TRANSFER SECTION TF CONTENTS DRIVELINE/AXLE TF-1 SERVICE INFORMATION... 2 DTC INDEX... 2 P1801-P P1820-P1855, U

Transcription

1 DRV/X ST T TRSR T TTS SRV RT... 2 DT DX , U RUTS... 3 recaution for Supplemental Restraint System (SRS) "R " and "ST T R-T- SR"...3 recaution for Transfer ssembly and Transfer ontrol Unit Replacement...3 recaution...5 Service otice...5 RRT... 7 Special Service Tool...7 ommercial Service Tool...9 4WD SYST...10 ross-section View...10 ower Transfer...10 System Description...12 Schematic...14 TRU DSS...16 ocation of lectrical arts...16 ircuit Diagram...17 Wiring Diagram - T/ Transfer ontrol Unit nput/utput Signal Reference Value...32 SUT- unction ( D WD/4WD)...38 Self-Diagnosis rocedure...41 Trouble Diagnosis hart by Symptom...44 omponent nspection...44 TRSR TR UT...48 Removal and nstallation...48 RT S...49 Removal and nstallation...49 RR S...51 Removal and nstallation...51 TRSR TR DV...53 Removal and nstallation...53 R RTR S...55 Removal and nstallation...55 TRSR SSY...56 Removal and nstallation...56 Disassembly and ssembly...56 TRY RRR...67 Disassembly and ssembly...67 ST TR...68 Disassembly and ssembly...68 SRV DT D STS (SDS)...69 eneral Specification...69 nspection and djustment...69 T-1

2 SRV RT DT DX DT DX D: DT , U1000 *T STRT* 1802 TR UT TR UT TR UT V SD S T 1808 V SD S S 1809 TR UT S SW T 1811 TTRY VT WD D SW WD DTT SWT 1816 SW/R 1817 ST TUTR 1818 ST T S SW 1819 ST T R tems (SUT- screen terms) Reference T-38, "SUT- unction ( D WD/4WD)" D: DT U1000 tems (SUT- screen terms) SD S V SD S R V SD S RR RUT Reference T-38, "SUT- unction ( D WD/4WD)" T-2

3 RUTS RUTS recaution for Supplemental Restraint System (SRS) "R " and "ST T R-TSR" D: The Supplemental Restraint System such as R and ST T R-TSR, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. nformation necessary to service the system safely is included in the SRS and S section of this Service anual. WR: To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized SS/T dealer. mproper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. or removal of Spiral able and ir ag odule, see the SRS section. Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service anual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. recaution for Transfer ssembly and Transfer ontrol Unit Replacement D: When replacing transfer assembly or transfer control unit, check the 4WD shift indicator pattern and adjustment of the position between transfer assembly and transfer control unit if necessary. 4WD ST DTR TTR 1. Set 4WD shift switch to 2WD, 4, 4, 4 and 2WD in order. Stay at each switch position for at least 2 seconds. 2. onfirm 4WD shift indicator lamp and 4 indicator lamp are changed properly as follows. T f, the position between transfer assembly and transfer control unit is correct. f, the position is different between transfer assembly and transfer control unit. djust the position between transfer assembly and transfer control unit. Refer to pattern table below. Transfer position adjustment pattern 4WD shift switch condition 4WD shift switch is under 2WD condition when engine is being stopped. 4WD shift switch is under 4 or 4 condition when engine is being stopped. T: ethod of adjustment can be chosen voluntarily, according to location of 4WD shift switch. TD R DUSTT WT 4WD ST SWT T 2WD Select djustment attern T-3 Refer procedure SD3289 "TD R DUSTT WT 4WD ST SWT T 2WD " "TD R DUSTT WT 4WD ST SWT T 4 R 4 "

4 RUTS 1. Start engine. Run engine for at least 10 seconds. 2. heck 4WD shift indicator lamp and 4 indicator lamp. ndicator lamp condition Refer procedure When 4WD shift indicator lamp or 4 indicator lamp is flashing. "attern " xcept for above. "attern " attern 1. Stay in the below for at least 2 seconds. or /T models, stop the vehicle and move /T selector lever to position with the brake pedal depressed. or /T models, stop the vehicle and move /T shift lever to the neutral position with the brake and clutch pedal depressed. 2. Turn 4WD shift switch to 4 position. Stay in "4" for at least 2 seconds. 3. Turn ignition switch. 4. Start engine. 5. rase self-diagnosis. Refer to T-38, "SUT- unction ( D WD/4WD)" (with SUT- ) or T-41, "Self-Diagnosis rocedure" (without SUT-). 6. heck 4WD shift indicator lamp and 4 indicator lamp again. Refer to " 4WD ST DTR TTR". f 4WD shift indicator lamp and 4 indicator lamp do not indicate proper pattern, install new transfer control unit and retry the above check. attern 1. Stay in the below for at least 2 seconds. or /T models, stop the vehicle and move /T selector lever to position with the brake pedal depressed. or /T models, stop the vehicle and move /T shift lever to the neutral position with the brake and clutch pedal depressed. 2. Turn ignition switch. 3. Start engine. 4. rase self-diagnosis. Refer to T-38, "SUT- unction ( D WD/4WD)" (with SUT- ) or T-41, "Self-Diagnosis rocedure" (without SUT-). 5. heck 4WD shift indicator lamp and 4 indicator lamp again. Refer to " 4WD ST DTR TTR". f 4WD shift indicator lamp and 4 indicator lamp do not indicate proper pattern, install new transfer control unit and retry the above check. TD R DUSTT WT 4WD ST SWT T 4 R 4 1. Start engine. Run the engine for at least 10 seconds. 2. Stay in the below for at least 2 seconds. or /T models, stop the vehicle and move /T selector lever to position with the brake pedal depressed. or /T models, stop the vehicle and move /T shift lever to the neutral position with the brake and clutch pedal depressed. 3. Turn 4WD shift switch to 2WD position. Stay in "2WD" for at least 2 seconds. 4. Turn ignition switch. 5. Start engine. 6. rase self-diagnosis. Refer to T-38, "SUT- unction ( D WD/4WD)" (with SUT- ) or T-41, "Self-Diagnosis rocedure" (without SUT-). 7. heck 4WD shift indicator lamp and 4 indicator lamp again. Refer to " 4WD ST DTR TTR". f 4WD shift indicator lamp and 4 indicator lamp do not indicate proper pattern, install new transfer control unit and retry the above check. T-4

