DLN PDF

TRANSMISSION & DRIVELINE
DLN
A
B
SECTION
DRIVELINE C
DLN
E
CONTENTS
TRANSFER: TX15B DTC Logic ................................................................25 F
Diagnosis Procedure ...............................................25
BASIC INSPECTION .................................... 7
P1808 VEHICLE SPEED SENSOR (ABS) ....... 26
G
DIAGNOSIS AND REPAIR WORKFLOW .......... 7 Description ...............................................................26
Work Flow ................................................................. 7 DTC Logic ................................................................26
Diagnosis Procedure ...............................................26
FUNCTION DIAGNOSIS ............................... 9 H
P1810 4 LO SWITCH ........................................ 27
4WD SYSTEM ..................................................... 9 Description ...............................................................27
System Diagram ........................................................ 9 DTC Logic ................................................................27 I
System Description ................................................. 10 Diagnosis Procedure ...............................................27
Component Parts Location ...................................... 12 Component Inspection .............................................29
CAN Communication ............................................... 13
Cross-Sectional View .............................................. 13 P1813 4WD SHIFT SWITCH ............................. 30 J
Power Transfer ........................................................ 14 Description ...............................................................30
DTC Logic ................................................................30
DIAGNOSIS SYSTEM (TRANSFER CON- Diagnosis Procedure ...............................................30 K
TROL UNIT) ........................................................16 Component Inspection .............................................32
CONSULT-III Function (ALL MODE AWD/4WD) .... 16
P1814 WAIT DETECTION SWITCH ................. 33
NOISE, VIBRATION AND HARSHNESS Description ...............................................................33 L
(NVH) TROUBLESHOOTING ............................19 DTC Logic ................................................................33
NVH Troubleshooting Chart .................................... 19 Diagnosis Procedure ...............................................33
Component Inspection .............................................35 M
COMPONENT DIAGNOSIS ......................... 20
P1816 PNP SWITCH (A/T) ................................ 36
P1801, P1811 POWER SUPPLY CIRCUIT Description ...............................................................36
FOR TRANSFER CONTROL UNIT ....................20 DTC Logic ................................................................36 N
Description .............................................................. 20 Diagnosis Procedure ...............................................36
DTC Logic ............................................................... 20
Diagnosis Procedure ............................................... 20 P1816 PNP SWITCH (M/T) ............................... 37 O
Component Inspection ............................................ 22 Description ...............................................................37
DTC Logic ................................................................37
P1802 – P1804, P1809 TRANSFER CON- Diagnosis Procedure ...............................................37
P
TROL UNIT .........................................................23 Component Inspection .............................................38
Description .............................................................. 23
DTC Logic ............................................................... 23 P1817 ACTUATOR MOTOR ............................. 39
Diagnosis Procedure ............................................... 23 Description ...............................................................39
DTC Logic ................................................................39
P1807 VEHICLE SPEED SENSOR (A/T) ..........25 Diagnosis Procedure ...............................................39
Description .............................................................. 25 Component Inspection .............................................44
Revision: October 2008 DLN-1 2009 Xterra

P1818 ACTUATOR POSITION SWITCH .......... 46 Precaution for Supplemental Restraint System
Description .............................................................. 46 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
DTC Logic ............................................................... 46 SIONER" ................................................................. 83
Diagnosis Procedure .............................................. 46 Precaution for Transfer Assembly and Transfer
Control Unit Replacement ....................................... 83
P1819 TRANSFER CONTROL DEVICE ........... 49 Precaution ............................................................... 85
Description .............................................................. 49 Service Notice ......................................................... 85
DTC Logic ............................................................... 49
Diagnosis Procedure .............................................. 49 PREPARATION .......................................... 87
P1820 ENGINE SPEED SIGNAL ...................... 52 PREPARATION ................................................. 87
Description .............................................................. 52 Special Service Tool ............................................... 87
DTC Logic ............................................................... 52 Commercial Service Tool ........................................ 89
Diagnosis Procedure .............................................. 52
ON-VEHICLE MAINTENANCE .................. 90
ECU DIAGNOSIS ........................................ 53
TRANSFER FLUID ............................................ 90
TRANSFER CONTROL UNIT ............................ 53 Replacement ........................................................... 90
Reference Value ..................................................... 53 Inspection ................................................................ 90
Wiring Diagram ....................................................... 58
DTC Index .............................................................. 66 ON-VEHICLE REPAIR ............................... 91
SYMPTOM DIAGNOSIS ............................. 69 TRANSFER CONTROL UNIT ........................... 91

Removal and Installation ......................................... 91
4WD SYSTEM SYMPTOMS .............................. 69
Symptom Table ...................................................... 69 FRONT OIL SEAL ............................................. 92
Removal and Installation ......................................... 92
4WD WARNING LAMP DOES NOT TURN ON... 70
Description .............................................................. 70 REAR OIL SEAL ............................................... 94
Diagnosis Procedure .............................................. 70 Removal and Installation ......................................... 94
4WD SHIFT INDICATOR LAMP AND 4LO IN- TRANSFER CONTROL DEVICE ...................... 96
DICATOR LAMP DO NOT TURN ON ............... 72 Removal and Installation ......................................... 96
Description .............................................................. 72 AIR BREATHER HOSE ..................................... 98
Diagnosis Procedure .............................................. 72 Removal and Installation ......................................... 98
4WD SHIFT INDICATOR LAMP OR 4LO INDI-
REMOVAL AND INSTALLATION ............. 100
CATOR LAMP DO NOT CHANGE .................... 74
Description .............................................................. 74 TRANSFER ASSEMBLY .................................. 100
Diagnosis Procedure .............................................. 74 Removal and Installation ....................................... 100
ATP WARNING LAMP DOES NOT TURN ON... 76 DISASSEMBLY AND ASSEMBLY ........... 102
Description .............................................................. 76
Diagnosis Procedure .............................................. 76 TRANSFER ASSEMBLY .................................. 102
Disassembly and Assembly .................................. 102
4WD SHIFT INDICATOR LAMP KEEPS
FLASHING ......................................................... 78 SHIFT CONTROL ............................................. 118
Description .............................................................. 78 Disassembly and Assembly .................................. 118
Diagnosis Procedure .............................................. 78
PLANETARY CARRIER ................................... 120
4WD WARNING LAMP FLASHES SLOWLY ... 79 Disassembly and Assembly .................................. 120
Description .............................................................. 79
Diagnosis Procedure .............................................. 79 FRONT DRIVE SHAFT ..................................... 124
Disassembly and Assembly .................................. 124
ATP SWITCH ..................................................... 80
Description .............................................................. 80 SERVICE DATA AND SPECIFICATIONS
Diagnosis Procedure .............................................. 80 (SDS) ......................................................... 126
Component Inspection ............................................ 81
SERVICE DATA AND SPECIFICATIONS
PRECAUTION ............................................. 83 (SDS) ................................................................ 126
General Specification ............................................ 126
PRECAUTIONS ................................................. 83 Inspection and Adjustment .................................... 126
PROPELLER SHAFT: 2F1310 SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 142 A
PREPARATION ......................................... 127
PREPARATION ................................................ 127 (SDS) ............................................................... 142
Commercial Service Tool ...................................... 127 B
FUNCTION DIAGNOSIS ............................ 128 Snap Ring .............................................................. 143
FRONT FINAL DRIVE: R180A C
NOISE, VIBRATION, AND HARSHNESS
(NVH) TROUBLESHOOTING .......................... 128 PRECAUTION ............................................ 144
NVH Troubleshooting Chart .................................. 128
PRECAUTIONS ............................................... 144 DLN
ON-VEHICLE REPAIR ............................... 129 Precaution for Servicing Front Final Drive ............. 144
PROPELLER SHAFT ....................................... 129 PREPARATION ......................................... 145

E
On-Vehicle Service ............................................... 129
PREPARATION ............................................... 145
REMOVAL AND INSTALLATION ............. 130 Special Service Tool .............................................. 145
Commercial Service Tool ...................................... 147 F
PROPELLER SHAFT ....................................... 130
Removal and Installation ....................................... 130 FUNCTION DIAGNOSIS ............................ 149
DISASSEMBLY AND ASSEMBLY ............ 132 NOISE, VIBRATION AND HARSHNESS G

(NVH) TROUBLESHOOTING ......................... 149
PROPELLER SHAFT ....................................... 132 NVH Troubleshooting Chart .................................. 149
Disassembly and Assembly .................................. 132 H
DESCRIPTION ................................................ 150
SERVICE DATA AND SPECIFICATIONS Cross-Sectional View ............................................ 150
(SDS) .......................................................... 134
ON-VEHICLE MAINTENANCE .................. 151 I
DIFFERENTIAL GEAR OIL ............................ 151
(SDS) ................................................................ 134
Changing Differential Gear Oil ............................... 151 J
Checking Differential Gear Oil ............................... 151
Snap Ring ............................................................. 134
PROPELLER SHAFT: 2S1330 ON-VEHICLE REPAIR ............................... 152
K
PREPARATION ......................................... 135 FRONT OIL SEAL ........................................... 152
Removal and Installation ....................................... 152
PREPARATION ................................................ 135
Commercial Service Tool ...................................... 135 SIDE OIL SEAL ............................................... 154 L
FUNCTION DIAGNOSIS ............................ 136
CARRIER COVER ........................................... 155 M
NOISE, VIBRATION, AND HARSHNESS Removal and Installation ....................................... 155
(NVH) TROUBLESHOOTING .......................... 136
NVH Troubleshooting Chart .................................. 136 REMOVAL AND INSTALLATION ............. 156
N
ON-VEHICLE REPAIR ............................... 137 FRONT FINAL DRIVE ASSEMBLY ................ 156
PROPELLER SHAFT ....................................... 137 O
On-Vehicle Service ............................................... 137 DISASSEMBLY AND ASSEMBLY ............ 158
REMOVAL AND INSTALLATION ............. 138 FRONT FINAL DRIVE ..................................... 158
Disassembly and Assembly ................................... 158 P
PROPELLER SHAFT ....................................... 138
Removal and Installation ....................................... 138 SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 177
DISASSEMBLY AND ASSEMBLY ............ 140
PROPELLER SHAFT ....................................... 140 (SDS) ............................................................... 177
Disassembly and Assembly .................................. 140 General Specification ............................................ 177

Inspection and Adjustment ....................................177 PREPARATION ................................................ 212
C200 Special Service Tool ............................................. 212
Commercial Service Tool ...................................... 215
PRECAUTION ............................................ 179
FUNCTION DIAGNOSIS ........................... 216
PRECAUTIONS ............................................... 179
Precaution for Servicing Rear Final Drive ..............179 DESCRIPTION .................................................. 216
Cross-Sectional View ............................................ 216
PREPARATION .......................................... 180
SYMPTOM DIAGNOSIS ........................... 217
PREPARATION ............................................... 180
Special Service Tool ..............................................180 NOISE, VIBRATION AND HARSHNESS
Commercial Service Tool ......................................182 (NVH) TROUBLESHOOTING ........................... 217
FUNCTION DIAGNOSIS ............................ 183
ON-VEHICLE MAINTENANCE ................. 218
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING .......................... 183 DIFFERENTIAL GEAR OIL .............................. 218
NVH Troubleshooting Chart ..................................183 Changing Differential Gear Oil .............................. 218
Checking Differential Gear Oil .............................. 218
DESCRIPTION ................................................. 184
Cross-Sectional View ............................................184 ON-VEHICLE REPAIR .............................. 219
ON-VEHICLE MAINTENANCE .................. 185 FRONT OIL SEAL ............................................ 219
DIFFERENTIAL GEAR OIL ............................. 185
Changing Differential Gear Oil ...............................185 CARRIER COVER ............................................ 221
Checking Differential Gear Oil ...............................185 Removal and Installation ....................................... 221
ON-VEHICLE REPAIR ............................... 186 REMOVAL AND INSTALLATION ............. 222

FRONT OIL SEAL ........................................... 186 REAR FINAL DRIVE ASSEMBLY ................... 222
Removal and Installation .......................................186 Removal and Installation ....................................... 222
CARRIER COVER ........................................... 188 DISASSEMBLY AND ASSEMBLY ........... 223

Removal and Installation .......................................188
REAR FINAL DRIVE ASSEMBLY ................... 223
REMOVAL AND INSTALLATION .............. 189 Disassembly and Assembly .................................. 223
REAR FINAL DRIVE ........................................ 189 SERVICE DATA AND SPECIFICATIONS

Removal and Installation .......................................189 (SDS) ......................................................... 239
DISASSEMBLY AND ASSEMBLY ............ 190 SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................ 239
REAR FINAL DRIVE ........................................ 190 General Specification ............................................ 239
Disassembly and Assembly ...................................190
Inspection and Adjustment .................................... 239
SERVICE DATA AND SPECIFICATIONS REAR FINAL DRIVE: M226 (ELD)
(SDS) .......................................................... 209 BASIC INSPECTION ................................. 241
SERVICE DATA AND SPECIFICATIONS DIAGNOSIS AND REPAIR WORKFLOW ........ 241
(SDS) ................................................................ 209 Work Flow ............................................................. 241
General Specification ............................................209
Inspection and Adjustment ....................................209 FUNCTION DIAGNOSIS ........................... 243
REAR FINAL DRIVE: M226
DIFFERENTIAL LOCK SYSTEM ..................... 243
PRECAUTION ............................................ 211 Cross-Sectional View ............................................ 243
System Diagram ................................................... 244
PRECAUTIONS ............................................... 211 System Description ............................................... 244
Precaution for Servicing Rear Final Drive ..............211 Component Parts Location ................................... 245
Component Description ........................................ 246
PREPARATION .......................................... 212

DIAGNOSIS SYSTEM (DIFFERENTIAL P1849 SOLENOID SHORT ............................. 263
LOCK CONTROL UNIT) .................................. 247 Description ............................................................. 263 A
DTC Logic .............................................................. 263
DIFFERENTIAL LOCK CONTROL UNIT ................ 247 Diagnosis Procedure ............................................. 263
DIFFERENTIAL LOCK CONTROL UNIT : CON-
B
SULT-III Function (DIFF LOCK) ............................ 247 P1850 SOLENOID CURRENT ........................ 265
Description ............................................................. 265
NOISE, VIBRATION AND HARSHNESS DTC Logic .............................................................. 265
(NVH) TROUBLESHOOTING .......................... 248 Diagnosis Procedure ............................................. 265 C
C1203 ABS SYSTEM ...................................... 267
COMPONENT DIAGNOSIS ....................... 249 Description ............................................................. 267 DLN
DTC Logic .............................................................. 267
U1000 CAN COMM CIRCUIT ........................... 249
Description ............................................................ 249 LOCK INDICATOR LAMP .............................. 268
DTC Logic ............................................................. 249 Description ............................................................. 268 E
Diagnosis Procedure ............................................ 249 Component Function Check .................................. 268
Diagnosis Procedure ............................................. 268
P1833 INITIAL START ..................................... 250
F
Description ............................................................ 250 ECU DIAGNOSIS ....................................... 269
DTC Logic ............................................................. 250
Diagnosis Procedure ............................................. 250 DIFFERENTIAL LOCK CONTROL UNIT ....... 269
Reference Value .................................................... 269 G
P1834 CONTROL UNIT 1 ................................ 251 Wiring Diagram ...................................................... 270
Description ............................................................ 251 DTC Index ............................................................. 275
DTC Logic ............................................................. 251
H
SYMPTOM DIAGNOSIS ............................ 276
P1835 CONTROL UNIT 2 ................................ 252
Description ............................................................ 252 DIFF LOCK INDICATOR LAMP INOPERA-
DTC Logic ............................................................. 252 TIVE ................................................................. 276 I
Inspection Procedure ............................................. 276
P1836 CONTROL UNIT 3 ................................ 253
Description ............................................................ 253 DIFF LOCK INDICATOR LAMP DOES NOT
J
DTC Logic ............................................................. 253 TURN ON WITH DIFFERENTIAL LOCK
SWITCHED ON ............................................... 277
P1837 CONTROL UNIT 4 ................................ 254
Inspection Procedure ............................................. 277
Description ............................................................ 254 K
DTC Logic ............................................................. 254 DIFF LOCK INDICATOR LAMP FLASHES
P1838 ON SWITCH .......................................... 255 WHILE DRIVING ............................................. 278
Description ............................................................. 278 L
Description ............................................................ 255
DTC Logic ............................................................. 255 Inspection Procedure ............................................. 278
Diagnosis Procedure ............................................. 255 PRECAUTION ............................................ 279
M
P1839 POSITION SWITCH ON ........................ 257 PRECAUTIONS ............................................... 279
Description ............................................................ 257
Precaution for Supplemental Restraint System
DTC Logic ............................................................. 257 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN- N
Diagnosis Procedure ............................................. 257 SIONER" ............................................................... 279
P1844 RELAY .................................................. 259 Precaution ............................................................. 279
Description ............................................................ 259 Precaution for Servicing Rear Final Drive ............. 280
O
DTC Logic ............................................................. 259
PREPARATION ......................................... 281
Diagnosis Procedure ............................................. 259
PREPARATION ............................................... 281 P
P1847 SOLENOID CIRCUIT ............................ 260
Special Service Tool .............................................. 281
Description ............................................................ 260
Commercial Service Tool ...................................... 284
DTC Logic ............................................................. 260
P1848 SOLENOID DISCONNECT ................... 261 ON-VEHICLE MAINTENANCE .................. 285

