
I Check working face of shift rod and fork for wear, partial wear, HA
bending and other abnormality. If any is found, replace with
new one.
SC

EL

IDX
SMT009D

TF-173
 REPAIR FOR COMPONENT PARTS ATX14A
Front Case (Cont’d)
I Measure clearance between shift fork and sleeve. If it is out of
specification, replace it with new one.
Standard value:
Less than 0.36 mm (0.0142 in)

SMT010D

Center Case
INSPECTION NATF0081
Sub-oil Pump NATF0081S01
1. Check inner and outer circumference, tooth face, and side-
face of inner and outer gears for damage or abnormal wear.
2. Measure side clearance between oil pump housing edge and
inner gear/outer gear.
3. Make sure side clearance is within specification. If the mea-
surement is out of specification, replace inner and outer gears
together with new ones as a set.
SMT942C
Specification:
0.015 - 0.035 mm (0.0006 - 0.0014 in)
For inner gear and outer gear, refer to SDS, TF-192.

Main Oil Pump NATF0081S02

1. Check inner and outer circumference, tooth face, and side-
face of inner and outer gears for damage or abnormal wear.
2. Measure side clearance between oil pump housing edge and
inner gear/outer gear.
3. Make sure side clearance is within specification. If the mea-
surement is out of specification, replace inner and outer gears
with new ones as a set.
Specification:
0.015 - 0.035 mm (0.0006 - 0.0014 in)
SMT943C
For inner gear and outer gear, refer to SDS, TF-192.
Mainshaft NATF0081S03
I Check surfaces which contact sun gear, clutch drum, clutch
hub, press flange, clutch piston, each bearing, etc. for damage,
peel, partial wear, dents, bending, or other abnormal damage.
If any is found, replace with new one.

SMT944C

TF-174
REPAIR FOR COMPONENT PARTS ATX14A
Center Case (Cont’d)
Control Valve NATF0081S04 GI
I Check oil filter screen for damage. If any is found, replace with
new one.
MA

EM

LC
SMT945C

I Check resistance between terminals of 4WD solenoid valve, EC

2-4WD shift solenoid valve and transfer fluid temperature sen-
sor.
Resistance: FE
Refer to “COMPONENT INSPECTION”, TF-147.
CL

MT
SMT946CA
AT
I Check sliding faces of control valves and plugs for abnormal-
ity. If any is found, replace the control valve assembly with new
one.
CAUTION:
Replace control valve body together with clutch return spring
as a set. PD
Control valve:
Refer to SDS, TF-192.
AX

SMT947C SU
I Check each control valve spring for damage or distortion, and
also check its free length, outer diameter and wire diameter. If
any damage or fatigue is found, replace control valve body with BR
new one.
I Replace control valve body together with clutch return
spring as a set.
ST
Inspection standard:
Refer to SDS, TF-192. RS

SMT948C BT
Clutch NATF0081S05
I Check drive plate facings and driven plate for damage, cracks HA
or other abnormality. If any, replace with new one.
I Check the thickness of drive plate facings and driven plate.
Inspection standard: SC
Refer to SDS, TF-193.
CAUTION: EL
I Measure facing thickness at 3 points to take an average.
I Check all the drive and driven plates.
I Check return spring for damage or deformation. IDX
SMT949C

TF-175
 REPAIR FOR COMPONENT PARTS ATX14A
Center Case (Cont’d)
I Check stamped mark shown in the figure. Then, check that
free length, outer diameter and wire diameter are within speci-
fications. If any abnormality is found, replace with new return
spring assembly of the same stamped number.
Inspection standard:
Refer to SDS, TF-193.

SMT178E

TF-176
 ASSEMBLY ATX14A
Front Case

Front Case GI
ASSEMBLY NATF0082
Planetary Carrier, Sun Gear and Internal Gear NATF0082S01 MA
1. Apply ATF to oil seal periphery, and install oil seal so that it is
flush with the end face of front case.
I Do not reuse oil seal. EM

LC
SMT011D

2. Install internal gear with its groove facing snap ring into front EC
case. Then secure it with snap ring.
I Do not reuse snap ring.
FE

CL

MT
SMT012D
AT
3. Install snap ring to main gear bearing.
I Do not reuse snap ring.