5 recaution RUTS efore connecting or disconnecting the transfer control unit harness connector, turn ignition switch and disconnect battery ground cable. ecause battery voltage is applied to transfer control unit even if ignition switch is turned. D: S289 T When connecting or disconnecting pin connectors into or from transfer control unit, take care not to damage pin terminals (bend or break). When connecting pin connectors make sure that there are not any bends or breaks on transfer control unit pin terminals. S291 efore replacing transfer control unit, perform transfer control unit input/output signal inspection and make sure whether transfer control unit functions properly or not. Refer to T-32, "Transfer ontrol Unit nput/utput Signal Reference Value". Service otice 040D D: fter overhaul refill the transfer with new transfer fluid. heck the fluid level or replace the fluid only with the vehicle parked on level ground. During removal or installation, keep inside of transfer clear of dust or dirt. Disassembly should be done in a clean work area. efore proceeding with disassembly, thoroughly clean the transfer. t is important to prevent the internal parts from becoming contaminated by dirt or other foreign matter. heck for the correct installation status prior to removal or disassembly. f match marks are required, be certain they do not interfere with the function of the parts when applied. ll parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly. heck appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them with a new ones if necessary. askets, seals and -rings should replaced any time the transfer is disassembled. n principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. f tightening sequence is specified, use it. bserve the specified torque when assembling. lean and flush the parts sufficiently and blow-dry them. e careful not to damage sliding surfaces and mating surfaces. T-5

6 RUTS Use lint-free cloth or towels for wiping parts clean. ommon shop rags can leave fibers that could interfere with the operation of the transfer. T-6

7 RRT Special Service Tool RRT D: Tool number Tool name Description V lange wrench a: 85 mm (3.35 in) b: 65 mm (2.56 in) Removing self-lock nut nstalling self-lock nut T V381054S0 uller T659 Removing front oil seal Removing rear oil seal Removing metal bushing ZZ0601D V Drift a: 80 mm (3.15 in) dia. b: 60 mm (2.36 in) dia. nstalling front oil seal nstalling rear oil seal nstalling rear bearing nstalling front bearing V Drift a: 89 mm (3.50 in) dia. b: 80.7 mm (3.17 in) dia. ZZ0811D nstalling dust cover ZZ1003D V Drift a: 65 mm (2.56 in) dia. b: 49 mm (1.93 in) dia. Removing sun gear assembly and planetary carrier assembly Removing input bearing nstalling sun gear assembly and planetary carrier assembly ZZ1143D ST Drift a: 77 mm (3.03 in) dia. b: 55 mm (2.17 in) dia. nstalling input bearing nstalling input oil seal nstalling carrier bearing ZZ0811D T-7

8 RRT Tool number Tool name V Drift a: 48 mm (1.89 in) dia. b: 41 mm (1.61 in) dia. Description nstalling mainshaft rear bearing ZZ0534D V Drift a: 70 mm (2.76 in) dia. b: 63.5 mm (2.50 in) dia. nstalling input oil seal ZZ1003D ST Drift a: 59 mm (2.32 in) dia. b: 45 mm (1.77 in) dia. Removing carrier bearing nstalling metal bushing Removing front bearing T073 ST uller Removing carrier bearing Removing front bearing Removing rear bearing ZZ0537D ST Drift a: 89 mm (3.5 in) b: 30 mm (1.18 in) dia. c: 24 mm (0.94 in) dia. Removing needle bearing Removing metal bushing Removing rear bearing ZZ1057D ST Drift bar a: 215 mm (8.46 in) b: 25 mm (0.98 in) dia. c: Removing metal bushing T663 ST Drift a: 37 mm (1.46 in) dia. b: 31 mm (1.22 in) dia. c: 22 mm (0.87 in) dia. nstalling needle bearing ZZ1046D T-8

9 RRT Tool number Tool name ST Drift a: 75 mm (2.95 in) dia. b: 62 mm (2.44 in) dia. Description nstalling carrier bearing ZZ1003D ST Drift a: 79 mm (3.11 in) dia. b: 45 mm (1.77 in) dia. c: 35.2 mm (1.38 in) dia. nstalling rear bearing nstalling front bearing T ommercial Service Tool ZZ0978D D: Tool name Description uller Removing companion flange Removing mainshaft rear bearing uller T077 Removing mainshaft rear bearing ZZ0823D in punch a: 6 mm (0.24 in) dia. Removing retaining pin T410 T-9

10 4WD SYST ross-section View 4WD SYST D: SD ainshaft 2. Rear case 3. il pump assembly 4. lutch gear shift fork sleeve 7. Drive chain 8. Sprocket 9. - shift fork sleeve 11. nternal gear 12. ront case 13. lanetary carrier assembly 14. Sun gear assembly shift rod 16. ontrol shift rod 17. ront revolution sensor 18. ompanion flange (/T models) (xcept for S models) 19. ront drive shaft 20. ontrol shift rod assembly 21. Transfer control device (/T models) 22. Speedometer drive gear (xcept for S models) ower Transfer WR TRSR DR D: T-10

11 4WD SYST T WD ainshaft 2. lutch gear sleeve 4. Drive chain 5. Sprocket 6. - sleeve 7. lanetary carrier assembly 8. Sun gear assembly 9. ront drive shaft WR TRSR W SD2213 T-11