Description ............................................................ 261 DIFFERENTIAL GEAR OIL ............................ 285
DTC Logic ............................................................. 261 Changing Differential Gear Oil ............................... 285
Diagnosis Procedure ............................................. 261 Checking Differential Gear Oil ............................... 285
ON-VEHICLE REPAIR ............................... 286 REAR FINAL DRIVE ASSEMBLY ................... 294
DIFFERENTIAL LOCK CONTROL UNIT ........ 286
Removal and Installation .......................................286 DISASSEMBLY AND ASSEMBLY ........... 295
DIFFERENTIAL LOCK POSITION SWITCH ... 287 REAR FINAL DRIVE ........................................ 295
Removal and Installation .......................................287 Disassembly and Assembly .................................. 295
FRONT OIL SEAL ........................................... 291 SERVICE DATA AND SPECIFICATIONS

Removal and Installation .......................................291 (SDS) ......................................................... 310
CARRIER COVER ........................................... 293 SERVICE DATA AND SPECIFICATIONS
Removal and Installation .......................................293 (SDS) ................................................................ 310
REMOVAL AND INSTALLATION .............. 294
Inspection and Adjustment .................................... 310

DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [TRANSFER: TX15B]
BASIC INSPECTION A
Work Flow INFOID:0000000004095514
B
WORK FLOW
C
DLN
M
@V CH@/ / 17F A
DETAILED FLOW
N
1.CUSTOMER INFORMATION
Interview the customer to obtain detailed information about the symptom. O
>> GO TO 2
2.INITIAL INSPECTION P
Perform an initial inspection of all accessible transfer case harnesses and connectors under the vehicle.
>> GO TO 3
3.SELF-DIAGNOSIS
Perform self-diagnosis. Refer to DLN-16, "CONSULT-III Function (ALL MODE AWD/4WD)".
< BASIC INSPECTION > [TRANSFER: TX15B]
>> GO TO 4
4.SYMPTOM
Check for symptoms. Refer to DLN-69, "Symptom Table".
>> GO TO 5
5.MALFUNCTIONING PARTS
Repair or replace the applicable parts.
>> GO TO 6
6.SYSTEM OPERATION
Check system operation.
>> GO TO 7
7.SELF-DIAGNOSIS
Perform self-diagnosis.
Are any DTC's displayed?
YES >> GO TO 5
NO >> Inspection End

4WD SYSTEM
< FUNCTION DIAGNOSIS > [TRANSFER: TX15B]
FUNCTION DIAGNOSIS A
4WD SYSTEM
System Diagram INFOID:0000000004095515
B
DLN
I
RCH@2305D
COMPONENT DESCRIPTION J
Components Function
K
Transfer control unit Controls transfer control device and controls shifts between 2WD/4WD and 4H/4LO.
Transfer control device Integrates actuator motor and actuator position switch.
Actuator motor Moves shift rods when signaled by transfer control unit. L
Actuator position switch Detects actuator motor position.
Wait detection switch Detects if transfer case is in 4WD.
4LO switch Detects if transfer case is in 4LO. M
ATP switch (A/T models) Detects if transfer case is in neutral.
4WD shift switch Allows driver to select from 2WD/4WD and 4H/4LO.
N
• Illuminates if malfunction is detected in 4WD system.
4WD warning lamp
• Flashes (1 flash / 2 seconds) if rotation difference of front wheels and rear wheels is large.
Indicates that A/T parking mechanism does not operate when A/T selector lever is in “P” position be- O
ATP warning lamp (A/T models)
cause transfer case is in neutral.
4WD shift indicator lamp Displays driving range selected by 4WD shift switch.
4LO indicator lamp Displays 4LO range. P
PNP switch
Detects if manual transmission is under neutral condition.
(M/T models)
Transmits the following signals via CAN communication to transfer control unit.
ABS actuator and electric unit
• Vehicle speed signal
(control unit)
• Stop lamp switch signal (brake signal)

4WD SYSTEM
Components Function
Transmits the following signal via CAN communication to transfer control unit.
TCM (A/T models) • Output shaft revolution signal
• A/T position indicator signal (PNP switch signal)
ECM Transmits engine speed signal via CAN communication to transfer control unit.
System Description INFOID:0000000004095516
TRANSFER CONTROL DEVICE

Integrates actuator motor and actuator position switch.
Actuator Motor
Moves shift rods when signaled by transfer control unit.
Actuator Position Switch
Detects actuator motor position and then sends signal to transfer control unit.
WAIT DETECTION SWITCH
Detects if transfer case is in 4WD by the 2-4 shift fork position.
NOTE:
If 4WD shift switch is switched to 4H or 4LO and the transfer case is not in 4WD completely, the wait detection
system will operate.
4LO SWITCH
4LO switch detects if the transfer case is in 4LO by the position of the L-H shift fork.
ATP SWITCH (A/T MODELS)
ATP switch detects if transfer case is in neutral by the position of the L-H shift fork.
NOTE:
Transfer case may be in neutral when shifting between 4H-4LO.
PNP SWITCH (M/T models)
PNP switch detects if manual transmission is under neutral condition.
TRANSFER CONTROL UNIT
• Transfer control unit controls transfer control device and it directs shifts from 4H-4LO and 2WD-4WD.
• Self-diagnosis can be done.
TRANSFER SHIFT HIGH AND LOW RELAYS
Transfer shift high and low relays apply power supply to transfer control device (actuator motor).
TRANSFER SHUT OFF RELAYS
Transfer shut off relays 1 and 2 apply power supply to transfer control unit.
4WD SHIFT SWITCH AND INDICATOR LAMP

4WD SYSTEM
DLN
H
RCH@218/ D
4WD Shift Switch

4WD shift switch is able to select from 2WD, 4H or 4LO. I
4WD Shift Indicator Lamp
• Displays driving conditions selected by the 4WD shift switch while engine is running. When the 4WD warn-
ing lamp is turned on, all 4WD shift indicator lamps will turn off. J
• Turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately for 1 sec-
ond after the engine starts if system is normal.
4LO Indicator Lamp K
• Displays 4LO while engine is running. 4LO indicator lamp flashes if transfer gear does not shift completely
into 4H⇔4LO. In this condition, the transfer case may be in neutral and the A/T parking mechanism may not
operate.
L
• Turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately for 1 sec-
ond after the engine starts if system is normal.
4WD WARNING LAMP M
Turns on or flashes when there is a malfunction in 4WD system.
Also turns on when ignition switch is turned ON, for purpose of lamp check. Turns OFF approximately for 1
second after the engine starts if system is normal.
N
4WD Warning Lamp Indication
Condition 4WD warning lamp

O
System normal OFF
Turns ON when ignition switch is turned ON.
Lamp check
Turns OFF after engine start.
P
4WD system malfunction ON
During self-diagnosis Flashes malfunction mode.
Large difference in diameter of front/ Flashes slow (1 flash / 2 seconds)
rear tires (Continues to flash until the ignition switch is turned OFF)
ATP WARNING LAMP (A/T MODELS)

4WD SYSTEM
When the A/T selector lever is in “P” position, the vehicle may move if the transfer case is in neutral. ATP
warning lamp is turned on to indicate this condition to the driver.
Component Parts Location INFOID:0000000004095517
V CH@/ 237D
1. Fuse and relay box 2. A: ATP switch F55 (A/T models) 3. Wait detection switch F59
A: Transfer shut off relay 1 E156 B: 4 LO switch F60
B: Transfer shift high relay E46 (View with front propeller shaft re-
C: Transfer shift low relay E47 moved.)
D: Transfer shut off relay 2 E157

4WD SYSTEM
4. Transfer control device F58 5. Transfer control unit M152, M153 6. Park/neutral position switch F66
(View with lower instrument cover LH (M/T models) A
removed.)
7. Combination meter M24 8. 4WD shift switch M141
A: 4WD warning lamp
B: 4LO indicator lamp
B
C: 4WD shift indicator lamp
D: ATP warning lamp (A/T models)
C
CAN Communication INFOID:0000000004095518
Refer to LAN-52, "DTC Index".

DLN
Cross-Sectional View INFOID:0000000004095519
O
RCH@2307D
1. Mainshaft 2. Rear case 3. Oil pump assembly

P
4. Clutch gear 5. 2-4 shift fork 6. 2-4 sleeve
7. Drive chain 8. Sprocket 9. L-H shift fork
10. L-H sleeve 11. Internal gear 12. Front case
13. Planetary carrier assembly 14. Sun gear assembly 15. L-H shift rod
16. Control shift rod A/T 17. Companion flange 18. Front drive shaft
19. Control shift rod M/T 20. Transfer control device

4WD SYSTEM
Power Transfer INFOID:0000000004095520
POWER TRANSFER DIAGRAM
V CH@/ 112D
1. Mainshaft 2. Clutch gear 3. 2-4 sleeve

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

4WD SYSTEM
DLN
E
RCH@1102D

DIAGNOSIS SYSTEM (TRANSFER CONTROL UNIT)
CONSULT-III Function (ALL MODE AWD/4WD) INFOID:0000000004095521
FUNCTION
CONSULT-III can display each diagnostic item using the diagnostic test modes shown following.
ALL MODE AWD/4WD diagnostic mode Description

SELF-DIAG RESULTS Displays transfer control unit self-diagnosis results.
DATA MONITOR Displays transfer control unit input/output data in real time.
CAN DIAG SUPPORT MNTR The results of transmit/receive diagnosis of CAN communication can be read.
ECU PART NUMBER Transfer control unit part number can be read.
SELF-DIAG RESULT MODE

Operation Procedure
1. Connect “CONSULT-III”.
2. With engine at idle, touch “SELF-DIAG RESULTS”.
Display shows malfunction experienced since the last erasing operation.
NOTE:
The details for "TIME" are as follows:
• "0": Error currently detected with transfer control unit.
• Except for "0": Error detected in the past and memorized with transfer control unit.
Detects frequency of driving after DTC occurs (frequency of turning ignition switch "ON/OFF").
How to Erase Self-diagnostic Results
1. Perform applicable inspection of malfunctioning item and then repair or replace.
2. Start engine and select “SELF-DIAG RESULTS” mode for “ALL MODE AWD/4WD” with CONSULT-III.
3. Touch “ERASE” on CONSULT-III screen to erase DTC memory.
CAUTION:
If memory cannot be erased, perform applicable diagnosis.
SELF-DIAGNOSTIC PROCEDURE (WITHOUT CONSULT-III)
Description
If the engine starts when there is something wrong with the 4WD system, the 4WD warning lamp turns ON or
flickers in the combination meter. When the system functions properly, the warning lamp turns ON when the
ignition switch is turned to “ON”, and it turns OFF after engine starts. To locate the cause of a problem, start
the self-diagnosis function. The 4WD warning lamp in the combination meter will indicate the problem area by
flickering according to the self-diagnostic results. Refer to DLN-66, "DTC Index".
Diagnostic Procedure (A/T models)
1. Warm up engine.
2. Turn ignition switch “ON” and “OFF” at least twice, and then turn ignition switch “OFF”.
3. Move A/T selector lever to “P” position.
4. Turn 4WD shift switch to “2WD” position.
5. Turn ignition switch “ON”. (Do not start engine.)
6. 4WD warning lamp should turn ON.
If 4WD warning lamp does not turn ON, refer to DLN-70, "Diagnosis Procedure".
7. Move A/T selector lever to “R” position.
8. Turn 4WD shift switch to “2WD”, “4H” and “2WD” in order.
10. Turn 4WD shift switch to “4H”, “2WD” and “4H” in order.
11. Move A/T selector lever to “N” position.
12. Turn 4WD shift switch to “2WD” position.

14. Read the flickering of 4WD warning lamp.
Refer to "Judgement Self-diagnosis". A
Diagnostic Procedure (M/T models)
1. Warm up engine.
B
2. Turn ignition switch “ON” and “OFF” at least twice, and then turn ignition switch “OFF”.
3. Move M/T shift lever to neutral position.
4. Turn 4WD shift switch to “2WD” position. C
6. 4WD warning lamp should turn ON.
If 4WD warning lamp does not turn ON, refer to DLN-70, "Diagnosis Procedure". DLN
7. Move M/T shift lever to any position other than neutral.
8. Turn 4WD shift switch to “2WD”, “4H” and “2WD” in order.
9. Move M/T shift lever to neutral position. E
10. Turn 4WD shift switch to “4H”, “2WD” and “4H” in order.
11. Move M/T shift lever to any position other than neutral.
12. Turn 4WD shift switch to “2WD” position. F
13. Move M/T shift lever to neutral position.
14. Read the flickering of 4WD warning lamp.
Refer to "Judgement Self-diagnosis". G
Self-diagnosis example
H
OCH@/ 116D
K
DATA MONITOR MODE
Operation Procedure
L
1. Connect “CONSULT-III.”
2. Touch “DATA MONITOR”.
3. Select from “SELECT MONITOR ITEM”, screen of data monitor mode is displayed. M
NOTE:
When malfunction is detected, CONSULT-III performs REAL-TIME DIAGNOSIS.
Also, any malfunction detected while in this mode will be displayed at real time.
N
Display Item List
×: Standard –: Not applicable
Monitor item selection O

Monitored item (Unit) ECU INPUT MAIN SELECTION Remarks
SIGNALS SIGNALS FROM MENU
Wheel speed calculated by ABS actuator P
VHCL/S SEN·FR [km/h] or [mph] × – × and electric unit (control unit).
Signal input with CAN communication line.
Wheel speed calculated by TCM.
VHCL/S SEN·RR [km/h] or [mph] × – ×
Engine speed is displayed.
ENGINE SPEED [rpm] × – ×

Monitor item selection
Monitored item (Unit) ECU INPUT MAIN SELECTION Remarks
SIGNALS SIGNALS FROM MENU
Power supply voltage for transfer control
BATTERY VOLT [V] × – ×
unit.
2WD SWITCH [ON/OFF] × – ×
4WD shift switch signal status is displayed.
4H SWITCH [ON/OFF] × – ×
(4L means 4LO of 4WD shift switch.)
4L SWITCH [ON/OFF] × – ×
4L POSI SW [ON/OFF] × – × 4LO switch signal status is displayed.
ATP SWITCH [ON/OFF] × – × ATP switch signal status is displayed.
Wait detection switch signal status is dis-
WAIT DETCT SW [ON/OFF] × – ×
played.
Control status of 4WD recognized by trans-
4WD MODE [2H/4H/4L] – × ×
fer control unit. (2WD, 4H or 4LO)
Vehicle speed recognized by transfer con-
VHCL/S COMP [km/h] or [mph] – × ×
trol unit.
Output condition to actuator motor (clock-
SHIFT ACT 1 [ON/OFF] – × ×
wise)
Check signal for transfer control unit signal
SHIFT AC MON 1 [ON/OFF] – – ×
output
Output condition to actuator motor (coun-
SHIFT ACT 2 [ON/OFF] – × ×
terclockwise)
Check signal for transfer control unit signal
SHIFT AC MON 2 [ON/OFF] – – ×
output
Operating condition of actuator motor relay
SFT ACT/R MON [ON/OFF] – – ×
(integrated in transfer control unit)
SHIFT POS SW 1 [ON/OFF] × – × Condition of actuator position switch 1
Control status of 4WD warning lamp is dis-
4WD FAIL LAMP [ON/OFF] – × ×
played.
Control status of 4WD shift indicator lamp
2WD IND [ON/OFF] – – ×
(rear) is displayed.
Control status of 4WD shift indicator lamp
4H IND [ON/OFF] – – ×
(front and center) is displayed.
Control status of 4LO indicator lamp is dis-
4L IND [ON/OFF] – – ×
played.