PD

AX

SMT014D SU
4. Set main gear bearing to front case, then press it.
BR

ST

RS

SMT015D BT
5. Install thrust needle bearing to sun gear.
6. Install sun gear to planetary carrier. HA

SC

EL

IDX
SMT016D

TF-177
 ASSEMBLY ATX14A
Front Case (Cont’d)
7. Set a support (KV40105500) to bushing replacer puller
(ST30911000) as shown in the figure, and place planetary
carrier on it.
8. Install thrust needle bearing to planetary carrier with its roller
facing front case.
9. Measure “C” from the end of sun gear to the roller surface of
thrust needle bearing.

SMT017D

10. Measure “D” from the end of sun gear to the main gear bear-
ing contact surface.
11. Calculate end play “E” using “C” and “D” obtained in steps 10
and 11. Select bearing race so that the end play becomes the
standard value.
Calculation formula:
End play “E” = “C” − “D”
Standard end play:
0.1 - 0.25 mm (0.0039 - 0.0098 in)
Bearing race:
SMT018D
Refer to SDS, TF-194.
12. Set planetary carrier to press in the status described in step 8.
Then install the selected bearing race to planetary carrier.

SMT019D

13. Install front case to planetary carrier. Set a support ring

(KV40105310) and an adapter B (KV40105230) to main gear
bearing inner race, then press it.

SMT020D

14. Install washer to sun gear assembly, and select proper snap
ring so that end play “F” of sun gear is within specifications.
Standard end play “F”:
0 - 0.15 mm (0 - 0.0059 in)
Snap ring: Refer to SDS, TF-194.

SMT021D

TF-178
 ASSEMBLY ATX14A
Front Case (Cont’d)
15. Install the selected snap ring. GI
I Do not reuse snap rings.
16. Apply ATF to the periphery of new transfer cover oil seal, and
attach it at 1.5 mm (0.059 in) from the transfer cover and face. MA
I Do not reuse oil seal.
EM

LC
SMT022D

17. Apply Genuine Anaerobic Liquid Gasket or equivalent to trans- EC

fer cover mounting surface of front case as shown in the fig-
ure.
Refer to TF-157. FE
CAUTION:
I Remove all foreign materials such as water, oil, and CL
grease from mating surfaces of front case and transfer
cover.
I Prevent Liquid Gasket from entering into oil holes of front MT
case.

AT

PD

AX

SMT179E SU
18. Align oil hole of front case with notch of transfer cover, and
tighten bolts.
: 49 - 58 N·m (5.0 - 5.9 kg-m, 36 - 43 ft-lb) BR
I Do not reuse bolts.
ST

RS

SMT024D BT
19. Apply petroleum jelly to radial needle bearing, and install it
inside sun gear. HA
20. Install shift rod assembly to front case assembly. Refer to “Shift
Rod Assembly”, TF-180.
SC

EL

IDX
SMT995C

TF-179
 ASSEMBLY ATX14A
Front Case (Cont’d)
Shift Rod Assembly NATF0082S02
1. Install fork guide, shift fork spring, 2-4 fork, and L-H fork to shift
rod, and secure them with retaining pins.
I Do not reuse retaining pins.

SMT195E

2. Install 2-4 sleeve and L-H sleeve to each fork.

SMT992C

3. While aligning L-H sleeve with planetary carrier, install shift rod
assembly to front case.

SMT991C

4. Remove all the liquid gasket on check plug and front case, and
install check ball and check spring to front case. Apply Genu-
ine Silicone RTV or equivalent* to check plug, install it to front
case, and tighten it to specified torque.
*: Refer to TF-157.
: 19 - 25 N·m (1.9 - 2.5 kg-m, 14 - 18 ft-lb)
5. Remove all the liquid gasket on the switch fitting and inner side
of front case, and with wait detection switch threaded one pitch
into the hole, apply Genuine Silicone RTV or equivalent* to the
thread, install it, and tighten it to specified torque.
SMT990C
: 15 - 20 N·m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
I Wait detection switch harness connector is black.
6. Install center case assembly to front case assembly. Refer to
“Final Assembly”, TF-189.
7. Install rear case assembly to center case. Refer to “Final
Assembly”, TF-189.