12 System Description 4WD SYST D: TRSR TR DV ctuator motor and actuator position switch are integrated. Transfer control device shifts from 4 4 and between 2WD 4WD. ctuator otor ctuator motor is operated by signal from transfer control unit and it operates control shift rod so as to shift from 4 4 and between 2WD 4WD. ctuator osition Switch ctuator position switch detects actuator motor position and sends it to transfer control unit. WT DTT SWT Wait detection switch detects if transfer gear is in 4WD by 2-4 shift fork position. T: f 4WD shift switch is switched to 4 or 4, transfer is not in 4WD completely when gear does not engage. (Wait detection system is operating.) 4 SWT 4 switch detects if transfer gear is under 4 condition by - shift fork position. T SWT T switch detects if transfer gear is under neutral condition by - shift fork position. T: Transfer gear may be under neutral condition when shifting between 4 4. TRSR TR UT Transfer control unit controls transfer control device by input signals of each sensor and each switch, and it directs shifts from 4 4 and 2WD 4WD. Self-diagnosis can be done. TRSR ST RY Transfer shift high relay and transfer shift low relay apply power supply to transfer control device (actuator motor). TRSR SUT RY Transfer shut off relay 1 and transfer shut off relay 2 apply power supply to transfer control unit. RT RVUT SSR (XT R S DS) ront revolution sensor detects a number of output revolution on the front side of transfer. 4WD ST SWT D DTR T-12

13 4WD SYST T 4WD Shift Switch 4WD shift switch is able to select from 2WD, 4 or 4. 4WD Shift ndicator amp Displays driving conditions selected by 4WD shift switch with front, rear and center indicators, while engine is running. (When shifting from 4 to 4, 4 indicator lamp also turns on. nd when 4WD warning lamp is turned on, all 4WD shift indicator lamps are turned off.) Turns when ignition switch is turned, for purpose of lamp check. Turns approximately 1 second after the engine starts if system is normal. 4 ndicator amp Displays 4 condition while engine is running. 4 indicator lamp flashes if transfer gear does not shift completely under 4 4. n this condition, transfer may be under neutral condition and /T parking mechanism may not operate. Turns when ignition switch is turned, for purpose of lamp check. Turns approximately 1 second after the engine starts if system is normal. 4WD WR Turns or flashes when there is a malfunction in 4WD system. lso turns when ignition switch is turned, for purpose of lamp check. Turns approximately 1 second after the engine starts if system is normal. 4WD Warning amp ndication SD3290 amp check T: ondition 4WD system malfunction During self-diagnosis arge difference in diameter of front/ rear tires ther than above (system normal) T-13 4WD warning lamp Turns when ignition switch is turned. Turns after engine start. (or indicated malfunction items, see the T ) lashes at malfunction mode. Slow flashing: 1 time/2 seconds (ontinues to flash until ignition switch is turned )

14 4WD SYST 4WD warning lamp is turned on when the following one or more parts are malfunctioning. Vehicle speed signal [S models: from S actuator and electric unit (control unit), except for S models: from combination meter] communication line D converter ngine speed signal 4WD shift switch Wait detection switch ctuator motor Transfer control device Transfer shut off relay Transfer shift relay switch signal T WR (/T DS) When /T selector lever is in position, vehicle may move because /T parking mechanism does not operate when transfer is under neutral condition. T warning lamp is turned on to indicate this condition to the driver. Schematic D: SD3291 TS UT omponent parts Transfer control unit Transfer control device ctuator motor ctuator position switch Wait detection switch 4 switch unction ontrols transfer control device and switches 4 4 under 4WD condition and 2WD 4WD. ctuator motor and actuator position switch are integrated so as to switch driving modes. ontrols shift rod by signals from transfer control unit. Detects actuator motor position. Detects that transfer is under 4WD condition. Detects that transfer is under 4 condition. T-14

15 4WD SYST T switch (/T models) 4WD shift switch 4WD warning lamp T warning lamp (/T models) 4WD shift indicator lamp 4 indicator lamp switch (/T models) S actuator and electric unit (control unit) T (/T models) omponent parts ombination meter (xcept for S models) Detects that transfer is under neutral condition. unction ble to select from 2WD, 4 or 4. lluminates if malfunction is detected in electrical system of 4WD system. There is 1 blink in 2 seconds if rotation difference of front wheels and rear wheels is large. ndicates that /T parking mechanism does not operate when /T selector lever is in position and transfer is under neutral condition. Displays driving condition selected by 4WD shift switch. Displays 4 condition. Detects that manual transmission is under neutral condition. Transmits the following signals via communication to Transfer control unit. Vehicle speed signal Stop lamp switch signal (brake signal) Transmits the following signal via communication to Transfer control unit. utput shaft revolution signal /T position indicator signal ( switch signal) Transmits engine speed signal via communication to Transfer control unit. ngine speed signal Transmits the following signals via communication to Transfer control unit. Vehicle speed signal T T-15

16 TRU DSS ocation of lectrical arts /T DS TRU DSS D: /T DS SD3587 T-16

17 TRU DSS T ircuit Diagram /T DS SD3588 D: T-17

18 TRU DSS /T DS TDW0099 T-18

19 TRU DSS T Wiring Diagram - T/ - /T DS TDW0100 D: T-19

20 TRU DSS TDW0101 T-20

21 TRU DSS T TDW0102 T-21

22 TRU DSS TDW0103 T-22

23 TRU DSS T TDW0104 T-23

24 TRU DSS TDW0105 T-24

25 TRU DSS T /T DS TDW0106 T-25

26 TRU DSS TDW0108 T-26

27 TRU DSS T TDW0109 T-27

28 TRU DSS TDW0110 T-28

29 TRU DSS T TDW0111 T-29

30 TRU DSS TDW0112 T-30

31 TRU DSS T TDW0113 T-31

32 TRU DSS Transfer ontrol Unit nput/utput Signal Reference Value TDW0114 D: TRSR TR UT ST T Specifications with SUT- T-32