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
A
NVH Troubleshooting Chart INFOID:0000000004095522
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec- B
tion. If necessary, repair or replace these parts.
DLN-102
DLN-102
DLN-102
DLN-102
DLN-90
C
Reference page
TRANSFER FLUID (Level too high)

DLN
SHIFT FORK (Worn or damaged)

TRANSFER FLUID (Level low)
BEARING (Worn or damaged)

OIL SEAL (Worn or damaged)
LIQUID GASKET (Damaged)
O-RING (Worn or damaged)

TRANSFER FLUID (Wrong)
GEAR (Worn or damaged)

E
SUSPECTED PARTS
(Possible cause)
F
G
Noise 1 2 3 3
Symptom Transfer fluid leakage 3 1 2 2 2
H
Hard to shift or will not shift 1 1 2

P1801, P1811 POWER SUPPLY CIRCUIT FOR TRANSFER CONTROL UNIT
< COMPONENT DIAGNOSIS > [TRANSFER: TX15B]
COMPONENT DIAGNOSIS
P1801, P1811 POWER SUPPLY CIRCUIT FOR TRANSFER CONTROL
UNIT
Description INFOID:0000000004095523
The transfer control unit controls the transfer control device which controls shifts between 4H and 4LO and
between 2WD and 4WD. When the vehicle battery is removed, the power supply to the transfer control unit is
interupted, and self-diagnosis memory function is suspended. These DTC's may also set when the power
supply voltage for the transfer control unit is abnormally low while driving.
DTC Logic INFOID:0000000004095524
DTC DETECTION LOGIC
DTC CONSULT-III Diagnostic item is detected when... Reference

Due to removal of battery which cuts off
power supply to transfer control unit,
[P1801] *INITIAL START*
self-diagnosis memory function is sus-
pended. DLN-20
Power supply voltage for transfer control

[P1811] BATTERY VOLTAGE
unit is abnormally low while driving.
DTC CONFIRMATION PROCEDURE

1.DTC CONFIRMATION PROCEDURE
1. Turn ignition switch ON.
2. Perform self-diagnosis.
Are DTC's “P1801 or P1811 detected?
YES >> Perform diagnosis procedure. Refer to DLN-20, "Diagnosis Procedure".
NO >> Inspection End.
Diagnosis Procedure INFOID:0000000004095525
1.CHECK POWER SUPPLY

1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connector.
3. Check voltage between transfer control unit harness connector
terminals and ground.
Connector Terminal Voltage (Approx.)

19 - Ground Battery voltage
M152
25 - Ground 0V
M153 44 - Ground
0V
45 - Ground RCH@225/ D

5. Check voltage between transfer control unit harness connector A
Connector Terminal Voltage (Approx.) B

19 - Ground
M152
25 - Ground
C
M153 44 - Ground
RCH@2250D
45 - Ground DLN
Is there voltage?
YES >> GO TO 2.
NO >> Check the following. If any items are damaged, repair or replace damaged parts. E
• 40A fuse (No. J, located in the fuse and fusible link box).
• 10A fuses (No. 21, located in the fuse block (J/B) and Nos. 57 and 58 located in the fuse and
relay box).
F
• Harness for short or open between battery and transfer control unit harness connector M152
terminal 19.
• Harness for short or open between battery and transfer shut off relay 2 harness connector E157
terminal 1 and 3. G
terminal 3.
• Harness for short or open between ignition switch and transfer control unit harness connector H
M152 terminal 25.
• Harness for short or open between ignition switch and transfer shut off relay 1 harness connec-
tor E156 terminal 1.
• Harness for short or open between transfer shut off relay 2 harness connector E157 terminal 5 I
and transfer control unit harness connector M153 terminals 44, 45.
• Harness for short or open between transfer shut off relay 1 harness connector E156 terminal 5
and transfer control unit harness connector M153 terminals 44, 45. J
and transfer control unit harness connector M153 terminal 40.
• Harness for open between transfer shut off relay 1 harness connector E156 terminal 2 and
ground. K
• Battery and ignition switch.
• Transfer shut off relay 1, 2. Refer to DLN-22, "Component Inspection".
2.CHECK GROUND CIRCUIT L
1. Turn ignition switch “OFF”.

3. Check continuity between transfer control unit harness connec- M
tor M152 terminals 6 and 18, and M153 terminal 32 and ground.
Continuity should exist. N

Also check harness for short to power.
Do you have continuity?
O
YES >> GO TO 3.
NO >> Repair open circuit or short to power in harness or con-
nectors.
P
RCH@2251D
3.CHECK TRANSFER CONTROL UNIT

Check transfer control unit input/output signal. Refer to DLN-53, "Reference Value".
Are the inspection results normal?
YES >> GO TO 4.

NO >> Check transfer control unit pin terminals for damage or loose connection with harness connector.
If any items are damaged, repair or replace damaged parts.
4.CHECK DTC
Drive vehicle and then perform Self-diagnosis.
Do DTC's P1801 or P1811 display?
YES >> Replace transfer control unit. Refer to DLN-91, "Removal and Installation".
Component Inspection INFOID:0000000004095526

2. Remove transfer shut off relay 1 and transfer shut off relay 2. Refer to DLN-12, "Component Parts Loca-
tion".
3. Apply 12V direct current between transfer shut off relay termi-
nals 1 and 2.
4. Check continuity between relay terminals 3 and 5.
Condition Continuity
12V direct current supply between terminals 1 and 2 Yes
OFF No
5. If inspection results are not normal, replace the transfer shut off
relay 1 or 2.
RBH@0134D

P1802 – P1804, P1809 TRANSFER CONTROL UNIT
A
The transfer control unit controls the transfer control device which controls shifts between 4H and 4LO and B
between 2WD and 4WD. A DTC may set when any of the following occur:
• Malfunction is detected in the memory (RAM) system of transfer control unit.
• Malfunction is detected in the memory (ROM) system of transfer control unit.
• Malfunction is detected in the memory (EEPROM) system of transfer control unit. C
• AD converter system of transfer control unit is malfunctioning.
DLN
DTC DETECTION LOGIC

E
Malfunction is detected in the memory
[P1802] CONTROL UNIT 1
(RAM) system of transfer control unit.
F
Malfunction is detected in the memory
[P1803] CONTROL UNIT 2
(ROM) system of transfer control unit.
Malfunction is detected in the memory DLN-23
[P1804] CONTROL UNIT 3 (EEPROM) system of transfer control G
unit.
AD converter system of transfer control
[P1809] CONTROL UNIT 4 H
unit is malfunctioning.

1.DTC CONFIRMATION PROCEDURE I
J
Are DTC's “P1802 - P1804 or P1809 detected?
K
1.INSPECTION START L
Do you have CONSULT-III?
YES or NO
YES >> GO TO 2. M
NO >> GO TO 3.
2.PERFORM SELF-DIAGNOSIS (WITH CONSULT-III) N
1. Turn ignition switch “ON”.
2. Select “SELF-DIAG RESULTS” mode for “ALL MODE AWD/4WD” with CONSULT-III.
3. Touch “ERASE”.
4. Turn ignition switch “OFF” and wait at least 10 seconds. O
5. Perform the self-diagnosis again.
Is the “CONTROL UNIT 1 [P1802]”, “CONTROL UNIT 2 [P1803]”, “CONTROL UNIT 3 [P1804]” or CONTROL
UNIT 4 [P1809]” displayed? P
3.PERFORM SELF-DIAGNOSIS (WITHOUT CONSULT-III)
1. Perform the self-diagnosis and then erase self-diagnostic results. Refer to DLN-16, "CONSULT-III Func-
tion (ALL MODE AWD/4WD)".

Do the self-diagnostic results indicate AD converter?

P1807 VEHICLE SPEED SENSOR (A/T)
P1807 VEHICLE SPEED SENSOR (A/T)
A
The transmission control module (TCM) transmits the output shaft revolution signal via CAN communication to B
Transfer control unit. DTC P1807 will set when a malfunction is detected in the output shaft revolution signal
or an improper signal is input while driving.
DTC Logic INFOID:0000000004095531 C
DTC DETECTION LOGIC

DLN
• Malfunction is detected in output shaft
revolution signalthat is output from E
[P1807] VHCL SPEED SEN·AT DLN-25
TCM through CAN communication.
• Improper signal is input while driving.
DTC CONFIRMATION PROCEDURE F

1. Turn ignition switch ON. G
Is DTC P1807 detected?
YES >> Perform diagnosis procedure. Refer to DLN-25, "Diagnosis Procedure". H
I
1.CHECK DTC WITH TCM
Perform self-diagnosis with TCM. Refer to TM-102, "CONSULT-III Function (TRANSMISSION)".
J
Is any malfunction detected by self-diagnosis?
YES >> Check the malfunctioning system.
NO >> GO TO 2.
K
Are the inspection results normal? L
YES >> GO TO 3.
If any items are damaged, repair or replace damaged parts. M
3.CHECK DTC
N
Is DTC P1807 displayed?
YES >> Perform self-diagnosis with TCM again.
O

P1808 VEHICLE SPEED SENSOR (ABS)
P1808 VEHICLE SPEED SENSOR (ABS)
The ABS actuator and electric unit (control unit) transmits a vehicle speed signal via CAN communication to
the transfer control unit. DTC P1808 sets when a malfunction is detected in the vehicle speed signal that is
output from the ABS actuator and electric unit (control unit) or an improper signal is input while driving.
DTC DETECTION LOGIC

• Malfunction is detected in vehicle
speed signal that is output from ABS
[P1808] VHCL SPEED SEN·ABS actuator and electric unit (control unit) DLN-26
through CAN communication.

Is DTC “P1808 displayed?
1.CHECK DTC WITH ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
Perform self-diagnosis with ABS actuator and electric unit (control unit) for specific BRC system type.
NO >> GO TO 2.
YES >> GO TO 3.
3.CHECK DTC
YES >> Perform self-diagnosis with ABS actuator and electric unit (control unit) for specific BRC system
type.

P1810 4 LO SWITCH
P1810 4 LO SWITCH
A
The 4LO switch detects that the transfer case is in 4LO range. DTC P1810 will set when an improper signal B
from the 4LO switch is input due to an open or short circuit.
C
DTC DETECTION LOGIC
DTC CONSULT-III Diagnostic item is detected when... Reference DLN

Improper signal from 4LO switch is input
[P1810] 4L POSI SW TF DLN-27
due to open or short circuit.
E
1. Turn ignition switch ON. F
YES >> Perform diagnosis procedure. Refer to DLN-27, "Diagnosis Procedure". G
H
1.CHECK 4LO POSITION SWITCH SIGNAL

I
With CONSULT-III
1. Start engine.
2. Select “DATA MONITOR” mode for “ALL MODE AWD/4WD” with CONSULT-III.
3. Read out the value of “4L POSI SW”. J
Condition Display value

K
• Vehicle stopped 4WD shift switch: 4LO ON
• Engine running
• A/T selector lever “N” position Except the above OFF
• Brake pedal depressed L
Without CONSULT-III
1. Start engine. M
terminal and ground.
N
Voltage
Connector Terminal Condition
(Approx.)
• Vehicle stopped 4WD shift switch: 4LO 0V O
• Engine running
24 - • A/T selector lever
M152 Battery
Ground “N” position Except the above
• Brake pedal de- voltage P
pressed RCH@2252D

YES >> GO TO 5.
NO >> GO TO 2.
2.CHECK HARNESS BETWEEN TRANSFER CONTROL UNIT AND 4LO SWITCH
P1810 4 LO SWITCH
2. Disconnect transfer control unit harness connector and the 4LO switch harness connector.
3. Check continuity between transfer control unit harness connec-
tor M152 terminal 24 and 4LO switch harness connector F60
terminal 13.
Continuity should exist.

Also check harness for short to ground and short to power.
Is there continuity?
YES >> GO TO 3.
NO >> Repair or replace damaged parts.
RCH@2253D
3.CHECK GROUND CIRCUIT

2. Disconnect 4LO switch harness connector.
3. Check continuity between 4LO switch harness connector F60
terminal 12 and ground.

YES >> GO TO 4.
nectors.
OCH@/ 1/ 2D
4.CHECK 4LO SWITCH

3. Remove 4LO switch. Refer to DLN-12, "Component Parts Location".
4. Push and release 4LO switch and check continuity between
4LO switch terminals 12 and 13.
Terminal Condition Continuity

Push 4LO switch Yes
12 - 13
Release 4LO switch No
YES >> GO TO 5.
NO >> Replace 4LO switch.
OCH@/ 1/ 3D

YES >> GO TO 6.
6.CHECK DTC
Drive the vehicle and then perform self-diagnosis.

P1810 4 LO SWITCH
A
3. Remove 4LO switch. Refer to DLN-12, "Component Parts Location". B
4. Push and release 4LO switch and check continuity between
4LO switch terminals 12 and 13.
C
Push 4LO switch Yes
12 - 13 DLN
Release 4LO switch No
5. If the inspection results are not normal replace the 4LO switch.
E
OCH@/ 1/ 3D

P1813 4WD SHIFT SWITCH
The 4WD shift switch allows the driver to select 2WD or 4WD and 4H or 4LO. DTC P1813 will set if more than
two switch inputs are simultaneously detected by the transfer control unit due to a short circuit in the 4WD shift
switch.
DTC DETECTION LOGIC

More than two switch inputs are simulta-
[P1813] 4WD MODE SW neously detected due to short circuit of DLN-30
4WD shift switch.