TF-180
 ASSEMBLY ATX14A
Center Case

Center Case GI
ASSEMBLY NATF0083
Oil Filter NATF0083S01 MA
1. Apply ATF or petroleum jelly to new O-ring, and install it to oil
filter stud.
I Do not reuse O-rings. EM
2. Install oil filter stud to center case, and tighten it.
: 26 - 35 N·m (2.6 - 3.6 kg-m, 20 - 26 ft-lb)
LC
SMT951C

3. Apply ATF or petroleum jelly to two new O-rings, and install EC

them to oil filter.
I Do not reuse O-rings.
FE
4. Install oil filter to center case and tighten bolts.
: 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb)
I Do not knock oil filter with a tool such as a hammer. CL

MT
SMT939C
AT
Sub-oil Pump NATF0083S02
1. Install new oil pump gasket to center case by aligning it with
dowel pin inside the center case.
I Do not reuse gaskets.
PD

AX

SMT935C SU
2. Install outer gear* and inner gear to sub-oil pump housing, and
measure side clearance. Refer to “Sub-oil Pump”,
“INSPECTION”, TF-174. BR
3. Set new O-ring to sub-oil pump housing, and install sub-oil
pump cover.
ST
I Do not reuse O-rings.
* Identification mark “H” is placed on the side of sub-oil pump
cover. RS

SMT936C BT
4. Align dowel pin hole and mounting bolt hole of sub-oil pump
assembly with center case. Then tighten bolts. HA
: 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb)

SC

EL

IDX
SMT955C

TF-181
 ASSEMBLY ATX14A
Center Case (Cont’d)
5. Apply ATF or petroleum jelly to new O-ring and install it to
transfer motor.
6. Fit double-flat end of transfer motor shaft into slot of sub-oil
pump assembly. Then tighten bolts.
: 42 - 48 N·m (4.2 - 4.9 kg-m, 31 - 35 ft-lb)

SMT956C

Main Oil Pump NATF0083S03

1. Install inner gear and outer gear in the main oil pump housing
with their identification marks facing toward center case
mounting surface side. Then, measure the side clearance.
Refer to “Main Oil Pump”, “Center Case”, TF-174.

SMT957C

2. Install main oil pump assembly to center case assembly, and

tighten bolts.
: 7 - 9 N·m (0.7 - 0.9 kg-m, 61 - 78 in-lb)
3. Install oil pump shaft to main oil pump, then install rear case
assembly to center case.
Refer to “Final Assembly”, TF-189.

SMT930C

Control Valve NATF0083S04

1. Clean upper body, control valves and springs with cleaning
agent, and apply air blow.
2. Dip control valves in ATF, and apply ATF to the valve-mount-
ing area of upper body.
3. Install each control valve, spring, and plug to upper body, and
fix it with retainer plates.
CAUTION:
I To insert control valves into upper body, place upper body
on a level surface in order to prevent flaw or damage.
SMT928C I Make sure each control valve is smoothly inserted.
4. Install reverse balls, relief balls and relief springs, accumula-
tor pistons and valve springs to upper body.

SMT177E

TF-182
 ASSEMBLY ATX14A
Center Case (Cont’d)
5. Install lower body and separator plate to upper body. GI
I Do not reuse separator plates.

MA

EM

LC
SMT925C

6. With lower body down, tighten two bolts in the position shown EC
in the figure.
7. Apply ATF or petroleum jelly to new O-ring, and install it to
2-4WD shift solenoid valve, terminal body, line pressure switch FE
and 4WD solenoid valve. Install them to control valve assem-
bly.
CL
I Do not reuse O-rings.

MT
SMT962CA
AT
8. Apply ATF or petroleum jelly to lip seals, and install them to
center case.
I Do not reuse lip seals.
I There are 2 kinds of lip seals (lip seal of large inner diam-
eter: 5 pieces, lip seal of small inner diameter: 2 pieces).
Confirm the position before installation. PD

AX

SMT922CA SU
9. Install bolts as shown in the figure, and tighten them to speci-
fied torque.
BR
Bolt symbol a b *c d e f g

Length under
head
38 43.5 62 19 47 40 52 ST
(1.50) (1.713) (2.44) (0.75) (1.85) (1.57) (2.05)
mm (in)

Q’ty 16 3 2 1 2 1 1 RS
Tightening torque
6.9 - 8.8 (0.70 - 0.90, 61.1 - 77.9)
N·m (kg-m, in-lb)
SMT180E BT
*: Tighten with oil strainer.