33 TRU DSS onitored item [Unit] ontent ondition Display value V/S S R [km/h] or [mph] V/S S RR [km/h] or [mph] SD [rpm] TTRY VT [V] 2WD SWT [/] 4 SWT [/] 4 SWT [/] 4 S SW [/] T SWT [/] WT DTT SW [/ ] 4WD D [2/4/4] Wheel speed (ront wheel) Wheel speed (Rear wheel) ngine speed ower supply voltage for transfer control unit nput condition from 4WD shift switch nput condition from 4WD shift switch nput condition from 4WD shift switch ondition of 4 switch ondition of T switch ondition of wait detection switch ontrol status of 4WD (utput condition of 4WD shift indicator lamp and 4 indicator lamp) Vehicle stopped Vehicle running heck air pressure of tire under standard condition. Vehicle stopped Vehicle running heck air pressure of tire under standard condition. ngine stopped (ngine speed: ess than 400 rpm) ngine running (ngine speed: 400 rpm or more) gnition switch: 4WD shift switch: 2WD 4WD shift switch: 4 and 4 4WD shift switch: 4 4WD shift switch: 2WD and 4 4WD shift switch: 4 4WD shift switch: 2WD and 4 Vehicle stopped 4WD shift switch: 4 ngine running or /T models, /T selector lever position with brake pedal depressed. xcept the above or /T models, /T shift lever neutral position with clutch and brake pedal depressed. Vehicle stopped ngine running /T selector lever position with brake pedal depressed. Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. 4WD shift switch (ngine running) 4WD shift switch: 4 to 4 or 4 to 4 (While actuator motor is operating.) xcept the above 4WD shift switch: 4 and 4 4WD shift switch: 2WD 2WD km/h (0 mph) pproximately equal to the indication on speedometer (nside of ±10%) 0 km/h (0 mph) pproximately equal to the indication on speedometer (nside of ±10%) 0 rpm pproximately equal to the indication on tachometer attery voltage n ff n ff n ff n ff n ff n ff T T-33

34 TRU DSS onitored item [Unit] ontent ondition Display value V/S [km/h] or [mph] ST T 1 [/] ST 1 [/ ] ST T 2 [/] ST 2 [/ ] ST T/R [/ ] Vehicle speed utput condition to actuator motor (clockwise) heck signal for transfer control unit signal output utput condition to actuator motor (counterclockwise) heck signal for transfer control unit signal output perating condition of actuator motor relay (integrated in transfer control unit) Vehicle stopped Vehicle running heck air pressure of tires under standard condition. Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. 4WD shift switch: 2WD to 4 or 4 to 4 or 2WD to 4 xcept the above 4WD shift switch: 2WD to 4 or 4 to 4 or 2WD to 4 xcept the above 4WD shift switch: 4 to 4 or 4 to 2WD or 4 to 2WD xcept the above 4WD shift switch: 4 to 4 or 4 to 2WD or 4 to 2WD xcept the above When 4WD shift switch is operated When 4WD shift switch is not operated 0 km/h (0 mph) pproximately equal to the indication on speedometer (nside of ±10%) n ff n ff n ff n ff n ff T-34

35 TRU DSS onitored item [Unit] ontent ondition Display value ST S SW1 [/ ] ST S SW2 [/ ] ST S SW3 [/ ] ST S SW4 [/ ] 4WD [/ ] 2WD D [/] 4 D [/] 4 D [/] ondition of actuator position switch 1 ondition of actuator position switch 2 ondition of actuator position switch 3 ondition of actuator position switch 4 4WD warning lamp condition Rear indicator of 4WD shift indicator lamp condition ront and center indicator of 4WD shift indicator lamp condition 4 indicator lamp condition Specifications etween Transfer ontrol Unit Terminals Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. 4WD warning lamp: 4WD warning lamp: 4WD shift switch: 2WD and 4 4WD shift switch: 4 4WD shift switch: 4 4WD shift switch: 2WD and 4 4WD shift switch: 2WD and 4 4WD shift switch: 4 4WD shift switch: 4 and 4 4WD shift switch: 2WD Rear indicator of 4WD shift indicator lamp: Rear indicator of 4WD shift indicator lamp: ront and center indicator of 4WD shift indicator lamp: ront and center indicator of 4WD shift indicator lamp: 4 indicator lamp: 4 indicator lamp: TRSR TR UT TR TR YUT n ff n ff n ff n ff n ff n ff n ff n ff T T: Data are reference value and are measured between each terminal and ground. SD3402 Terminal Wire color tem ondition Data (pprox.) S - (SUT- signal) 5 (xcept for S models) W ront revolution sensor (+) 4WD shift switch: 4 T-35 Vehicle running pprox. 1V [30 km/h (19 )] Voltage rises in response to vehicle speed. 6 round lways 0V 7 (xcept for S models) ront revolution sensor (-) gnition switch: ess than 1V

36 TRU DSS Terminal Wire color 10 R ctuator position switch 1 11 W ctuator position switch 2 12 Y ctuator position switch 3 13 ctuator position switch WD shift switch (2WD) 15 4WD shift switch (4) 16 S 4WD shift switch (4) 17 V Wait detection switch Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. gnition switch: Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. 4WD shift switch: 2WD and 4 4WD shift switch: 4 4WD shift switch: 4 4WD shift switch: 2WD and 4 4WD shift switch: 2WD and 4 4WD shift switch: 4 4WD shift switch: 4 and 4 4WD shift switch: 2WD 4WD shift switch: 2WD 4WD shift switch: 4 and 4 4WD shift switch: 4 4WD shift switch: 2WD and 4 4WD shift switch: 4 4WD shift switch: 2WD and 4 4WD shift switch: 4 and 4 4WD shift switch: 2WD 18 round lways 0V 19 ower supply (emory back-up) 23 R T switch tem ondition Data (pprox.) gnition switch: gnition switch: Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. 4WD shift switch: 4 to 4 or 4 to 4 (While actuator motor is operating.) xcept the above 0V attery voltage 0V attery voltage 0V attery voltage 0V attery voltage attery voltage 0V attery voltage 0V attery voltage 0V 0V attery voltage attery voltage 0V attery voltage T-36