1.CHECK 4WD SHIFT SWITCH SIGNAL

With CONSULT-III
3. Read out ON/OFF switching action of the “2WD SWITCH”, “4H SWITCH”, “4L SWITCH” with operating
4WD shift switch.
Without CONSULT-III
Voltage (Ap-
prox.)
4WD shift switch: 2WD Battery voltage
14 - Ground
4WD shift switch: 4H and 4LO 0V
4WD shift switch: 4H Battery voltage
M152 15 - Ground
4WD shift switch: 2WD and 4LO 0V
RCH@2254D
4WD shift switch: 4LO Battery voltage
16 - Ground
4WD shift switch: 2WD and 4H 0V

YES >> GO TO 5.
NO >> GO TO 2.
2.CHECK 4WD SHIFT SWITCH POWER SUPPLY CIRCUIT

2. Disconnect 4WD shift switch harness connector.
3. Check voltage between 4WD shift switch harness connector ter- A
minal 1 and ground.
Connector Terminal Voltage (Approx.) B

M141 1 - Ground 0V
RCH@17/ 2D DLN

5. Check voltage between 4WD shift switch harness connector ter- E
minal 1 and ground.

F
M141 1 - Ground Battery voltage
Is there voltage?
YES >> GO TO 3. G
NO >> 1. Check harness for short or open between 4WD shift
switch harness connector terminal 1 and transfer RCH@17/ 1D
shut off relay 2 harness connector E157 terminal 5 H

and 10A fuse (No. 58 located in the fuse block). If any items are damaged, repair or replace
damaged parts.
2. Perform trouble diagnosis for power supply circuit. Refer to DLN-20, "Diagnosis Procedure".
I
3.CHECK HARNESS BETWEEN 4WD SHIFT SWITCH AND TRANSFER CONTROL UNIT
2. Disconnect transfer control unit harness connector and the 4WD shift switch harness connector. J
3. Check continuity between the following terminals.
- Transfer control unit harness connector M152 terminal 14 and
4WD shift switch harness connector M141 terminal 3.
K
4WD shift switch harness connector M141 terminal 5.
4WD shift switch harness connector M141 terminal 6. L

Also check harness for short to ground and short to power. M
RCH@2255D
YES >> GO TO 4.
NO >> Repair or replace damaged parts. N
4.CHECK 4WD SHIFT SWITCH
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.) O
2. Remove 4WD shift switch harness connector.

3. Operate 4WD shift switch and check continuity between 4WD
shift switch terminals.

4WD shift switch: 2WD Yes
1-3
4WD shift switch: 4H and 4LO No
4WD shift switch: 4H Yes
1-5
4WD shift switch: 2WD and 4LO No
4WD shift switch: 4LO Yes RCH@17/ 4D
1-6
4WD shift switch: 2WD and 4H No
YES >> GO TO 5.
NO >> Replace 4WD shift switch.
YES >> GO TO 6.
6.CHECK DTC

2. Remove 4WD shift switch harness connector.
3. Operate 4WD shift switch and check continuity between 4WD
shift switch terminals.

4WD shift switch: 2WD Yes
1-3
4WD shift switch: 4H and 4LO No
4WD shift switch: 4H Yes
1-5
4WD shift switch: 2WD and 4LO No
4WD shift switch: 4LO Yes RCH@17/ 4D
1-6
4WD shift switch: 2WD and 4H No
4. If the inspection results are abnormal replace the 4WD shift switch.

P1814 WAIT DETECTION SWITCH
A
The wait detection switch detects if the transfer case is in 4WD. DTC P1814 will set if an improper signal from B
the wait detection switch is input due to open or short circuit.
C
DTC DETECTION LOGIC

Improper signal from wait detection
[P1814] 4WD DETECT SWITCH switch is input due to open or short cir- DLN-33
cuit. E
1.DTC CONFIRMATION PROCEDURE F
Is DTC P1814 detected? G
H
1.CHECK WAIT DETECTION SWITCH SIGNAL

I
With CONSULT-III
1. Start engine.
2. Select “DATA MONITOR” mode for “ALL MODE AWD/4WD” with CONSULT-III. J
3. Read out the value of “WAIT DETCT SW”.
Condition Display value K

• Vehicle stopped 4WD shift switch: 4H and 4LO ON
• Engine running
• A/T selector lever “N” position 4WD shift switch: 2WD OFF L
• Brake pedal depressed
Without CONSULT-III M
1. Start engine.
N
Voltage
(Approx.)
O
• Vehicle stopped 4WD shift switch
0V
• Engine running : 4H and 4LO
17 - • A/T selector lever
M152
Ground “N” position Battery P
• Brake pedal de- 4WD shift switch: 2WD
voltage
pressed RCH@2256D

YES >> GO TO 5.
NO >> GO TO 2.
2.CHECK HARNESS BETWEEN TRANSFER CONTROL UNIT AND WAIT DETECTION SWITCH
2. Disconnect transfer control unit harness connector and the wait detection switch harness connector.
tor M152 terminal 17 and wait detection switch harness connec-
tor F59 terminal 10.

YES >> GO TO 3.
RCH@2257D

2. Disconnect wait detection switch harness connector.
3. Check continuity between wait detection switch harness con-
nector F59 terminal 11 and ground.

YES >> GO TO 4.
nectors.
OCH@/ 1/ 6D
4.CHECK WAIT DETECTION SWITCH

3. Remove wait detection switch. Refer to DLN-12, "Component Parts Location".
4. Push and release wait detection switch and check continuity
between wait detection switch terminals 10 and 11.

Push wait detection switch Yes
10 - 11
Release wait detection switch No
YES >> GO TO 5.
NO >> Replace wait detection switch.
OCH@/ 1/ 7D

YES >> GO TO 6.
6.CHECK DTC

A
3. Remove wait detection switch. Refer to DLN-12, "Component Parts Location". B
4. Push and release wait detection switch and check continuity
between wait detection switch terminals 10 and 11.
C
Push wait detection switch Yes
10 - 11 DLN
Release wait detection switch No
5. If the inspection results are abnormal replace the wait detection
switch. E
OCH@/ 1/ 7D

P1816 PNP SWITCH (A/T)
P1816 PNP SWITCH (A/T)
The A/T PNP switch transmits the A/T position indicator signal (PNP switch signal) via CAN communication to
the transfer control unit. DTC P1816 will set when the A/T PNP switch signal is malfunctioning or there is a
communication error.
DTC DETECTION LOGIC

When A/T PNP switch signal is malfunc-
[P1816] PNP SW/CIRC tion or communication error between the DLN-36
vehicles.

1.CHECK DTC WITH TCM

Perform self-diagnosis with TCM. Refer to TM-102, "CONSULT-III Function (TRANSMISSION)".
NO >> GO TO 2.
Is the inspection result normal?
YES >> GO TO 3.
3.CHECK DTC
YES >> Perform self-diagnosis with TCM again.

P1816 PNP SWITCH (M/T)
A
The M/T PNP switch signals neutral position to the transfer control unit. DTC P1816 will set when the M/T B
PNP switch signal is malfunctioning.
C
DTC DETECTION LOGIC

When M/T PNP switch signal is malfunc-
[P1816] PNP SW/CIRC DLN-37
tion.
E
1. Turn ignition switch ON. F
YES >> Perform diagnosis procedure. Refer to DLN-37, "Diagnosis Procedure". G
H
1.CHECK PARK/NEUTRAL POSITION SWITCH SIGNAL

1. Turn ignition switch ON. I
M152 terminal 33 and ground.
J
Voltage
(Approx.)
M/T shift lever neutral K
0V
33 - position
M152 Ignition switch: ON
Ground Battery
Except the above
voltage
L
Is the inspection result normal? V CH@/ 134D
YES >> GO TO 5.
NO >> GO TO 2. M
2.CHECK HARNESS BETWEEN TRANSFER CONTROL UNIT AND PARK/NEUTRAL POSITION SWITCH
1. Turn ignition switch OFF. (Stay for at least 5 seconds.)
2. Disconnect transfer control unit harness connector and the park/neutral position switch harness connec- N
tor.
tor M152 terminal 33 and park/neutral position switch harness O
connector F66 terminal 1.

P
YES >> GO TO 3.
V CH@/ 135D

2. Disconnect park/neutral position switch harness connector.
3. Check continuity between park/neutral position switch harness
connector F66 terminal 2 and ground.

YES >> GO TO 4.
nectors.
V CH@/ 136D
4.CHECK PARK/NEUTRAL POSITION SWITCH

2. Remove park/neutral position switch. Refer to DLN-12, "Component Parts Location".
3. Push and release park/neutral position switch and check conti-
nuity between park/neutral position switch terminals 1 and 2.

Push park/neutral position switch Yes
1-2 Release park/neutral position
No
switch
YES >> GO TO 5.
NO >> Replace park/neutral position switch. Refer to DLN-12, V CH@/ 162D
"Component Parts Location".

YES >> Inspection End.

2. Disconnect neutral position switch harness connector.
3. Remove neutral position switch. Refer to DLN-12, "Component Parts Location".
4. Push and release neutral position switch and check continuity
between neutral position switch terminals 1 and 2.

Push neutral position switch Yes
1-2
Release neutral position switch No
5. If NG, replace the neutral position switch.
V CH@/ 162D

P1817 ACTUATOR MOTOR
A
The actuator motor receives signals from the transfer control unit and controls shift rods which shift the trans- B
fer case. DTC P1817 will set when any of the following occur:
• Motor does not operate properly due to open or short circuit in actuator motor.
• Malfunction is detected in the actuator motor. (When 4WD shift switch is operated and actuator motor does
not operate) C
• Malfunction is detected in transfer shift high relay or transfer shift low relay.
DLN
DTC DETECTION LOGIC

E
• Motor does not operate properly due
to open or short circuit in actuator mo-
tor. F
• Malfunction is detected in the actuator
[P1817] SHIFT ACTUATOR motor. (When 4WD shift switch is op- DLN-39
erated and actuator motor is not oper-
ated)
G
• Malfunction is detected in transfer shift
high relay or transfer shift low relay.
H
1. Turn ignition switch ON. I
YES >> Perform diagnosis procedure. Refer to DLN-39, "Diagnosis Procedure". J
K
1.CHECK ACTUATOR MOTOR SIGNAL

L
With CONSULT-III
1. Start engine.
3. Read out the value of “SHIFT ACT1”, “SHIFT AC MON1”, “SHIFT ACT2”, “SHIFT AC MON2”. M

Monitored item Condition Display value

4WD shift switch: 2WD to
4H or 4H to 4LO or 2WD to ON
SHIFT ACT1 4LO
Except the above OFF
• Vehicle 4WD shift switch: 2WD to

stopped 4H or 4H to 4LO or 2WD to ON
SHIFT AC MON1 4LO
• Engine run-
ning Except the above OFF
• A/T selector
lever “N” po- 4WD shift switch: 4LO to
sition 4H or 4H to 2WD or 4LO to ON
SHIFT ACT2 2WD
• Brake pedal
depressed Except the above OFF
4WD shift switch: 4LO to
4H or 4H to 2WD or 4LO to ON
SHIFT AC MON2 2WD
Except the above OFF
Without CONSULT-III
1. Start engine.
2. Depress brake pedal and stop vehicle.
3. Set A/T selector lever to "N" position.
Voltage
(Approx.)
Battery
When 4WD shift switch is operated (While
28 - voltage →
actuator motor is operating.)
Ground 0V
When 4WD shift switch is not operated 0V
31 -
Always 0V V CH@/ 033D
Ground
M153 • Vehicle 4WD shift switch: 2WD to

stopped 4H or 4H to 4LO or 2WD to 0V
• Engine run- 4LO
ning
42 -
• A/T selector
Ground
lever “N” po- Battery
sition Except the above
voltage
• Brake pedal
depressed
4WD shift switch: 2WD to Battery
47 - 4H or 4H to 4LO or 2WD to voltage →
Ground 4LO 0V
• Vehicle Except the above 0V
stopped
• Engine run- 4WD shift switch: 4LO to Battery
48 - ning 4H or 4H to 2WD or 4LO to voltage →
M153 Ground • A/T selector 2WD 0V
lever “N” po- Except the above 0V
sition
• Brake pedal 4WD shift switch: 4LO to
depressed 4H or 4H to 2WD or 4LO to 0V
50 - 2WD
Ground
Battery
Except the above
voltage

YES >> GO TO 9. A
NO >> GO TO 2.
2.CHECK ACTUATOR MOTOR POWER SUPPLY CIRCUIT
B
terminal 27 and ground. C

DLN
M153 27 - Ground 0V
RCH@17/ 7D
F
terminal 27 and ground. G

H

YES >> GO TO 3. I
NO >> 1. Check harness for short or open between transfer
control unit harness connector M153 terminal 27 RCH@17/ 6D
and transfer shut off relay 2 harness connector

E157 terminal 5 and 10A fuse (No. 57, located in the fuse and relay block). If any items are J
damaged, repair or replace damaged parts.
2. Perform trouble diagnosis for power supply circuit. Refer to DLN-20, "Diagnosis Procedure".
3.CHECK TRANSFER RELAY POWER SUPPLY CIRCUIT K
2. Remove transfer shift high relay and transfer shift low relay. Refer to DLN-12, "Component Parts Loca-
tion". L
M
E46 2 - Ground 0V
N
E47 2 - Ground 0V
O
RCH@2273D


E46 2 - Ground Battery voltage
E47 2 - Ground Battery voltage
YES >> GO TO 4.
NO >> Check the following. If any items are damaged, repair RCH@2274D
or replace damaged parts.

• Harness for short or open between transfer control unit harness connector terminal 27 and
transfer shift high relay harness connector E46 terminal 2.
• Harness for short or open between transfer control unit harness connector terminal 27 and
transfer shift low relay harness connector terminal E47 terminal 2.
4.CHECK TRANSFER RELAY
2. Remove transfer shift high relay and transfer shift low relay.
3. Apply 12V direct current between transfer shift high and low
relay terminals 1 and 2.
4. Check continuity between relay terminals 3 and 4, 3 and 5.

12V direct current supply between terminals 1 and 2 No
3-4
OFF Yes
3-5
OFF No
KCH@/ / 88D
YES >> GO TO 5.
NO >> Replace the transfer shift high or low relay.
5.CHECK (1): HARNESS BETWEEN TRANSFER CONTROL UNIT AND TRANSFER SHIFT RELAY
transfer shift low relay harness connector E47 terminal 1.

YES >> GO TO 6. RCH@2275D
6.CHECK (2): HARNESS BETWEEN TRANSFER CONTROL UNIT AND TRANSFER SHIFT RELAY

- Transfer control unit harness connector M153 terminal 28 and A
transfer shift low relay harness connector E47 terminal 5.
B
transfer shift low relay harness connector E47 terminal 4. C
Continuity should exist. RCH@2276D
Also check harness for short to ground and short to power. DLN
YES >> GO TO 7.
NO >> Repair or replace damaged parts. E
7.CHECK ACTUATOR MOTOR OPERATION CIRCUIT

1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.) F
2. Disconnect transfer control unit harness connector and the transfer control device (actuator motor) har-
ness connector.
- Transfer control unit harness connector M153 terminal 47 and G
transfer control device (actuator motor) harness connector F58
terminal 23.
- Transfer control unit harness connector M153 terminal 48 and H
transfer control device (actuator motor) harness connector F58
terminal 24.
I
J
RCH@1700D
- Transfer control device (actuator motor) harness connector F58

terminal 24 and transfer shift high relay harness connector E46 K
terminal 3.
- Transfer control device (actuator motor) harness connector F58
terminal 23 and transfer shift low relay harness connector E47 L
terminal 3.
Continuity should exist. M

RCH@2283D
YES >> GO TO 8. N
8.CHECK ACTUATOR MOTOR
O
1. Remove transfer control device. Refer to DLN-96, "Removal and Installation".