HA

SC

EL

IDX

TF-183
 ASSEMBLY ATX14A
Center Case (Cont’d)
10. Install control valve assembly to center case, and tighten bolts.
: 6.9 - 8.8 N·m (0.70 - 0.90 kg-m, 61.1 - 77.9 in-lb)

SMT920C

11. Remove terminal from center case installation hole, and

secure terminal body with snap ring.

SMT921C

12. Apply ATF or petroleum jelly to O-rings, and install them to oil
strainer.
CAUTION:
Do not reuse O-rings.
13. Install oil strainer to control valve assembly.
14. Install mainshaft and clutch drum to center case. Refer to
“Mainshaft and Clutch Drum”, TF-185.
15. Install front case assembly and rear case assembly. Refer to
“Final Assembly”, TF-189.

SMT919C

Clutch Piston NATF0083S05

1. Apply ATF to D-ring and lip seal, and install them to clutch pis-
ton.
I Do not reuse lip seal and D-ring.

SMT917C

2. Set clutch piston to a clutch piston attachment (KV31103400).

SMT969C

TF-184
 ASSEMBLY ATX14A
Center Case (Cont’d)
3. Set the clutch piston attachment to center case, and install GI
clutch piston, tap it lightly.
4. Install slide needle bearing race to clutch piston.
MA

EM

LC
SMT970C

5. Remove all the liquid gasket from oil pressure check port and EC
inside center case. With oil pressure check plug threaded in 1
or 2 pitches, apply Genuine Silicone RTV or equivalent to the
thread of plug, and tighten. FE
Refer to TF-157.
: 10 - 17 N·m (1.0 - 1.7 kg-m, 87 - 148 in-lb)
CL
I Do not reuse oil pressure check plug.
6. Install mainshaft and clutch drum. Refer to “Mainshaft and
Clutch Drum”, TF-185. MT
SMT915C
AT
Mainshaft and Clutch Drum NATF0083S06
1. Install drive plates, driven plates and press flange to clutch
hub.
2. Place clutch hub on a surface plate and measure dimension
“A” between snap ring mounting surface of press flange and
clutch drum sliding face of clutch hub. PD
CAUTION:
Measure at least 2 points, and take an average. AX

SMT972C SU
3. Measure dimension “B” between the gear end of mainshaft
and the snap ring mounting portion.
4. Calculate end play using dimension “A” and dimension “B” BR
(obtained in steps 2 and 3), and select proper retaining plate
so that the end play is within specifications.
ST
Calculation formula:
End play = B − A − Retaining plate thickness
Standard end play: RS
0.2 - 0.5 mm (0.008 - 0.020 in)
Retaining plate:
SMT973C BT
Refer to SDS, TF-193.
5. Install clutch drum, needle bearing and clutch hub to
mainshaft, and secure them with snap ring. HA
I Do not reuse snap ring.

SC

EL

IDX
SMT974C

TF-185
 ASSEMBLY ATX14A
Center Case (Cont’d)
6. Install each clutch to clutch drum.

SMT220E

7. Align the notch of return spring assembly with the pin of clutch
hub, and install it.

SMT911C

8. Install press flange (with the holes indicated by arrows aligned

with pins of clutch hub).

SMT977C

9. Install washer.

SMT909C

10. Pass mainshaft through snap ring. Set a drift (KV31103300),

a support ring (KV40104710), a support ring (ST27863000)
and a drift (ST35271000) to press flange at the position shown
in the figure, and press snap ring until it fits into snap ring
groove on mainshaft.
I Do not reuse snap ring.

SMT907C

TF-186
 ASSEMBLY ATX14A
Center Case (Cont’d)
11. Fix snap ring to mainshaft. GI

MA

EM

LC
SMT908C

12. Install thrust needle bearing to press flange. EC

FE

CL

MT
SMT905C
AT
13. Apply petroleum jelly to new seal rings, and install them to
mainshaft. Measure clearance between seal ring and groove
using feeler gauge.
Standard clearance:
0.05 - 0.30 mm (0.0020 - 0.0118 in)
Limit clearance: PD
0.30 mm (0.0118 in)
I Pass seal ring from mainshaft rear end to install it. AX
Seal ring dimension:
Refer to SDS, TF-194.
SMT982C SU
14. Install mainshaft rear bearing to center case.
BR

ST

RS

SMT983C BT
15. Place puller (ST30911000) to mainshaft rear bearing inner
race, and set it to press stand. HA
16. Place adapter (ST33061000) to the tip of mainshaft, and press
mainshaft into center case.
SC

EL

IDX
SMT984C

TF-187
 ASSEMBLY ATX14A
Center Case (Cont’d)
17. Install baffle plate to center case, and tighten bolts.
: 3.7 - 5.0 N·m (0.38 - 0.51 kg-m, 33.0 - 44.3 in-lb)
18. Install front drive shaft and drive chain. Refer to “Front Drive
Shaft and Drive Chain” below.
19. Install front case assembly and rear case assembly.
Refer to “Final Assembly”, TF-189.