37 TRU DSS Terminal 24 R 4 switch 25 gnition switch monitor 27 ctuator motor power supply 28 S ctuator motor (+) Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. T-37 4WD shift switch: 4 xcept the above gnition switch: gnition switch: gnition switch: gnition switch: (5 seconds after ignition switch is turned ) Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. When 4WD shift switch is operated (while actuator motor is operating) When 4WD shift switch is not operated 31 W ctuator motor (-) lways 0V 0V attery voltage attery voltage 0V attery voltage 0V attery voltage 0V 32 round lways 0V 33 /T shift lever neutral position 0V (or /T ark/neutral position switch gnition switch: models) xcept the above attery voltage 35 V 36 R 4WD shift indicator lamp (Rear indicator) 4WD shift indicator lamp (ront and center indicator) 37 4 indicator lamp 38 R 4WD warning lamp 39 (or /T models) Wire color T warning lamp 40 S Transfer shut off relay tem ondition Data (pprox.) ngine running Vehicle stopped ngine running /T selector lever position rake pedal depressed Rear indicator of 4WD shift indicator lamp: Rear indicator of 4WD shift indicator lamp: ront and center indicator of 4WD shift indicator lamp: ront and center indicator of 4WD shift indicator lamp: 4 indicator lamp: 4 indicator lamp: 4WD warning lamp: 4WD warning lamp: 4WD shift switch: 4 to 4 or 4 to 4 (While actuator motor is operating.) xcept the above gnition switch: gnition switch: (5 seconds after ignition switch is turned ) 0V 0V attery voltage 0V attery voltage 0V attery voltage 0V attery voltage attery voltage 0V 0V attery voltage T

38 TRU DSS Terminal Wire color 42 Transfer shift high relay 44 ower supply 45 R ower supply R Transfer shift high relay monitor Transfer shift low relay monitor 50 Y Transfer shift low relay tem ondition Data (pprox.) Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. When using a circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals. SUT- unction ( D WD/4WD) 4WD shift switch: 2WD to 4 or 4 to 4 or 2WD to 4 xcept the above gnition switch: gnition switch: (5 seconds after ignition switch is turned ) gnition switch: gnition switch: (5 seconds after ignition switch is turned ) Vehicle stopped ngine running or /T models, /T selector lever position with brake pedal depressed. or /T models, /T shift lever neutral position with clutch and brake pedal depressed. 4WD shift switch: 2WD to 4 or 4 to 4 or 2WD to 4 (while actuator motor is operating) xcept the above 4WD shift switch: 4 to 4 or 4 to 2WD or 4 to 2WD (while actuator motor is operating) xcept the above 4WD shift switch: 4 to 4 or 4 to 2WD or 4 to 2WD xcept the above UT SUT- can display each diagnostic item using the diagnostic test modes shown following. 0V attery voltage attery voltage 0V attery voltage 0V attery voltage 0V 0V attery voltage 0V 0V 0V attery voltage D: Diagnostic test mode Self-diagnostic results Data monitor diagnostic support monitor unction Self-diagnostic results can be read and erased quickly. nput/utput data in the transfer control unit can be read. The results of transmit/receive diagnosis of communication can be read. S-D RSUT D Display tem ist tems (SUT- screen terms) Diagnostic item is detected when... heck item *T STRT* [1801] TR UT 1 [1802] Due to removal of battery which cuts off power supply to transfer control unit, self-diagnosis memory function is suspended. alfunction is detected in the memory (R) system of transfer control unit. heck transfer control unit power supply heck transfer control unit ground heck Transfer shut off relay 1, 2 Replace transfer control unit T-38

39 TRU DSS tems (SUT- screen terms) TR UT 2 [1803] TR UT 3 [1804] V SD S T [1807] V SD S S [1808] TR UT 4 [1809] 4 S SW T [1810] TTRY VT [1811] 4WD D SW [1813] 4WD DTT SWT [1814] SW/R [1816] ST TUTR [1817] ST T S SW [1818] ST T R [1819] SD S [1820] V SD S R [1854] V SD S RR [1855] RUT [U1000] DT S DTTD. URTR TST Y RQURD. Diagnostic item is detected when... alfunction is detected in the memory (R) system of transfer control unit. alfunction is detected in the memory (R) system of transfer control unit. alfunction is detected in output shaft revolution signal that is output from T through communication. mproper signal is input while driving. alfunction is detected in vehicle speed signal that is output from S actuator and electric unit (control unit) through communication. mproper signal is input while driving. D converter system of transfer control unit is malfunctioning. mproper signal from 4 switch is input due to open or short circuit. ower supply voltage for transfer control unit is abnormally low while driving. ore than two switch inputs are simultaneously detected due to short circuit of 4WD shift switch. mproper signal from wait detection switch is input due to open or short circuit. When /T switch signal is malfunction or communication error between the vehicles. otor does not operate properly due to open or short circuit in actuator motor. alfunction is detected in the actuator motor. (When 4WD shift switch is operated and actuator motor is not operated) alfunction is detected in transfer shift high relay and transfer shift low relay. mproper signal from actuator position switch is input due to open or short circuit. alfunction is detected in actuator position switch. alfunction is detected in transfer shut off relay 1 and transfer shut off relay 2. alfunction occurs in transfer control device drive circuit. alfunction is detected in engine speed signal that is output from through communication. mproper signal is input while driving. alfunction is detected in front revolution sensor. mproper signal is input while driving. alfunction is detected in vehicle speed signal that is output from combination meter through communication. mproper signal is input while driving. When transfer control unit is not transmitting or receiving communication signal for 2 seconds or more. heck item Replace transfer control unit Replace transfer control unit erform self-diagnosis with T heck transfer control unit erform self-diagnosis with S actuator and electric unit (control unit) heck transfer control unit Replace transfer control unit heck 4 switch heck 4 switch circuit heck transfer control unit heck transfer control unit power supply heck transfer control unit ground heck Transfer shut off relay 1, 2 heck 4WD shift switch heck 4WD shift switch circuit heck transfer control unit heck wait detection switch heck wait detection switch circuit heck transfer control unit erform self-diagnosis with T heck transfer control unit heck actuator motor heck actuator motor circuit heck transfer relay heck transfer relay circuit heck transfer control unit heck actuator position switch circuit heck transfer control unit heck transfer control unit power supply heck transfer control unit ground heck Transfer shut off relay 1, 2 heck transfer control unit erform self-diagnosis with heck transfer control unit heck front revolution sensor heck front revolution sensor circuit heck transfer control unit erform self-diagnosis with combination meter heck transfer control unit heck communication line o item has been detected. T T-39