2. Check operation by applying battery voltage to transfer control
device (actuator motor) terminals 23 and 24.
CAUTION:
Be careful not to overheat the harness.
Terminal Actuator motor

24 (Battery voltage) - 23 (Ground) Clockwise rotate
23 (Battery voltage) - 24 (Ground) Counterclockwise rotate
Does actuator motor rotate?
YES >> GO TO 9. RCH@1275D
NO >> Replace transfer control device (actuator motor).

YES >> GO TO 10.
10.CHECK DTC
Perform the self-diagnosis, after driving a vehicle for a while.
ACUTATOR MOTOR
1. Remove transfer control device. Refer to DLN-96, "Removal and Installation".
2. Check operation by applying battery voltage to transfer control
device (actuator motor) terminals 23 and 24.
CAUTION:
Be careful not to overheat the harness.
Terminal Actuator motor

24 (Battery voltage) - 23 (Ground) Clockwise rotate
23 (Battery voltage) - 24 (Ground) Counterclockwise rotate
3. If the inspection results are abnormal replace the transfer control
device (actuator motor). RCH@1275D
TRANSFER RELAY
2. Remove transfer shift high relay and transfer shift low relay 2. Refer to DLN-12, "Component Parts Loca-
tion".
3. Apply 12V direct current between transfer shift high and low relay terminals 1 and 2.

4. Check continuity between relay terminals 3 and 4, and 3 and 5.
A
12V direct current supply between terminals 1 and 2 No
3-4 B
OFF Yes
3-5
OFF No C
5. If the inspection results are abnormal replace the transfer shift
high or low relay. KCH@/ / 88D
DLN

P1818 ACTUATOR POSITION SWITCH
The actuator position switch detects the current actuator motor range. DTC P1818 will set if either of the fol-
lowing occur:
• Improper signal from actuator position switch is input due to open or short circuit.
• Malfunction is detected in actuator position switch.
DTC DETECTION LOGIC

• Improper signal from actuator position
switch is input due to open or short cir-
[P1818] SHIFT ACT POSI SW cuit. DLN-46
• Malfunction is detected in actuator po-
sition switch.

1.CHECK ACTUATOR POSITION SWITCH SIGNAL

With CONSULT-III
1. Start engine.
5. Read out the value of “SHIFT POS SW1”, “SHIFT POS SW2”, “SHIFT POS SW3”, “SHIFT POS SW4”.
Monitored item Condition Display value

4WD shift switch: 2WD and 4LO ON
SHIFT POS SW1
4WD shift switch: 4H OFF
4WD shift switch: 4LO ON
SHIFT POS SW2
4WD shift switch: 2WD and 4H OFF
4WD shift switch: 2WD and 4H ON
SHIFT POS SW3
4WD shift switch: 4LO OFF
4WD shift switch: 4H and 4LO ON
SHIFT POS SW4
4WD shift switch: 2WD OFF
Without CONSULT-III
1. Start engine.

terminal and ground. A
Voltage
(Approx.) B
10 -
Ground Battery
4WD shift switch: 4H
voltage C
4WD shift switch: 4LO 0V
11 -
Ground Battery RCH@2258D
4WD shift switch: 2WD and 4H DLN
voltage
M152
12 -
Ground Battery
4WD shift switch: 4LO E
voltage
13 -
Ground Battery
4WD shift switch: 2WD
voltage
F

YES >> GO TO 4. G
NO >> GO TO 2.
2.CHECK HARNESS BETWEEN TRANSFER CONTROL UNIT AND ACTUATOR POSITION SWITCH
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.) H
2. Disconnect transfer control unit harness connector and the transfer control device (actuator position
switch) harness connector.
3. Check continuity between the following terminals. I
transfer control device (actuator position switch) harness con-
nector F58 terminal 26.
- Transfer control unit harness connector M152 terminal 11 and J
- Transfer control unit harness connector M152 terminal 12 and K
RCH@226/ D L
Continuity should exist. M

N
YES >> GO TO 3.
3.CHECK GROUND CIRCUIT O

2. Check continuity between transfer control device (actuator posi-
tion switch) harness connector F58 terminal 22 and ground.

YES >> GO TO 4.
nectors.
RCH@1704D

YES >> GO TO 5.
5.CHECK DTC
YES >> Replace transfer control device. Refer to DLN-96, "Removal and Installation".

P1819 TRANSFER CONTROL DEVICE
A
The transfer control device integrates the actuator motor and actuator position switch. DTC P1819 will set if B
either of the following conditions exist:
• Malfunction occurs in transfer control device drive circuit.
• Malfunction is detected in transfer shut off relay 1 and transfer shut off relay 2.
C
DTC DETECTION LOGIC DLN

• Malfunction is detected in transfer E
shut off relay 1 and transfer shut off re-
[P1819] SHIFT ACT CIR lay 2. DLN-49
• Malfunction occurs in transfer control
device drive circuit. F

1.DTC CONFIRMATION PROCEDURE G
Is DTC P1819 detected? H
I
1.CHECK POWER SUPPLY J

3. Check voltage between transfer control unit harness connector K
Connector Terminal Voltage (Approx.) L

M152 25 - Ground
0V
M153 27 - Ground
M
RCH@2260D N

terminals and ground. O

P
M152 25 - Ground
Battery voltage
M153 27 - Ground
YES >> GO TO 2.
NO >> Check the following. If any items are damaged, repair RCH@2261D
or replace damaged parts.

• 10A fuse (No. 57, located in the fuse and relay box).
• 40A fuse (No. J, located in the fuse and fusible link box).
terminal 3.
• Harness for short or open between transfer control unit harness connector M153 terminal 27
and transfer shut off relay 1 harness connector E156 terminal 5.
• Harness for short or open between ignition switch and transfer shut off relay 1 harness connec-
tor E156 terminal 1.
and ground.
• Harness for short or open between ignition switch and transfer control unit harness connector
M152 terminal 25.
• Battery and ignition switch.
• Transfer shut off relay 1. Refer to DLN-22, "Component Inspection".
1. Turn ignition switch "OFF".
tor M153 terminal 32 and ground.

YES >> GO TO 3.
nectors.
RCH@1707D
3.CHECK POWER SUPPLY SIGNAL

2. Connect transfer control unit harness connector.

RCH@1708D


M153 40 - Ground 0V
YES >> GO TO 4.
NO >> Check the following. If any items are damaged, repair
or replace damaged parts. RCH@171/ D
• Harness for short or open between battery and trans-

fer shut off relay 2 harness connector E157 terminal 1.
and transfer control unit harness connector M153 terminal 40.
• Transfer shut off relay 2.
4.CHECK TRANSFER CONTROL UNIT A

YES >> GO TO 5 (With CONSULT-III) or GO TO 6 (Without CONSULT-III). B
5.PERFORM SELF-DIAGNOSIS (WITH CONSULT-III) C
With CONSULT-III
1. Turn ignition switch “ON”. (Do not start engine.) DLN
2. Select “SELF-DIAG RESULTS” mode for “ALL MODE AWD/4WD” with CONSULT-III.
3. Touch “ERASE”.
4. Turn ignition switch “OFF” and wait at least 10 seconds.
E
Is the “SHIFT ACT CIR [P1819]” displayed?
F
6.PERFORM SELF-DIAGNOSIS (WITHOUT CONSULT-III)
G
Without CONSULT-III
1. Perform the self-diagnosis and then erase self-diagnostic results. Refer to DLN-16, "CONSULT-III Func-
tion (ALL MODE AWD/4WD)".
H
Do the self-diagnostic results indicate transfer control device?
YES >> Replace transfer control unit. Refer to DLN-91, "Removal and Installation". I

P1820 ENGINE SPEED SIGNAL
P1820 ENGINE SPEED SIGNAL
The ECM transmits the engine speed signal via CAN communication to the transfer control unit. DTC P1820
will set when either of the following occur:
• Malfunction is detected in engine speed signal that is output from the ECM.
DTC DETECTION LOGIC

• Malfunction is detected in engine
speed signal that is output from ECM
[P1820] ENGINE SPEED SIG DLN-52
through CAN communication.

1.CHECK DTC WITH ECM

Perform self-diagnosis with ECM. Refer to EC-67, "CONSULT-III Function (ENGINE)".
NO >> GO TO 2.
YES >> GO TO 3.
3.CHECK DTC
YES >> Perform self-diagnosis with ECM again.

< ECU DIAGNOSIS > [TRANSFER: TX15B]
ECU DIAGNOSIS A
Reference Value INFOID:0000000004095568
B
VALUE ON THE DIAGNOSIS TOOL

CONSULT-III data monitor item C
Monitored item [Unit] Content Condition Display value

Vehicle stopped 0 km/h (0 mph) DLN
VHCL/S SEN·FR [km/h] Vehicle running Approximately

Wheel speed (Front wheel) CAUTION: equal to the indica-
or [mph]
Check air pressure of tire under standard condition on speedome- E
tion. ter (Inside of ±10%)
Vehicle stopped 0 km/h (0 mph)
VHCL/S SEN·RR [km/h] Vehicle running Approximately F

Wheel speed (Rear wheel) CAUTION: equal to the indica-
or [mph]
Check air pressure of tire under standard condition on speedome-
G
Engine stopped
0 rpm
(Engine speed: Less than 400 rpm)
ENGINE SPEED [rpm] Engine speed Approximately
Engine running H
equal to the indica-
(Engine speed: 400 rpm or more)
tion on tachometer
Power supply voltage for
BATTERY VOLT [V] Ignition switch: ON Battery voltage I
transfer control unit
Input condition from 4WD 4WD shift switch: 2WD ON

2WD SWITCH [ON/OFF]
shift switch 4WD shift switch: 4H and 4LO OFF
J
Input condition from 4WD 4WD shift switch: 4H ON
4H SWITCH [ON/OFF]
shift switch 4WD shift switch: 2WD and 4LO OFF
Input condition from 4WD 4WD shift switch: 4LO ON K

4L SWITCH [ON/OFF]
shift switch 4WD shift switch: 2WD and 4H OFF
• Vehicle stopped 4WD shift switch: 4LO ON
• Engine running L
4L POSI SW [ON/OFF] Condition of 4LO switch • A/T selector lever “N”
position Except the above OFF
M
• Engine running : 4H to 4LO or 4LO to 4H
ON
ATP SWITCH [ON/OFF] Condition of ATP switch • A/T selector lever “N” (While actuator motor is
position operating.) N
• Brake pedal depressed Except the above OFF
ON O
• Engine running : 4H and 4LO
WAIT DETCT SW [ON/ Condition of wait detection
• A/T selector lever “N”
OFF] switch
position 4WD shift switch: 2WD OFF
P
Control status of 4WD 2WD 2H
(Output condition of 4WD 4WD shift switch
4WD MODE [2H/4H/4L] 4H 4H
shift indicator lamp and (Engine running)
4LO indicator lamp) 4LO 4L

Monitored item [Unit] Content Condition Display value
Vehicle stopped 0 km/h (0 mph)
VHCL/S COMP [km/h] or Vehicle running Approximately

Vehicle speed CAUTION: equal to the indica-
[mph]
Check air pressure of tire under standard condition on speedome-
• Engine running : 2WD to 4H or 4H to 4LO ON
Output condition to actua-
SHIFT ACT 1 [ON/OFF] • A/T selector lever “N” or 2WD to 4LO
tor motor (clockwise)
position

• Engine running : 2WD to 4H or 4H to 4LO ON
SHIFT AC MON1 [ON/ Check signal for transfer
• A/T selector lever “N” or 2WD to 4LO
OFF] control unit signal output
position

Output condition to actua- • Engine running : 4LO to 4H or 4H to 2WD ON
SHIFT ACT 2 [ON/OFF] tor motor (counterclock- • A/T selector lever “N” or 4LO to 2WD
wise) position

• Engine running : 4LO to 4H or 4H to 2WD ON
SHIFT AC MON2 [ON/ Check signal for transfer
• A/T selector lever “N” or 4LO to 2WD
OFF] control unit signal output
position
• Vehicle stopped When 4WD shift switch is

ON
Operating condition of ac- • Engine running operated
SHIFT ACT/R MON [ON/
tuator motor relay (integrat- • A/T selector lever “N”
OFF] When 4WD shift switch is
ed in transfer control unit) position OFF
• Brake pedal depressed not operated
4WD shift switch: 2WD

SHIFT POS SW1 [ON/ Condition of actuator posi- ON
and 4LO
OFF] tion switch 1
4WD shift switch: 4H OFF
4WD shift switch: 4LO ON
SHIFT POS SW2 [ON/ Condition of actuator posi-
• Vehicle stopped 4WD shift switch: 2WD
OFF] tion switch 2 OFF
• Engine running and 4H
• A/T selector lever “N”
position 4WD shift switch: 2WD
• Brake pedal depressed and 4H
OFF] tion switch 3
4WD shift switch: 4LO OFF
4WD shift switch: 4H and
4LO
OFF] tion switch 4
4WD shift switch: 2WD OFF
4WD FAIL LAMP [ON/ 4WD warning lamp condi- 4WD warning lamp: ON ON
OFF] tion 4WD warning lamp: OFF OFF
Rear indicator of 4WD shift Rear indicator of 4WD shift indicator lamp: ON ON
2WD IND [ON/OFF]
indicator lamp condition Rear indicator of 4WD shift indicator lamp: OFF OFF
Front and center indicator of 4WD shift indicator lamp
Front and center indicator ON
: ON
4H IND [ON/OFF] of 4WD shift indicator lamp
condition Front and center indicator of 4WD shift indicator lamp
OFF
: OFF
4LO indicator lamp condi- 4LO indicator lamp: ON ON

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

Terminal Layout
A
V CH@/ 15/ D
DLN
Wire
Terminal Item Condition Data (Approx.)
color
1 L CAN-H – –
E
2 P CAN-L – –
3 SB K-LINE (CONSULT-III signal) – –
6 B Ground Always 0V F
10 LG Actuator position switch 1
• Vehicle stopped
G
4WD shift switch: 4LO 0V
11 W Actuator position switch 2 • Engine running
• A/T selector le- 4WD shift switch: 2WD and 4H Battery voltage
ver “N” position 4WD shift switch: 2WD and 4H 0V H
12 BR Actuator position switch 3 • Brake pedal de-
pressed 4WD shift switch: 4LO Battery voltage
13 L Actuator position switch 4 I
14 G 4WD shift switch (2WD)
4WD shift switch: 4H and 4LO 0V J
15 O 4WD shift switch (4H) Ignition switch: ON
4WD shift switch: 4LO Battery voltage K
16 W 4WD shift switch (4LO)
• Vehicle stopped 4WD shift switch: 4H and 4LO 0V L
• Engine running
• A/T selector le-
17 O Wait detection switch
ver “N” position 4WD shift switch: 2WD Battery voltage
• Brake pedal de- M
pressed
18 B Ground Always 0V
Power supply Ignition switch: ON Battery voltage N

19 R
(Memory back-up) Ignition switch: OFF Battery voltage
• Engine running : 4H to 4LO or 4LO to 4H 0V O
• A/T selector le- (While actuator motor is operating.)
23 R ATP switch
ver “N”
• Brake pedal de- Except the above Battery voltage
pressed P
• Vehicle stopped 4WD shift switch: 4LO 0V
• Engine running
24 Y 4LO switch
ver “N” position Except the above Battery voltage
• Brake pedal de-
pressed