SMT903CA

Front Drive Shaft and Drive Chain NATF0083S07

1. Place a base (ST30032000) to front drive shaft rear bearing
inner race, and press it using a drift (KV40100621).

SMT986C

2. Place base (ST30032000) to front drive shaft front bearing

inner race, and press it using the drift (KV40100621).

SMT987C

3. Install drive chain temporarily to front drive shaft and drive gear
of clutch drum.
4. Tap front drive shaft with a plastic hammer while keeping it
upright and press-fit front drive shaft rear bearing.
I Be careful not to tap drive chain with a hammer.

SMT988C

5. Align claw of oil gutter with center case, and install it.
6. Install front case assembly and rear case assembly.
Refer to “Final Assembly”, TF-189.

SMT989C

TF-188
 ASSEMBLY ATX14A
Final Assembly

Final Assembly NATF0084

GI
1. Install C-rings to mainshaft rear bearing.
MA

EM

LC
SMT891C

2. Check speedometer drive gear teeth for abnormal wear. Set EC

speedometer drive gear properly on mainshaft, and secure it
with snap ring.
I Do not reuse snap ring. FE

CL

MT
SMT889C
AT
3. Apply Genuine Anaerobic Liquid Gasket or equivalent to the
entire center case mounting surface of front case as shown in
the figure.
Refer to TF-157.
CAUTION:
Remove all foreign materials such as water, oil and grease PD
from center case and front case mating surfaces.

AX

SU

BR

ST

RS

SMT181E
BT
4. Make sure the two claws of oil gutter are securely attached to
slots in center case. HA

SC

EL

IDX
SMT894C

TF-189
 ASSEMBLY ATX14A
Final Assembly (Cont’d)
5. With the claws of oil gutter held by a finger, install center case
assembly to front case assembly.
CAUTION:
Pay careful attention so that mainshaft end does not damage
radial needle bearing in sun gear assembly.
6. Tap center case lightly with a rubber hammer or the like and
press-fit front drive shaft bearing into front case.

SMT895C

7. Make sure oil gutter rear end protrudes from point “A” in the
figure.
8. Tighten bolts to specified torque.
: 42 - 48 N·m (4.2 - 4.9 kg-m, 31 - 35 ft-lb)
I Be sure to install air breather hose clamp, connector
bracket and harness clip.

SMT896C

9. Fit double-flat end of oil pump shaft into slot of main oil pump
and install it.
NOTE:
When oil pump shaft is rotated slightly, it drops into position where
both parts fit.

SMT883C

10. Install stem bleeder to center case.

SMT884C

11. Remove rear oil seal.

I Do not reuse oil seal.

SMT881C

TF-190
 ASSEMBLY ATX14A
Final Assembly (Cont’d)
12. Apply ATF to the circumference of new rear oil seal, and tap it GI
using a drift as shown in the figure so that it is aligned with
case tip face.
I Apply multi-purpose grease to oil seal lip. MA

EM

LC
SMT882C

13. Apply Genuine Anaerobic Liquid Gasket or equivalent to entire EC

rear case mounting surface of center case as shown in the
figure.
Refer to TF-157. FE
CAUTION:
I Remove all foreign materials such as water, oil, and CL
grease from center case and rear case mating surfaces.
I Be careful not to allow Liquid Gasket to clog bleeder hole.
14. Install rear case to center case, and tighten bolts to specified MT
torque.
: 42 - 48 N·m (4.2 - 4.9 kg-m, 31 - 35 ft-lb)
I Be sure to attach harness clips. AT

PD

AX

SMT182E SU
15. Remove all the gasket fluid from switch mounting area and
inside rear case, with ATP switch and neutral-4LO switch
threaded in 1 to 2 pitches, apply Genuine Silicone RTV or BR
equivalent to the thread of the switches and tighten it to speci-
fied torque.
: 15 - 20 N·m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
ST
16. Install rear case assembly to center case assembly.
RS