40 TRU DSS f RUT [U1000] is displayed with other DTs, first perform the trouble diagnosis for communication line. T: f ST T S SW [1818] or ST T R [1819] is displayed, first erase self-diagnostic results. ( ST T S SW [1818] or ST T R [1819] may be displayed after installing transfer control unit or transfer assembly.) DT TR D Display tem ist : Standard : ptional tem onitored item (Unit) onitor item selection U UT SS V/S S R [km/h] or [mph] V/S S RR [km/h] or [mph] SD [rpm] SS Remarks or S models, wheel speed calculated by S actuator and electric unit (control unit). Signal input with communication line. xcept for S models, wheel speed calculated by front revolution sensor. or S models, wheel speed calculated by T. Signal input with communication line. xcept for S models, wheel speed calculated by combination meter. Signal input with communication line. ngine speed is displayed. Signal input with communication line. TTRY VT [V] ower supply voltage for transfer control unit. 2WD SWT [/] 4 SWT [/] 4 SWT [/] 4 S SW [/] 4WD shift switch signal status is displayed. (4 means 4 of 4WD shift switch.) This means 4 switch. 4 switch signal status is displayed. T SWT [/] T switch signal status is displayed. WT DTT SW [/] Wait detection switch signal status is displayed. 4WD D [2/4/4] ontrol status of 4WD recognized by transfer control unit. (2WD, 4 or 4) V/S [km/h] or [mph] Vehicle speed recognized by transfer control unit. ST T 1 [/] utput condition to actuator motor (clockwise) ST 1 [/] heck signal for transfer control unit signal output ST T 2 [/] utput condition to actuator motor (counterclockwise) ST 2 [/] ST T/R [/] heck signal for transfer control unit signal output perating condition of actuator motor relay (integrated in transfer control unit) ST S SW 1 [/] ondition of actuator position switch 1 ST S SW 2 [/] ondition of actuator position switch 2 ST S SW 3 [/] ondition of actuator position switch 3 ST S SW 4 [/] ondition of actuator position switch 4 4WD [/] ontrol status of 4WD warning lamp is displayed. 2WD D [/] ontrol status of 4WD shift indicator lamp (rear) is displayed. T-40

41 TRU DSS < SRV RT > onitored item (Unit) onitor item selection U UT SS SS Remarks 4 D [/] 4 D [/] Voltage [V] requency [z] DUTY- (high) [%] DUTY-W (low) [%] S WDT- [msec] S WDT-W [msec] Self-Diagnosis rocedure ontrol status of 4WD shift indicator lamp (front and center) is displayed. ontrol status of 4 indicator lamp is displayed. The value measured by the voltage probe is displayed. The value measured by the pulse probe is displayed. D: T S-DST RDUR (WT SUT-) Refer to T-38, "SUT- unction ( D WD/4WD)". S-DST RDUR (WTUT SUT-) Description f the engine starts when there is something wrong with the 4WD system, the 4WD warning lamp turns or flickers in the combination meter. When the system functions properly, the warning lamp turns when the ignition switch is turned to, and it turns after engine starts. To begin trouble diagnosis, start the selfdiagnosis function. The 4WD warning lamp in the combination meter will flicker according to the self-diagnostic results. s for the details of the 4WD warning lamp flickering patterns, refer to "Diagnostic rocedure (/T models)", "Diagnostic rocedure (/T models)". Diagnostic rocedure (/T models) 1. Warm up engine. 2. Turn ignition switch and at least twice, and then turn ignition switch. 3. ove /T selector lever to position. 4. Turn 4WD shift switch to 2WD position. 5. Turn ignition switch. (Do not start engine.) 6. 4WD warning lamp. f 4WD warning lamp does not turn, refer to T-44, "Trouble Diagnosis hart by Symptom". 7. ove /T selector lever to R position. 8. Turn 4WD shift switch to 2WD, 4 and 2WD in order. 9. ove /T selector lever to position. 10. Turn 4WD shift switch to 4, 2WD and 4 in order. 11. ove /T selector lever to position. 12. Turn 4WD shift switch to 2WD position. 13. ove /T selector lever to position. 14. Read the flickering of 4WD warning lamp. Refer to "udgment self-diagnosis". Diagnostic rocedure (/T models) 1. Warm up engine. 2. Turn ignition switch and at least twice, and then turn ignition switch. 3. ove /T shift lever to neutral position. 4. Turn 4WD shift switch to 2WD position. 5. Turn ignition switch. (Do not start engine.) T-41