Wire
color
Ignition switch: ON Battery voltage
25 W/G Ignition switch monitor
Ignition switch: OFF 0V
27 L Actuator motor power supply Ignition switch: OFF (5 seconds after ingnition switch is turned
0V
OFF)
• Vehicle stopped When 4WD shift switch is operated (while Battery voltage
28 SB Actuator motor (+)
• Engine running actuator motor is operating) → 0V
When 4WD shift switch is not operated 0V
ver “N” position
31 G Actuator motor (-) • Brake pedal de-
Always 0V
pressed
32 B Ground Always 0V
Park/Neutral position switch M/T shift lever neutral position 0V

33 P Ignition switch:ON
(M/T models) Except the above Battery voltage
Rear indicator of 4WD shift indicator lamp
0V
4WD shift indicator lamp : ON
35 V
(Rear indicator) Rear indicator of 4WD shift indicator lamp
Battery voltage
: OFF
Front and center indicator of 4WD shift in-
0V
4WD shift indicator lamp dicator lamp: ON
36 BR
(Front and center indicator) Engine running Front and center indicator of 4WD shift in-
Battery voltage
dicator lamp: OFF
4LO indicator lamp: ON 0V
37 O 4LO indicator lamp
4LO indicator lamp: OFF Battery voltage
4WD warning lamp: ON 0V
38 GR 4WD warning lamp
4WD warning lamp: OFF Battery voltage
• Vehicle stopped 4WD shift switch: 4H to 4LO or 4LO to 4H
Battery voltage
• Engine running (While actuator motor is operating.)
39 LG ATP warning lamp
ver “P” position
• Brake pedal de- Except the above 0V
pressed
Ignition switch: ON 0V
40 V Transfer shut off relay Ignition switch: OFF (5 seconds after ingnition switch is turned
Battery voltage
OFF)
• Vehicle stopped 4WD shift switch: 2WD to 4H or 4H to 4LO
0V
• Engine running or 2WD to 4LO
42 LG Transfer shift high relay
ver “N” position
• Brake pedal de- Except the above Battery voltage
pressed
44 Y Power supply Ignition switch: OFF (5 seconds after ingnition switch is turned
0V
OFF)
45 GR Power supply Ignition switch: OFF (5 seconds after ingnition switch is turned
0V
OFF)

Wire
color A
4WD shift switch: 2WD to 4H or 4H to 4LO
Battery voltage
Transfer shift high relay moni- or 2WD to 4LO (while actuator motor is op-
47 O → 0V
tor erating) B
• Vehicle stopped Except the above 0V
• Engine running 4WD shift switch: 4LO to 4H or 4H to 2WD
• A/T selector le- Battery voltage
Transfer shift low relay moni- or 4LO to 2WD (while actuator motor is op-
→ 0V C
48 R ver “N” position erating)
tor
• Brake pedal de-
pressed Except the above 0V
4WD shift switch: 4LO to 4H or 4H to 2WD DLN
0V
50 Y Transfer shift low relay or 4LO to 2WD
Except the above Battery voltage
CAUTION: E
When using a circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals.
NOTE:
Data are reference value and are measured between each terminal and ground. F

Wiring Diagram INFOID:0000000004095569
@ACV @/ / 50F A

DLN
@ACV @/ / 51F A

@ACV @/ / 52F A

DLN
@ACH@/ 044F A

@ACH@/ 045F A

DLN
@ACH@/ 046F A

@ACH@/ 047F A

DLN
@ACH@/ 048F A

@ACH@/ 05/ F A
DTC Index INFOID:0000000004095570
DTC CHART

DTC CONSULT-III Diagnostic item is detected when... Reference A

Due to removal of battery which cuts off power sup-
[P1801] *INITIAL START* ply to transfer control unit, self-diagnosis memory DLN-20
function is suspended.
B
Malfunction is detected in the memory (RAM) sys-
[P1802]
tem of transfer control unit.
Malfunction is detected in the memory (ROM) sys- C
[P1803] CONTROL UNIT (1,2,3) DLN-23
tem of transfer control unit.
Malfunction is detected in the memory (EEPROM)
[P1804]
system of transfer control unit.
DLN
• Malfunction is detected in output shaft revolution
signal that is output from TCM through CAN
[P1807] VHCL SPEED SEN·AT DLN-25
communication.
• Improper signal is input while driving. E
• Malfunction is detected in vehicle speed signal
that is output from ABS actuator and electric unit
[P1808] VHCL SPEED SEN·ABS DLN-26
(control unit) through CAN communication. F
AD converter system of transfer control unit is mal-
[P1809] CONTROL UNIT 4 DLN-23
functioning.
G
Improper signal from 4LO switch is input due to
[P1810] 4L POSI SW TF DLN-27
open or short circuit.
Power supply voltage for transfer control unit is ab- H
[P1811] BATTERY VOLTAGE DLN-20
normally low while driving.
More than two switch inputs are simultaneously de-
[P1813] 4WD MODE SW DLN-30
tected due to short circuit of 4WD shift switch.
I
Improper signal from wait detection switch is input
[P1814] 4WD DETECT SWITCH DLN-33
due to open or short circuit.
DLN-36 (A/T models), DLN-37 (M/T mod-
[P1816] PNP SW/CIRC When PNP switch signal is malfunctioning. J
els)
• Motor does not operate properly due to open or
short circuit in actuator motor.
• Malfunction is detected in the actuator motor. K
[P1817] SHIFT ACTUATOR (When 4WD shift switch is operated and actuator DLN-39
motor is not operated)
• Malfunction is detected in transfer shift high relay
or transfer shift low relay.
L
• Improper signal from actuator position switch is
input due to open or short circuit.
[P1818] SHIFT ACT POSI SW DLN-46
• Malfunction is detected in actuator position M
switch.
• Malfunction is detected in transfer shut off relay
1 and transfer shut off relay 2. N
[P1819] SHIFT ACT CIR DLN-49
• Malfunction occurs in transfer control device
drive circuit.
• Malfunction is detected in engine speed signal
that is output from ECM through CAN communi- O
[P1820] ENGINE SPEED SIG DLN-52
cation.
NOTE: P
If “SHIFT ACT POSI SW [P1818]” or “SHIFT ACT CIR [P1819]” is displayed, first erase self-diagnostic results. (“SHIFT ACT POSI SW
[P1818]” or “SHIFT ACT CIR [P1819]” may be displayed after installing transfer control unit or transfer assembly.)
FLASH CODE CHART

Flashing pattern Item Diagnostic item is detected when... Reference

• Malfunction is detected in output shaft revo-
Output shaft revolution lution signal that is output from TCM through
2 DLN-25
signal (from TCM) CAN communication.
• Malfunction is detected in vehicle speed sig-
nal that is output from ABS actuator and
Vehicle speed signal
3 electric unit (control unit) through CAN com- DLN-26
(from ABS)
munication.
Malfunction has been detected from CAN
4 CAN communication DLN-13
communication.
AD converter system of transfer control unit is
5 AD converter DLN-23
malfunctioning.
Improper signal from 4LO switch is input due
6 4LO switch DLN-27
to open or short circuit.
• Malfunction is detected in engine speed sig-
nal that is output from ECM through CAN
7 Engine speed signal DLN-52
communication.
Power supply voltage for transfer control unit is
8 Power supply DLN-20
abnormally low while driving.
More than two switch inputs are simultaneous-
9 4WD shift switch ly detected due to short circuit of 4WD shift DLN-30
switch.
Improper signal from wait detection switch is
10 Wait detection switch DLN-33
input due to open or short circuit.
• Motor does not operate properly due to open
or short circuit in actuator motor.
• Malfunction is detected in the actuator mo-
11 Actuator motor tor. (When 4WD shift switch is operated and DLN-39
actuator motor is not operated.)
• Malfunction is detected in transfer shift high
relay or transfer shift low relay.
• Improper signal from actuator position
Actuator position switch is input due to open or short circuit.
12 DLN-46
switch • Malfunction is detected in the actuator posi-
tion switch.
• Malfunction is detected in transfer shut off
relay 1 and transfer shut off 2.
13 Transfer control device DLN-49
• Malfunction occurs in transfer control device
drive circuit.
DLN-36 (A/T models), DLN-37 (M/T
14 PNP switch signal When PNP switch signal is malfunctioning.
models)
• Power supply failure of memory back-up.
Repeats flickering
Data erase display • Battery is disconnected for a long time. DLN-20
every 0.25 sec.
• Battery performance is poor.
Repeats flickering Circuits that the self-diagnosis covers have no
— —
every 2 to 5 sec. malfunction.
PNP switch or 4WD PNP switch or 4WD shift switch circuit is short-
No flickering DLN-36 or DLN-30
shift switch ed or open.
NOTE:
If actuator position switch” or transfer control device” is displayed, first erase self-diagnostic results. (They may be displayed after install-
ing transfer control unit or transfer assembly.)

4WD SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [TRANSFER: TX15B]
SYMPTOM DIAGNOSIS A
4WD SYSTEM SYMPTOMS
Symptom Table INFOID:0000000004095571
B
Symptom Condition Reference page

C
4WD shift indicator lamp and 4LO indicator lamp do not turn ON (lamp check) DLN-72
Ignition switch: ON
4WD warning lamp does not turn ON (lamp check) DLN-70
4WD shift indicator lamp or 4LO indicator lamp does not change DLN-74 DLN
ATP warning lamp does not turn ON Engine running DLN-76
ATP switch is malfunctioning DLN-80
E
4WD shift indicator lamp repeats flashing DLN-78
While driving
4WD warning lamp flashes slowly (1 time/2 seconds) DLN-79

4WD WARNING LAMP DOES NOT TURN ON
4WD warning lamp does not turn ON when turning ignition switch to ON.
1.CHECK TRANSFER CONTROL UNIT POWER SUPPLY AND GROUND CIRCUITS

Refer to DLN-20, "Diagnosis Procedure".
YES >> GO TO 2.
NO >> Perform repairs as necessary.
2.CHECK COMBINATION METER POWER SUPPLY CIRCUIT
2. Disconnect combination meter harness connector.
3. Check voltage between combination meter harness connector

M24 16 - Ground 0V
V CH@/ 067D


YES >> GO TO 3.
or replace damaged parts. V CH@/ 068D
• 10A fuse [No. 14, located in the fuse block (J/B)] or

ignition switch.
• Harness for short or open between ignition switch and combination meter harness connector
terminal 16
3.CHECK HARNESS BETWEEN TRANSFER CONTROL UNIT AND COMBINATION METER
tor M153 terminal 38 and combination meter harness connector
M24 terminal 26.

YES >> GO TO 4.
V CH@/ 163D

4.CHECK INDICATOR LAMP CIRCUIT A

2. Connect combination meter harness connector.
B
4. Turn ignition switch "ON". (Do not start engine.)
5. Ground the following terminal using suitable wiring.
ground. C
Does the indicator lamp turn on?
YES >> GO TO 5.
NO >> Replace the combination meter. Refer to MWI-90, DLN
"Removal and Installation".
E
RCH@2341D
5.SYMPTOM CHECK F
Check again.
Does the symptom still occur?
YES >> GO TO 6. G
H
YES >> Inspection End. I
J

4WD SHIFT INDICATOR LAMP AND 4LO INDICATOR LAMP DO NOT TURN ON
4WD SHIFT INDICATOR LAMP AND 4LO INDICATOR LAMP DO NOT
TURN ON
4WD shift indicator lamp and 4LO indicator lamp do not turn ON for approx. 1 second when turning ignition
switch to ON.
1.CHECK TRANSFER CONTROL UNIT POWER SUPPLY AND GROUND CIRCUITS

Refer to DLN-20, "Diagnosis Procedure".
YES >> GO TO 2.
NO >> Perform repairs as necessary.
2.CHECK COMBINATION METER POWER SUPPLY CIRCUIT
2. Disconnect combination meter harness connector.

M24 16 - Ground 0V
V CH@/ 067D


YES >> GO TO 3.
or replace damaged parts. V CH@/ 068D
• 10A fuse [No. 14, located in the fuse block (J/B)] or

ignition switch.
• Harness for short or open between ignition switch and combination meter harness connector
terminal 16

4WD SHIFT INDICATOR LAMP AND 4LO INDICATOR LAMP DO NOT TURN ON
- Transfer control unit harness connector M153 terminal 35 and A
combination meter harness connector M24 terminal 30.
B
Continuity should exist. C

RCH@1712D
Does continuity exist?
DLN
YES >> GO TO 4.
4.CHECK INDICATOR LAMP CIRCUIT E
2. Connect combination meter harness connector.
3. Disconnect transfer control unit harness connector. F
4. Turn ignition switch "ON". (Do not start engine.)
5. Ground the following terminals using suitable wiring.
ground. G
ground.
- Transfer control unit harness connector M153 terminal 37 and H
ground.
Do indicator lamps turn on?
YES >> GO TO 5. I
NO >> Replace the combination meter. Refer to MWI-90,
"Removal and Installation". RCH@2340D
5.SYMPTOM CHECK J
Check again.
K
YES >> GO TO 6.
6.CHECK TRANSFER CONTROL UNIT L
YES >> Inspection End. M
N

4WD SHIFT INDICATOR LAMP OR 4LO INDICATOR LAMP DO NOT CHANGE
4WD SHIFT INDICATOR LAMP OR 4LO INDICATOR LAMP DO NOT
CHANGE
4WD shift indicator lamp or 4LO indicator lamp do not change when switching the 4WD shift switch.
1.CONFIRM THE SYMPTOM

Confirm 4WD shift indicator lamp and 4LO indicator lamp when ignition switch is turned to ON.
Do 4WD shift indicator lamp and 4LO indicator lamp turn on?
YES >> GO TO 2.
NO >> Go to DLN-72, "Diagnosis Procedure".
2.CHECK SYSTEM FOR 4WD SHIFT SWITCH
Perform trouble diagnosis for 4WD shift switch system. Refer to DLN-30, "Diagnosis Procedure".
YES >> GO TO 3.
3.CHECK SYSTEM FOR WAIT DETECTION SWITCH
Perform trouble diagnosis for wait detection switch system. Refer to DLN-33, "Diagnosis Procedure".
YES >> GO TO 4.
4.CHECK SYSTEM FOR 4LO SWITCH
Perform trouble diagnosis for 4LO switch system. Refer to DLN-27, "Diagnosis Procedure".
YES >> GO TO 5.
5.CHECK SYSTEM FOR ATP SWITCH
Perform trouble diagnosis for ATP switch system. Refer to DLN-80, "Diagnosis Procedure".
YES >> GO TO 6.
6.SYMPTOM CHECK
Check again.
YES >> GO TO 7.
NO >> Inspection End
YES >> GO TO 8.
8.CHECK TRANSFER INNER PARTS
1. Disassemble transfer assembly. Refer to DLN-102, "Disassembly and Assembly".
2. Check transfer inner parts.