SMT880C BT
17. Install companion flange to front drive shaft, and tighten lock
nut. HA
: 226 - 324 N·m (23.0 - 33.0 kg-m, 166 - 239 ft-lb)
I Do not reuse lock nut.
SC

EL

IDX
SMT845DB

TF-191
 SERVICE DATA AND SPECIFICATIONS (SDS) ATX14A
General Specifications

General Specifications NATF0085

Transfer model ATX14A

High 1.000
Gear ratio
Low 2.596

Sun gear 57
Planetary gear
Internal gear 91
Number of teeth
Front drive sprocket 35

Front drive shaft 35

Fluid capacity  (US qt, Imp qt)* 3.0 (3-1/8, 2-5/8)

*: Refer to MA-12, “Fluids and Lubricants”.

Inner Gear and Outer Gear NATF0086

SUB-OIL PUMP NATF0086S01

Allowable clearance 0.015 - 0.035 mm (0.0006 - 0.0014 in)

Part No.*
Gear thickness mm (in)
Inner gear Outer gear

9.27 - 9.28 (0.3650 - 0.3654) 31346 0W462 31347 0W462

9.28 - 9.29 (0.3654 - 0.3657) 31346 0W461 31347 0W461

9.29 - 9.30 (0.3657 - 0.3661) 31346 0W460 31347 0W460

*: Always check with the Parts Department for the latest parts information.

MAIN OIL PUMP NATF0086S02

Allowable clearance 0.015 - 0.035 mm (0.0006 - 0.0014 in)

Part No.*
Gear thickness mm (in)
Inner gear Outer gear

14.67 - 14.68 (0.5776 - 0.5780) 31346 0W412 31347 0W412

14.68 - 14.69 (0.5780 - 0.5783) 31346 0W411 31347 0W411

14.69 - 14.70 (0.5783 - 0.5787) 31346 0W410 31347 0W410

*: Always check with the Parts Department for the latest parts information.

Control Valve NATF0087

VALVE NATF0087S01

Mounting position Part name Part No.* Outer dia. mm (in) Overall length mm (in)

L1 2-4 shift valve 31772 21X00 8.0 (0.315) 38.5 (1.516)

L2 Clutch valve 31772 80X11 10.0 (0.394) 40.0 (1.575)

L4 Pilot valve 31772 80X11 10.0 (0.394) 40.0 (1.575)

L5 Regulator valve 31741 0W410 12.0 (0.472) 68.0 (2.677)

*: Always check with the Parts Department for the latest parts information.

SPRING NATF0087S02

Free length Outer dia.

Mounting position Part name Part No.* Wire dia. mm (in) Winding direction
mm (in) mm (in)

2-4 shift valve

L1 31742 2W500 31.85 (1.2539) 7.0 (0.276) 0.6 (0.024) Clockwise
spring

TF-192
 SERVICE DATA AND SPECIFICATIONS (SDS) ATX14A
Control Valve (Cont’d)

Free length Outer dia. GI

Mounting position Part name Part No.* Wire dia. mm (in) Winding direction
mm (in) mm (in)

L2 Clutch valve spring 31742 2W505 40.6 (1.598) 8.8 (0.346) 0.7 (0.028) Clockwise
MA
L4 Pilot valve spring 31742 0W410 28.1 (1.106) 9.0 (0.354) 1.2 (0.047) Clockwise

Regulator valve
L5
spring
31742 2W515 39.7 (1.563) 11.0 (0.433) 1.3 (0.051) Clockwise EM
*: Always check with the Parts Department for the latest parts information.
LC
Clutch NATF0088
DRIVE PLATE NATF0088S01
EC
Part No.* Quantity Initial thickness mm (in) Limit value mm (in)

31532 0W410 8 2.0 (0.079) 1.8 (0.071)

FE
*: Always check with the Parts Department for the latest parts information.

DRIVEN PLATE NATF0088S04 CL

Part No.* Quantity Initial thickness mm (in) Limit value mm (in)

31536 0W410 7 2.0 (0.079) 0 (0) (steel plate) MT

*: Always check with the Parts Department for the latest parts information.