42 TRU DSS 6. 4WD warning lamp. f 4WD warning lamp does not turn, refer to T-44, "Trouble Diagnosis hart by Symptom". 7. ove /T shift lever to any position other than neutral. 8. Turn 4WD shift switch to 2WD, 4 and 2WD in order. 9. ove /T shift lever to neutral position. 10. Turn 4WD shift switch to 4, 2WD and 4 in order. 11. ove /T shift lever to any position other than neutral. 12. Turn 4WD shift switch to 2WD position. 13. ove /T shift lever to neutral position. 14. Read the flickering of 4WD warning lamp. Refer to "udgment self-diagnosis". udgment Self-diagnosis When a malfunction is detected, the malfunction route is indicated by flickering of the 4WD warning lamp. D0227 lickering pattern tems Diagnostic item is detected when... heck item 1 Vehicle speed signal (from front revolution sensor) alfunction is detected in front revolution sensor. mproper signal is input while driving. heck front revolution sensor heck front revolution sensor circuit heck transfer control unit 2 utput shaft revolution signal (from T) alfunction is detected in output shaft revolution signal that is output from T through communication. mproper signal is input while driving. erform self-diagnosis with T heck transfer control unit 3 Vehicle speed signal [from S actuator and electric unit (control unit)] alfunction is detected in vehicle speed signal that is output from S actuator and electric unit (control unit) through communication. mproper signal is input while driving. erform self-diagnosis with S actuator and electric unit (control unit) heck transfer control unit 4 communication 5 D converter 6 4 switch When transfer control unit is not transmitting or receiving communication signal for 2 seconds or more. D converter system of transfer control unit is malfunctioning. mproper signal from 4 switch is input due to open or short circuit. heck communication line Replace transfer control unit heck 4 switch heck 4 switch circuit heck transfer control unit 7 ngine speed signal (from ) alfunction is detected in engine speed signal that is output from through communication. mproper signal is input while driving. erform self-diagnosis with heck transfer control unit 8 ower supply ower supply voltage for transfer control unit is abnormally low while driving. heck transfer control unit power supply heck transfer control unit ground heck Transfer shut off relay 1, 2 T-42

43 TRU DSS lickering pattern 9 4WD shift switch 10 Wait detection switch 11 ctuator motor 12 ctuator position switch 13 Transfer control device 14 switch signal 15 Repeats flickering every 0.25 sec. Repeats flickering every 2 to 5 sec. o flickering Vehicle speed signal (from combination meter) Data erase display tems Diagnostic item is detected when... heck item switch or 4WD shift switch ore than two switch inputs are simultaneously detected due to short circuit of 4WD shift switch. mproper signal from wait detection switch is input due to open or short circuit. otor does not operate properly due to open or short circuit in actuator motor. alfunction is detected in the actuator motor. (When 4WD shift switch is operated and actuator motor is not operated.) alfunction is detected in transfer shift high relay and transfer shift low relay. mproper signal from actuator position switch is input due to open or short circuit. alfunction is detected in the actuator position switch. alfunction is detected in transfer shut off relay 1 and transfer shut off relay 2. alfunction occurs in transfer control device drive circuit. When /T switch signal is malfunction or communication error between the vehicles. alfunction is detected in vehicle speed signal that is output from combination meter through communication. mproper signal is input while driving. ower supply malfunction of memory back-up. attery is disconnected for a long time. attery performance is poor. ircuits that the self-diagnosis covers have no malfunction. switch or 4WD shift switch circuit is shorted or open. heck 4WD shift switch heck 4WD shift switch circuit heck transfer control unit heck wait detection switch heck wait detection switch circuit heck transfer control unit heck actuator motor heck actuator motor circuit heck transfer relay heck transfer relay circuit heck transfer control unit heck actuator position switch circuit heck transfer control unit heck transfer control unit power supply heck transfer control unit ground heck Transfer shut off relay 1, 2 heck transfer control unit erform self-diagnosis with T heck transfer control unit erform self-diagnosis with combination meter heck transfer control unit heck transfer control unit power supply heck transfer control unit ground heck Transfer shut off relay 1, 2 T: f flickering pattern 12 or 13 is displayed, first erase self-diagnostic results. lickering pattern 12 or 13 may be displayed after installing transfer control unit or transfer assembly. RS S-DSS n order to make it easier to find the cause of hard-to-duplicate malfunctions, malfunction information is stored into the control unit as necessary during use by the user. This memory is not erased no matter how many times the ignition switch is turned and. owever, this information is erased by turning ignition switch after performing self-diagnostics or by erasing the memory using the SUT-. erform self-diagnosis with T heck 4WD shift switch heck 4WD shift switch circuit heck transfer control unit T T-43

44 Trouble Diagnosis hart by Symptom TRU DSS D: f 4WD warning lamp turns, perform self-diagnosis. Refer to T-41, "Self-Diagnosis rocedure". Symptom ondition heck item 4WD shift indicator lamp and 4 indicator lamp do not turn (4WD shift indicator lamp and 4 indicator lamp check) 4WD warning lamp does not turn (4WD warning lamp check) 4WD shift indicator lamp or 4 indicator lamp does not change T warning lamp does not turn 4WD shift indicator lamp repeats flashing 4WD warning lamp flashes slowly Slow flashing: 1 time/2 seconds omponent nspection TRSR SUT RY 1, 2 gnition switch: gnition switch: ngine running ngine running ngine running While driving ower supply and ground for transfer control unit Transfer shut off relay ombination meter ower supply and ground for transfer control unit Transfer shut off relay ombination meter 4WD shift switch Wait detection switch 4 switch T switch Transfer inner parts communication line 4WD shift switch switch signal T switch ombination meter Transfer inner parts Wait detection switch 4 switch Transfer inner parts Tire size is different between front and rear of vehicle. D: Turn ignition switch. (Stay for at least 5 seconds.) 2. Remove transfer shut off relay 1 and transfer shut off relay 2. Refer to T-16, "ocation of lectrical arts". 3. pply 12V direct current between transfer shut off relay terminals 1 and heck continuity between relay terminals 3 and f, replace transfer shut off relay 1 or transfer shut off relay 2. Refer to T-16, "ocation of lectrical arts". 4 SWT ondition 12V direct current supply between terminals 1 and 2 ontinuity Yes o 1. Turn ignition switch. (Stay for at least 5 seconds.) 2. Disconnect 4 switch harness connector. 3. Remove 4 switch. Refer to T-16, "ocation of lectrical arts". S1245 T-44