4WD SHIFT INDICATOR LAMP OR 4LO INDICATOR LAMP DO NOT CHANGE
NO >> Repair or replace damaged parts. A
DLN

ATP WARNING LAMP DOES NOT TURN ON
ATP warning lamp does not turn ON when the transfer case is switched in or out of 4LO with the A/T selector
lever in N position.
1.CHECK SYSTEM FOR CAN COMMUNICATION LINE

Perform self-diagnosis. Refer to DLN-16, "CONSULT-III Function (ALL MODE AWD/4WD)".
Do the self-diagnostic results indicate CAN communication?
YES >> Perform trouble diagnosis for CAN communication line. Refer to LAN-52, "DTC Index".
NO >> GO TO 2.
2.CHECK SYSTEM FOR 4WD SHIFT SWITCH
Perform trouble diagnosis for 4WD shift switch system. Refer to DLN-30, "Diagnosis Procedure".
YES >> GO TO 3.
3.CHECK SYSTEM FOR PNP SWITCH SIGNAL
Perform trouble diagnosis for PNP switch signal system. Refer to DLN-36, "Diagnosis Procedure".
YES >> GO TO 4.
4.CHECK SYSTEM FOR ATP SWITCH
Perform trouble diagnosis for ATP switch system. Refer to DLN-80, "Diagnosis Procedure".
YES >> GO TO 5.
5.CHECK ATP WARNING LAMP CIRCUIT
1. Disconnect ATP switch harness connector.
3. Ground terminal 8 on ATP switch connector F55 using suitable
wiring.
Does ATP warning lamp turn on?
YES >> GO TO 9.
NO >> GO TO 6.
RCH@1721D

2. Disconnect transfer control unit harness connector and combination meter harness connector.

tor M153 terminal 39 and combination meter harness connector A
M24 terminal 21.
Continuity should exist. B

YES >> GO TO 7. C
RCH@1714D
7.CHECK HARNESS BETWEEN COMBINATION METER AND ATP SWITCH DLN

E
3. Check continuity between combination meter harness connector
M24 terminal 1 and ATP switch harness connector F55 terminal
8.
F
G
YES >> GO TO 8.
H
RCH@1722D
8.SYMPTOM CHECK
Check again. I
YES >> GO TO 9.
NO >> Inspection End. J
Check transfer control unit input/output signal. Refer to DLN-53, "Reference Value". K
YES >> GO TO 10.
NO >> Check transfer control unit pin terminals for damage or loose connection with harness connector. L
1. Disassemble transfer assembly. Refer to DLN-102, "Disassembly and Assembly". M
YES >> Inspection End. N

4WD SHIFT INDICATOR LAMP KEEPS FLASHING
4WD SHIFT INDICATOR LAMP KEEPS FLASHING
The 4WD shift indicator lamp keeps flashing.

1.CONFIRM THE SYMPTOM

1. Set 4WD shift switch to “2WD”.
2. Drive the vehicle straight forward and backward keeping speed under 20 km/h (12 MPH).
Does 4WD shift indicator lamp keep flashing?
YES >> GO TO 2.
2.CHECK SYSTEM FOR WAIT DETECTION SWITCH
Perform trouble diagnosis for wait detection switch system. Refer to DLN-33, "Diagnosis Procedure".
YES >> GO TO 3.
3.CHECK SYSTEM FOR 4LO SWITCH
Perform trouble diagnosis for 4LO switch. Refer to DLN-27, "Diagnosis Procedure".
YES >> GO TO 4.
4.SYMPTOM CHECK
Check again.
YES >> GO TO 5.
YES >> GO TO 6.
1. Disassemble transfer assembly. Refer to DLN-102, "Disassembly and Assembly".

4WD WARNING LAMP FLASHES SLOWLY
4WD WARNING LAMP FLASHES SLOWLY
A
The 4WD warning lamp flashes slowly while driving (1 time / 2 seconds). The lamp continues to flash until the B
ignition switch is turned OFF.
C
1.CHECK TIRES
Check the following. Refer to WT-50, "Tire".
• Tire size DLN
• Tire wear
• Tire pressure
Are the inspection results normal? E
YES >> GO TO 2.
2.SYMPTOM CHECK F
Check again.
G
YES >> GO TO 3.
3.CHECK TRANSFER CONTROL UNIT H
YES >> Inspection End. I
J

ATP SWITCH
ATP SWITCH
The ATP indicator does not come on when the transfer is in neutral and the A/T lever is in neutral or, the ATP
indicator stays on when the transfer case is not in neutral.
DIAGNOSTIC PROCEDURE
1.CHECK ATP SWITCH SIGNAL
With CONSULT-III
1. Start engine.
3. Read out the value of “ATP SWITCH”.
Condition Display value

• Vehicle stopped 4WD shift switch: 4H to 4LO or 4LO to 4H
ON
• Engine running (While actuator motor is operating.)
• A/T selector lever
“N” position
• Brake pedal de- Except the above OFF
pressed
Without CONSULT-III
1. Start engine.
Voltage
(Approx.)
• Vehicle stopped 4WD shift switch: 4H

• Engine running to 4LO or 4LO to 4H
0V
23 - • A/T selector lever (While actuator motor
M152 is operating.)
Ground “N” position
• Brake pedal de- Battery
pressed Except the above
voltage RCH@2264D

YES >> GO TO 5.
NO >> GO TO 2.
2.CHECK HARNESS BETWEEN TRANSFER CONTROL UNIT AND ATP SWITCH
2. Disconnect transfer control unit harness connector and the ATP switch harness connector.
tor M152 terminal 23 and ATP switch harness connector F55
terminal 8.

YES >> GO TO 3.
RCH@2265D

ATP SWITCH
3.CHECK GROUND CIRCUIT A

3. Check continuity between ATP switch harness connector F55
B
terminal 9 and ground.

C
YES >> GO TO 4. DLN
nectors.
RCH@1283D
E
4.CHECK ATP SWITCH
2. Remove ATP switch. Refer to DLN-12, "Component Parts Location". F
3. Push and release ATP switch and check continuity between ATP
switch terminals 8 and 9.
G
Push ATP switch Yes
8-9 H
Release ATP switch No
YES >> GO TO 5.
I
NO >> Replace ATP switch.
RCH@1284D

J
YES >> GO TO 6. K
6.CHECK ATP WARNING LAMP L
2. A/T selector lever “N” position and engage the parking brake.
3. Switch 4WD shift switch from 4H to 4LO or 4LO to 4H. M
Does the ATP warning lamp turn ON while the actuator motor is operating?
NO >> Refer to DLN-76, "Diagnosis Procedure". N
1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.) O

3. Remove ATP switch. Refer to DLN-12, "Component Parts Location".
P

ATP SWITCH
4. Push and release ATP switch and check continuity between ATP
switch terminals 8 and 9.

Push ATP switch Yes
8-9
Release ATP switch No
5. If the inspection results are abnormal replace the ATP switch.
RCH@1284D

PRECAUTIONS
< PRECAUTION > [TRANSFER: TX15B]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000004095587
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. DLN
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
WARNING: E
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
F
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this G
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
Precaution for Transfer Assembly and Transfer Control Unit Replacement INFOID:0000000004095588 H
When replacing transfer assembly or transfer control unit, check the 4WD shift indicator pattern and adjust-
ment of the position between transfer assembly and transfer control unit if necessary. I
CHECK 4WD SHIFT INDICATOR PATTERN
1. Set 4WD shift switch to “2WD”, “4H”, “4LO”, “4H” and “2WD” in order. Stay at each switch position for at
least 2 seconds. J
2. Confirm 4WD shift indicator lamp and 4LO indicator lamp change properly as follows.
RCH@2178D
• If OK, the position between transfer assembly and transfer control unit is correct. P
• If NG, the position is different between transfer assembly and transfer control unit.
Adjust the position between transfer assembly and transfer control unit. Refer to pattern table below.

PRECAUTIONS
Transfer position adjustment pattern
4WD shift switch condition Refer procedure
"METHOD FOR ADJUSTMENT WITH 4WD SHIFT
4WD shift switch is in “2WD” when engine is stopped.
SWITCH AT “2WD”"
"METHOD FOR ADJUSTMENT WITH 4WD SHIFT
4WD shift switch is in “4H” or “4LO” when engine is stopped.
SWITCH AT “4H” OR “4LO”"
NOTE:
Method of adjustment can be chosen voluntarily, according to location of 4WD shift switch.
METHOD FOR ADJUSTMENT WITH 4WD SHIFT SWITCH AT “2WD”

Select Adjustment Pattern
1. Start engine. Run engine for at least 10 seconds.
2. Check 4WD shift indicator lamp and 4LO indicator lamp.
Indicator lamp condition Refer procedure

When 4WD shift indicator lamp or 4LO indicator lamp is flashing. "Pattern A"
Except for above. "Pattern B"
Pattern A
1. Shift the transmission according to the directions below, and stay in "N" for at least 2 seconds.
• For A/T models, stop vehicle and move A/T selector lever to “N” position with brake pedal depressed.
• For M/T models, stop vehicle and move M/T shift lever to the neutral position with brake and clutch pedal
depressed.
2. Turn 4WD shift switch to “4LO” position. Stay in "4LO" for at least 2 seconds.
4. Start engine.
5. Erase self-diagnosis. Refer to DLN-16, "CONSULT-III Function (ALL MODE AWD/4WD)".
6. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to "CHECK 4WD SHIFT INDICATOR
PATTERN".
If 4WD shift indicator lamp and 4LO indicator lamp do not indicate proper pattern, install new transfer con-
trol unit and retry the above check.
Pattern B
depressed.
3. Start engine.
5. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to "CHECK 4WD SHIFT INDICATOR
PATTERN".
trol unit and retry the above check.
METHOD FOR ADJUSTMENT WITH 4WD SHIFT SWITCH AT “4H” OR “4LO”
1. Start engine. Run the engine for at least 10 seconds.
depressed.
3. Turn 4WD shift switch to “2WD” position. Stay in "2WD" for at least 2 seconds.
5. Start engine.

PRECAUTIONS
7. Check 4WD shift indicator lamp and 4LO indicator lamp again. Refer to "CHECK 4WD SHIFT INDICATOR A
PATTERN".
trol unit and retry the above check. B
Precaution INFOID:0000000004095589
• Before connecting or disconnecting the transfer control unit C

harness connector, turn ignition switch “OFF” and disconnect
the battery cables. Battery voltage is applied to transfer con-
trol unit even if ignition switch is turned “OFF”.
DLN
RDE178G F
• When connecting or disconnecting pin connectors into or

from transfer control unit, take care not to damage pin termi- G
nals (bend or break).
When connecting pin connectors make sure that there are not
any bends or breaks on transfer control unit pin terminals.
H
RDE180G
J
• Before replacing transfer control unit, perform transfer con-
trol unit input/output signal inspection and make sure transfer
control unit functions properly. Refer to DLN-53, "Reference K
Value".
M
L DE/ 3/ CA
Service Notice INFOID:0000000004095590

N
• After overhaul refill the transfer with new transfer fluid.
• Check the fluid level or replace the fluid only with the vehicle parked on level ground.
• During removal or installation, keep inside of transfer clear of dust or dirt. O
• Disassembly should be done in a clean work area.
• Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal
parts from becoming contaminated by dirt or other foreign matter. P
• Check for the correct installation status prior to removal or disassembly. If matchmarks are required, be cer-
tain they do not interfere with the function of the parts when applied.
• All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary.
• Gaskets, seals and O-rings should replaced any time the transfer is disassembled.

PRECAUTIONS
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tight-
ening sequence is specified, use it.
• Observe the specified torque when assembling.
• Clean and flush the parts sufficiently and blow-dry them.
• Be careful not to damage sliding surfaces and mating surfaces.
• Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
with the operation of the transfer.

PREPARATION
< PREPARATION > [TRANSFER: TX15B]
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000004095591
B
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.) C
Tool name
KV40104000 • Removing self-lock nut
( — ) • Installing self-lock nut DLN
Flange wrench a: 85 mm (3.35 in)
b: 65 mm (2.56 in)
MS548
ST33290001 • Removing front oil seal F

(J-34286) • Removing rear oil seal
Puller • Removing metal bushing
G
YY@/ 5/ 0C
H
KV38100500 • Installing front oil seal

( — ) • Installing rear oil seal
Drift • Installing rear bearing I
• Installing front bearing
a: 80 mm (3.15 in) dia.
b: 60 mm (2.36 in) dia.
J
YY@/ 700C
KV40105310 • Installing dust cover

K
( — ) a: 89 mm (3.50 in) dia.
Drift b: 80.7 mm (3.17 in) dia.
YY@0/ / 2C
M
KV38100200 • Removing sun gear assembly and planetary
( — ) carrier assembly
Drift • Removing input bearing
• Installing sun gear assembly and planetary N
carrier assembly
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
O
YY@0032C
ST30720000 • Installing input bearing

(J-25405) • Installing input oil seal P
Drift • Installing carrier bearing
a: 77 mm (3.03 in) dia.
b: 55 mm (2.17 in) dia.
YY@/ 700C

PREPARATION
(Kent-Moore No.)
Tool name
KV32102700 • Installing mainshaft rear bearing
( — ) a: 48 mm (1.89 in) dia.
Drift b: 41 mm (1.61 in) dia.
YY@/ 423C
KV40104830 • Installing input oil seal

( — ) a: 70 mm (2.76 in) dia.
YY@0/ / 2C
ST35300000 • Removing carrier bearing

( — ) • Installing metal bushing
Drift • Removing front bearing
a: 59 mm (2.32 in) dia.
b: 45 mm (1.77 in) dia.
MS/ 62
ST30021000 • Removing carrier bearing

(J-22912-01) • Removing front bearing
Puller • Removing rear bearing
YY@/ 426C
ST33710000 • Removing needle bearing

( — ) • Removing metal bushing
Drift • Removing rear bearing
a: 89 mm (3.5 in)
b: 30 mm (1.18 in) dia.
c: 24 mm (0.94 in) dia.
YY@0/ 46C
ST35325000 • Removing metal bushing

( — ) a: 215 mm (8.46 in)
Drift bar b: 25 mm (0.98 in) dia.
c: M12 × 1.5P
MS552
ST33220000 • Installing needle bearing

( — ) a: 37 mm (1.46 in) dia.
c: 22 mm (0.87 in) dia.
YY@0/ 35C

PREPARATION
(Kent-Moore No.) A
Tool name
ST27863000 • Installing carrier bearing
( — ) a: 75 mm (2.95 in) dia. B
YY@0/ / 2C
ST30901000 • Installing rear bearing DLN

(J-26010-01) • Installing front bearing
Drift a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.38 in) dia.
E
YY@/ 867C F
Commercial Service Tool INFOID:0000000004095592
Tool name Description

Puller • Removing companion flange H
• Removing mainshaft rear bearing
MS/ 66
J
Puller • Removing mainshaft rear bearing
L
YYA/ 712C
Pin punch • Removing retaining pin

a: 6 mm (0.24 in) dia. M
MS30/
Power tool • Loosening bolts and nuts O
OAHB/ 08/ D

TRANSFER FLUID
< ON-VEHICLE MAINTENANCE > [TRANSFER: TX15B]
ON-VEHICLE MAINTENANCE
TRANSFER FLUID
Replacement INFOID:0000000004095593
DRAINING
1. Stop engine.
2. Remove the drain plug and gasket. Drain the fluid.
3. Install the drain plug with a new gasket to the transfer. Tighten to
the specified torque. Refer to DLN-102, "Disassembly and
Assembly".
CAUTION:
Do not reuse gasket.
RCH@2175D
FILLING
1. Remove the filler plug and gasket.
2. Fill the transfer with new fluid until the fluid level reaches the
specified limit near the filler plug hole.
Fluid grade and capacity : Refer to MA-11, "Fluids

and Lubricants".
CAUTION:
Carefully fill fluid. (Fill up for approx. 3 minutes.)
3. Leave the vehicle for 3 minutes, and check fluid level again.
4. Install the filler plug with a new gasket to the transfer. Tighten to
the specified torque. Refer to DLN-102, "Disassembly and RCH@2176D
Assembly".
CAUTION:
Inspection INFOID:0000000004095594
FLUID LEAKAGE AND FLUID LEVEL

1. Make sure that fluid is not leaking from the transfer assembly or around it.
2. Check fluid level from the filler plug hole as shown.
CAUTION:
Do not start engine while checking fluid level.
3. Install the filler plug with a new gasket to the transfer. Tighten to
Assembly".
CAUTION:
RCH@2176D

< ON-VEHICLE REPAIR > [TRANSFER: TX15B]
ON-VEHICLE REPAIR A
Removal and Installation INFOID:0000000004095595
B
REMOVAL
1. Switch 4WD shift switch to 2WD and set transfer assembly to 2WD. C
CAUTION:
When removing transfer control unit, transfer state must be at 2WD.
2. Turn the ignition switch OFF and disconnect negative battery terminal. DLN
3. Remove the lower instrument panel LH. Refer to IP-10, "Exploded View".
4. Disconnect the two transfer control unit connectors.
5. Remove the transfer control unit bolts. E
6. Remove the transfer control unit.
KCH@/ 057D
H
INSTALLATION
Installation is in the reverse order of removal.
• When installing the transfer control unit, tighten bolts to the specified torque.
I
Transfer control unit bolts : 3.4 N·m (0.35 kg-m, 30 in-lb)
• After the installation, check 4WD shift indicator pattern. If NG, adjust position between transfer assembly and
transfer control unit. Refer to DLN-83, "Precaution for Transfer Assembly and Transfer Control Unit Replace- J
ment".