RETURN SPRING NATF0088S02

AT
Stamped mark Part No.* Free length mm (in) Outer dia. mm (in) Wire dia. mm (in) Winding direction

1 31521 2W511 38.4 (1.512)

2 31521 2W512 39.0 (1.535)

3 31521 2W513 39.6 (1.559) PD

4 31521 2W514 40.2 (1.583)
12.0 (0.472) 1.8 (0.071) Clockwise
5 31521 2W515 40.8 (1.606) AX
6 31521 2W516 41.5 (1.634)

7 31521 2W517 37.8 (1.488)

SU
8 31521 2W518 42.1 (1.657)

*: Always check with the Parts Department for the latest parts information.
BR
RETAINING PLATE NATF0088S03
ST
Standard end play 0.2 - 0.5 mm (0.008 - 0.020 in)

Measured value mm (in) Part No.* Thickness mm (in)

RS
2.30 - 2.50 (0.0906 - 0.0984) 31537 0W410 2.1 (0.083)

2.50 - 2.70 (0.0984 - 0.1063) 31537 0W411 2.3 (0.091)

BT
2.70 - 2.90 (0.1063 - 0.1142) 31537 0W412 2.5 (0.098)

2.90 - 3.10 (0.1142 - 0.1220) 31537 0W413 2.7 (0.106)

HA
3.10 - 3.30 (0.1220 - 0.1299) 31537 0W414 2.9 (0.114)

3.30 - 3.50 (0.1299 - 0.1378) 31537 0W415 3.1 (0.122)

SC
3.50 - 3.70 (0.1378 - 0.1457) 31537 0W416 3.3 (0.130)

3.70 - 3.90 (0.1457 - 0.1535) 31537 0W417 3.5 (0.138)

EL
3.90 - 4.10 (0.1535 - 0.1614) 31537 0W418 3.7 (0.146)

4.10 - 4.30 (0.1614 - 0.1693) 31537 0W419 3.9 (0.154)

IDX

TF-193
 SERVICE DATA AND SPECIFICATIONS (SDS) ATX14A
Clutch (Cont’d)

Standard end play 0.2 - 0.5 mm (0.008 - 0.020 in)

Measured value mm (in) Part No.* Thickness mm (in)

4.30 - 4.50 (0.1693 - 0.1772) 31537 0W420 4.1 (0.161)

4.50 - 4.70 (0.1772 - 0.1850) 31537 0W421 4.3 (0.169)

4.70 - 4.90 (0.1850 - 0.1929) 31537 0W422 4.5 (0.177)

4.90 - 5.10 (0.1929 - 0.2008) 31537 0W423 4.7 (0.185)

*: Always check with the Parts Department for the latest parts information.

Seal Ring (Mainshaft side) NATF0089

Standard clearance 0.05 - 0.30 mm (0.0020 - 0.0118 in)

Limit clearance 0.30 mm (0.0118 in)

Part No.* Outer dia. mm (in) Inner dia. mm (in) Thickness mm (in)

31525 0W410 40.8 (1.606) 36.9 (1.453) 1.97 (0.0776)

*: Always check with the Parts Department for the latest parts information.

Bearing Race (Thrust needle bearing side) NATF0090

Standard end play 0.1 - 0.25 mm (0.0039 - 0.0098 in)

End play (Dimension “E”) mm (in) Part No.* Thickness mm (in)

1.785 - 1.800 (0.0703 - 0.0709) 31439 0W410 1.6 (0.063)

1.800 - 1.900 (0.0709 - 0.0748) 31439 0W411 1.7 (0.067)

1.900 - 2.000 (0.0748 - 0.0787) 31439 0W412 1.8 (0.071)

2.000 - 2.100 (0.0787 - 0.0827) 31439 0W413 1.9 (0.075)

2.100 - 2.200 (0.0827 - 0.0866) 31439 0W414 2.0 (0.079)

2.200 - 2.270 (0.0866 - 0.0894) 31439 0W415 2.1 (0.083)

*: Always check with the Parts Department for the latest parts information.

Snap Ring (Sun gear side) NATF0091

Standard end play 0 - 0.15 mm (0 - 0.0059 in)

End play (Dimension “F”) mm (in) Part No.* Thickness mm (in)

2.40 - 2.50 (0.0945 - 0.0984) 33112 0W411 2.4 (0.094)

2.50 - 2.60 (0.0984 - 0.1024) 33112 0W412 2.5 (0.098)

2.60 - 2.70 (0.1024 - 0.1063) 33112 0W413 2.6 (0.102)

*: Always check with the Parts Department for the latest parts information.

TF-194