45 TRU DSS 4. ush and release 4 switch and check continuity between 4 switch terminals 12 and 13. Terminal ondition ontinuity ush 4 switch Release 4 switch Yes o 5. f, replace the 4 switch. Refer to T-16, "ocation of lectrical arts". 4WD ST SWT 1. Turn ignition switch. (Stay for at least 5 seconds.) 2. Remove 4WD shift switch harness connector. 3. perate 4WD shift switch and check continuity between 4WD shift switch terminals. Terminal ondition ontinuity D0204 T 1-3 4WD shift switch: 2WD 4WD shift switch: 4 and 4 Yes o 1-5 4WD shift switch: 4 4WD shift switch: 2WD and WD shift switch: 4 Yes 4WD shift switch: 2WD and 4 o 4. f, replace the 4WD shift switch. WT DTT SWT 1. Turn ignition switch. (Stay for at least 5 seconds.) 2. Disconnect wait detection switch harness connector. 3. Remove wait detection switch. Refer to T-16, "ocation of lectrical arts". 4. ush and release wait detection switch and check continuity between wait detection switch terminals 10 and 11. Yes o SD2805 Terminal ondition ontinuity ush wait detection switch Yes Release wait detection switch o 5. f, replace the wait detection switch. Refer to T-16, "ocation of lectrical arts". TUTR TR 1. Remove transfer control device. Refer to T-53, "Removal and nstallation". 2. heck operation by applying battery voltage to transfer control device (actuator motor) terminals 23 and 24. e careful not to overheat the harness. D0208 Terminal ctuator motor 24 (attery voltage) - 23 (round) lockwise rotate 23 (attery voltage) - 24 (round) ounterclockwise rotate T-45 SD2386

46 TRU DSS 3. f, replace transfer control device (actuator motor). Refer to T-53, "Removal and nstallation". TRSR ST RY 1. Turn ignition switch. (Stay for at least 5 seconds.) 2. Remove transfer shift high relay and transfer shift low relay. Refer to T-16, "ocation of lectrical arts". 3. pply 12V direct current between transfer relay terminals 1 and heck continuity between relay terminals 3 and 4, and 3 and 5. Terminal ondition ontinuity V direct current supply between terminals 1 and 2 o Yes V direct current supply between terminals 1 and 2 5. f, replace transfer shift high relay or transfer shift low relay. Refer to T-16, "ocation of lectrical arts". RT RVUT SSR Yes o 1. Turn ignition switch. (Stay for at least 5 seconds.) 2. Disconnect front revolution sensor harness connector. 3. hecks resistance or continuity between the following terminals. D : pprox Ω 1-3 : ontinuity should no exist. 2-3 : ontinuity should no exist. 4. f, replace the front revolution sensor. Refer to T-16, "ocation of lectrical arts". SD3312 T SWT 1. Turn ignition switch. (Stay for at least 5 seconds.) 2. Disconnect T switch harness connector. 3. Remove T switch. Refer to T-16, "ocation of lectrical arts". 4. ush and release T switch and check continuity between T switch terminals 8 and 9. Terminal ondition ontinuity ush T switch Yes 8-9 Release T switch o 5. f, replace the T switch. Refer to T-16, "ocation of lectrical arts". SD2395 R/UTR ST SWT 1. Turn ignition switch. (Stay for at least 5 seconds.) 2. Disconnect park/neutral position switch harness connector. 3. Remove park/neutral position switch. Refer to T-16, "ocation of lectrical arts". T-46

47 TRU DSS 4. ush and release park/neutral position switch and check continuity between park/neutral position switch terminals 1 and 2. Terminal ondition ontinuity 1-2 ush park/neutral position switch Release park/neutral position switch Yes o 5. f, replace the park/neutral position switch. Refer to T-16, "ocation of lectrical arts". WD0248 T T-47

48 TRSR TR UT Removal and nstallation TRSR TR UT D: RV Switch 4WD shift switch to 2WD and set transfer assembly to 2WD. When removal transfer control unit, transfer state must be at 2WD or UT. STT nstallation is in the reverse order of removal. When installing the transfer control unit, tighten bolts to the specified torque. Transfer control unit bolts : 3.4 m (0.35 kg-m, 30 in-lb) Do not connect harness connector to transfer control unit when 4WD shift switch is at 4. fter the installation, check 4WD shift indicator pattern. f, adjust position between transfer assembly and transfer control unit. Refer to T-3, "recaution for Transfer ssembly and Transfer ontrol Unit Replacement". SD3201 T-48

49 RT S Removal and nstallation RT S D: RV ut a matching mark on top of the front drive shaft in line with the mark on the companion flange. Use paint to make the matching mark on the front drive shaft. Do not damage the front drive shaft. T SD2779 Remove the front oil seal from the front case, using Tool. Tool number Do not damage front case. : V381054S0 STT nstall the front oil seal until it is flush with the end face of the front case, using Tool. Tool number : V Do not reuse oil seal. pply petroleum jelly to oil seal. D0144 lign the matching mark of the front drive shaft with the matching mark of the companion flange, then install the companion flange. D0145 SD2214 T-49

50 RT S nstall the self-lock nut and tighten to the specified torque, using Tool. Refer to T-56, "Disassembly and ssembly". Tool number Do not reuse self-lock nut. : V D0147 T-50

51 RR S Removal and nstallation RR S D: RV Remove the dust cover from the rear case. Do not damage the rear case. T WD0127 Remove the rear oil seal from the rear case, using Tool. Do not damage the rear case. Tool number : V381054S0 STT nstall the rear oil seal until it is flush with the end face of the rear case, using Tool. Tool number : V Do not reuse oil seal. pply petroleum jelly to oil seal. D0139 pply petroleum jelly to the circumference of the new dust cover. osition the dust cover using the identification mark as shown. Do not reuse dust cover. osition the identification mark at the position shown. D0140 SD3377 T-51

52 nstall the dust cover to the rear case, using Tool. Tool number : V Do not reuse dust cover. pply petroleum jelly to dust cover. RR S D0116 T-52