FRONT OIL SEAL
FRONT OIL SEAL
REMOVAL
1. Partially drain the transfer fluid. Refer to DLN-90, "Replacement".
2. Remove the front propeller shaft. Refer to DLN-130, "Removal and Installation".
3. Remove the companion flange self-lock nut, using Tool.
Tool number : KV40104000 ( — )
KCH@/ 031D
4. Put a matching mark on top of the front drive shaft in line with
the mark on the companion flange.
CAUTION:
Use paint to make the matching mark on the front drive
shaft. Do not damage the front drive shaft.
RCH@1668D
5. Remove the companion flange, using suitable tool.
V CH@/ 082D
6. Remove the front oil seal from the front case, using Tool.
Tool number : KV381054S0 (J-34286)

CAUTION:
Do not damage front case.
KCH@/ 033D
INSTALLATION

FRONT OIL SEAL
1. Install the new front oil seal until it is flush with the end face of
the front case, using Tool. A

CAUTION: B
• Do not reuse oil seal.
• Apply petroleum jelly to oil seal.
C
KCH@/ 034D
DLN
2. Align the matching mark of the front drive shaft with the match-
ing mark of the companion flange, then install the companion
flange.
E
G
RCH@1103D
3. Install the new self-lock nut and tighten to the specified torque,
H
using Tool. Refer to DLN-102, "Disassembly and Assembly".

I
CAUTION:
Do not reuse self-lock nut.
4. Install the front propeller shaft. Refer to DLN-130, "Removal and J
Installation".
5. Refill the transfer with fluid and check fluid level. Refer to DLN-
90, "Replacement". KCH@/ 036D
K
6. Check the transfer for fluid leakage. Refer to DLN-90, "Inspec-
tion".

REAR OIL SEAL
REAR OIL SEAL
REMOVAL
1. Partially drain the transfer fluid. Refer to DLN-90, "Replacement".
2. Remove the rear propeller shaft. Refer to DLN-138, "Removal and Installation".
3. Remove the dust cover from the rear case.
CAUTION:
Do not damage the rear case.
V CH@/ 016D
4. Remove the rear oil seal from the rear case using Tool.
CAUTION:
Do not damage the rear case.
Tool number : ST33290001 (J-34286)
KCH@/ 028D
INSTALLATION
1. Install the new rear oil seal until it is flush with the end face of the
rear case using Tool.

CAUTION:
KCH@/ 03/ D
2. Apply petroleum jelly to the circumference of the new dust cover.

Position the new dust cover as shown.
CAUTION:
• Do not reuse dust cover.
• Position the protrusions mark at the position shown.
• 1: Dust cover
• A: Protrusions
• 2: Rear case assembly
@V CH@/ 44/ F A

REAR OIL SEAL
3. Install the new dust cover to the rear case using Tool.
A
CAUTION:
• Do not reuse dust cover. B
• Apply petroleum jelly to dust cover.
4. Install the rear propeller shaft. Refer to DLN-138, "Removal and
Installation". C
5. Refill the transfer with fluid and check for fluid leakage and fluid
level. Refer to DLN-90, "Inspection". OCH@/ 005D
DLN

REMOVAL
1. Switch the 4WD shift switch to 2WD and set the transfer assembly to 2WD.
2. Disconnect the transfer control device connector.
3. Remove the breather hose from the transfer control device.
4. Remove the bolts and detach the transfer control device.
KCH@/ 025D
INSTALLATION
1. Install the new O-ring to the transfer control device.
CAUTION:
• Do not reuse O-ring.
• Apply petroleum jelly to O-ring.
RCH@2267D
2. Install the transfer control device.

a. Turn the control shift rod fully counterclockwise using suitable
tool, and then put a mark on the control shift rod.
OCH@/ 008D
b. Align the transfer control device shaft cutout with the mark on
the control shift rod, and install.
NOTE:
Turn the transfer control device when the transfer control device
connection does not match.
OCH@/ 01/ D

c. Tighten the bolts to the specified torque. Refer to DLN-102, "Dis-
assembly and Assembly". A
3. Install the breather hose to the transfer control device.
4. Connect the transfer control device connector.
5. After the installation, check the 4WD shift indicator pattern. If B
NG, adjust the position between the transfer assembly and
transfer control unit. Refer to DLN-83, "Precaution for Transfer
Assembly and Transfer Control Unit Replacement". C
RCH@1101D
DLN

AIR BREATHER HOSE
AIR BREATHER HOSE
RCH@2240D
1. Breather tube 2. Clip A 3. Clip B

4. Clip C 5. Clip D 6. Breather tube (transfer)
7. Air breather hose clamp 8. Transfer control device
CAUTION:
• Make sure there are no pinched or restricted areas on each air breather hose caused by bending or
winding when installing it.
• Install each air breather hose into the breather tube (metal
connector) until the hose end reaches the end of the curved
section. Set each air breather hose with paint mark facing
upward.
RCH@2188D
• Install transfer control device air breather hose and transfer

air breather hose on clip A and clip B with the paint mark fac-
ing upward.
RCH@2242D

AIR BREATHER HOSE
• Install clip C on transfer control device air breather hose and
transfer air breather hose with the paint mark matched. A
RCH@2243D
DLN
• Install transfer control device air breather hose and transfer
air breather hose on clip D with the paint mark facing upward.
E
G
RCH@2244D
• Install transfer air breather hose into the breather tube (trans- H
fer, metal connector) until the hose end reaches the base of
the tube. Set transfer air breather hose with paint mark facing
upward. I
K
RCH@2085D
• Install transfer control device air breather hose into transfer

L
control device (case connector) until the hose end reaches
the base of the tube. Set transfer control device air breather
hose with paint mark facing forward.
M
RCH@22/ / D
O

TRANSFER ASSEMBLY
< REMOVAL AND INSTALLATION > [TRANSFER: TX15B]
REMOVAL AND INSTALLATION

TRANSFER ASSEMBLY
REMOVAL
1. Switch 4WD shift switch to 2WD and set transfer assembly to 2WD.
2. Drain the transfer fluid. Refer to DLN-90.
3. Remove undercovers using power tool.
4. Remove the center exhaust tube and main muffler. Refer to EX-5, "Exploded View".
5. Remove the front and rear propeller shafts. Refer to DLN-130, "Removal and Installation" (front), DLN-
138, "Removal and Installation" (rear).
CAUTION:
Do not damage spline, sleeve yoke and rear oil seal when removing rear propeller shaft.
NOTE:
Insert a plug into the rear oil seal after removing the rear propeller shaft.
6. Remove the transmission bolts. Refer to TM-30, "Disassembly and Assembly" (for M/T) or TM-270,
"Removal and Installation (4WD)" (for A/T).
7. Position two suitable jacks under the transmission and transfer assembly.
8. Remove the transmission crossmember. Refer to TM-23, "Removal and Installation from Vehicle (For
4WD Models)" (for M/T) or TM-270, "Removal and Installation (4WD)" (for A/T).
WARNING:
Support transmission and transfer assembly using two suitable jacks while removing transmis-
sion crossmember.
9. Disconnect the electrical connectors from the following:
• ATP switch
• 4LO switch
• Wait detection switch
• Transfer control device
10. Disconnect each air breather hose from the following. Refer to DLN-98, "Removal and Installation".
• Transfer control device
• Breather tube (transfer)
11. Remove the transfer to transmission and transmission to trans-
fer bolts.
WARNING:
Support transfer assembly with suitable jack while remov-
ing it.
12. Remove the transfer assembly.
CAUTION:
Do not damage transmission rear oil seal.
V CH@/ 40/ D
INSTALLATION

TRANSFER ASSEMBLY
< REMOVAL AND INSTALLATION > [TRANSFER: TX15B]
• Tighten the bolts to specification.
A
Tightening torque : 36 N·m (3.7kg-m, 27 ft-lb)
• Fill the transfer with new fluid. Refer to DLN-90, "Replacement".
• Check the transfer fluid. Refer to DLN-90, "Inspection". B
• Start the engine for one minute. Then stop the engine and recheck
the transfer fluid. Refer to DLN-90, "Inspection".
• After the installation, check the 4WD shift indicator pattern. If NG, C
adjust the position between the transfer assembly and transfer
control unit. Refer to DLN-83, "Precaution for Transfer Assembly
and Transfer Control Unit Replacement". V CH@/ 40/ D
DLN

TRANSFER ASSEMBLY
< DISASSEMBLY AND ASSEMBLY > [TRANSFER: TX15B]
DISASSEMBLY AND ASSEMBLY

TRANSFER ASSEMBLY
Disassembly and Assembly INFOID:0000000004095601
COMPONENTS
V CH@/ 274D
1. Baffle plate 2. Breather tube 3. Front case

4. Snap ring 5. Input oil seal 6. Self-lock nut
7. Companion flange 8. Front oil seal 9. 4LO switch (gray with green
paint)
10. ATP switch (black) 11. Rear case 12. Wait detection switch (gray)
13. Gasket 14. Filler plug 15. Drain plug
16. O-ring 17. Transfer control device 18. Harness bracket
19. Dust cover 20. Rear oil seal 21. Air breather hose clamp
22. Retainer bolt 23. Gasket A. Apply Genuine Anaerobic Liquid
Gasket or equivalent.
B. Apply Genuine Silicone RTV or
equivalent.

TRANSFER ASSEMBLY
DLN
@V CH@/ / 05F A
K
1. Input bearing 2. Snap ring 3. Internal gear

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

TRANSFER ASSEMBLY
2. Remove the transfer control device from the rear case.
3. Remove the O-ring from the transfer control device.
RCH@1101D
4. Remove the self-lock nut from the companion flange using Tool.
RCH@1730D
5. Put a matching mark on top of the front drive shaft in line with
the mark on the companion flange.
CAUTION:
Use paint to make the matching mark on the front drive
shaft. Do not damage the front drive shaft.
RCH@1668D
6. Remove the companion flange using suitable tool.
V CH@/ 022D
7. Remove the front oil seal from the front case using Tool.
Tool number : ST33290001 (J-34286)

CAUTION:
Do not damage front case or front drive shaft.
RCH@1312D

TRANSFER ASSEMBLY
8. Remove the 4LO switch [gray (with green paint)] and ATP switch
(black) from the front case. A
OCH@/ / 8/ D
DLN
9. Remove the wait detection switch (gray) from the rear case.
G
OCH@/ / 80D
10. Remove the dust cover from the rear case using suitable tool.
H
CAUTION:
Do not damage rear case.
OCH@/ / 81D
K
11. Remove the rear oil seal from the rear case using Tool.
Tool number : ST33290001 (J-34286) L
CAUTION:
Do not damage rear case or mainshaft.
M
N
RCH@1313D
12. Remove the input oil seal from the front case using suitable tool. O
CAUTION:
Do not damage front case, sun gear or input bearing.
P
OCH@/ / 83D

TRANSFER ASSEMBLY
13. Remove the retainer bolts and gaskets.
RCH@1678D
14. Remove the rear case bolts, harness bracket and air breather
hose clamp from the rear case.
RCH@2311D
15. Separate the front case from the rear case. Then remove the
rear case by prying it up using suitable tool.
CAUTION:
Do not damage the mating surface.
16. Remove the spacer from the control shift rod.
CAUTION:
Do not drop spacer.
OCH@/ / 85D
17. Remove the snap ring from the mainshaft using suitable tool.
RCH@132/ D
18. Remove the mainshaft rear bearing from the mainshaft using
suitable tool.
19. Remove the retainer from the mainshaft.
V CH@/ 024D

TRANSFER ASSEMBLY
A
21. Remove the oil pump assembly from the mainshaft.
RCH@1350D
DLN
23. Remove the clutch gear from the mainshaft.
E
G
RCH@1351D
24. Remove the snap ring from the L-H shift rod assembly using H
suitable tool.
25. Remove the 2-4 sleeve and 2-4 shift fork assembly from the
mainshaft. I
RCH@1352D K
26. Remove the drive chain together with the sprocket and front
drive shaft from the front case.
L
27. Remove the mainshaft from the sun gear assembly.
28. Remove the L-H shift rod assembly and control shift rod assem-
bly from the front case.
M
29. Remove the L-H sleeve together with the L-H shift fork from the
planetary carrier assembly.
N
RCH@1353D
30. Remove the snap ring from the sun gear. O

CAUTION:
Do not damage sun gear or input bearing.
P
OCH@/ / 88D

TRANSFER ASSEMBLY
31. Press the sun gear assembly and planetary carrier assembly
from the front case using Tool.
OCH@/ 0/ / D
32. Remove the snap ring from the front case.
OCH@/ 0/ 0D
33. Remove the internal gear from the front case.
OCH@/ 2/ 4D
34. Remove the snap ring from the front case.
OCH@/ 0/ 2D
35. Remove the input bearing from the front case using Tool.
OCH@/ 0/ 3D

TRANSFER ASSEMBLY
36. Remove the baffle plate from the front case.
37. Remove the breather tube from the front case. A
OCH@/ 0/ 4D
DLN
INSPECTION AFTER DISASSEMBLY
Case
Check the contact surfaces of the shift rod and bearing for wear and E
damage. If any is found, replace with a new one.
OCH@/ 034D H
Sleeve
Check the items below. If necessary, replace them with new ones.
• Damage and excessive wear of the contact surfaces of the I
sprocket, mainshaft and sleeve.
• Sleeve must move smoothly.
J
OCH@/ 025D
L
Gear, Shaft and Drive Chain
• Damage, peeling, uneven wear and bending of the shaft.
• Excessive wear, damage and peeling of the gear. M
O
RCH@168/ D
Bearing P

TRANSFER ASSEMBLY
Check the bearing for damage and rough rotation. If necessary,
replace it with a new one.
L SE/ / 30C
ASSEMBLY
1. Install the breather tube.
CAUTION:
Install breather tube in the direction shown.
OCH@/ 0/ 6D
2. Install the baffle plate to the front case. Tighten the bolt to the
specified torque. Refer to DLN-102, "Disassembly and Assem-
bly".
CAUTION:
Install baffle plate by pushing it in the direction shown
while tightening the bolt.
RCH@1368D
3. Install the input bearing to the front case using Tool.
Tool number : ST30720000 (J-25405)
OCH@/ 0/ 7D
4. Install the new snap ring to the front case.

CAUTION:
Do not reuse snap ring.
OCH@/ 0/ 2D

TRANSFER ASSEMBLY
5. Install the internal gear with the groove facing up into the front
case. A
OCH@/ 0/ 1D
DLN
6. Install the new snap ring to the front case.
CAUTION:
Do not reuse snap ring. E
G
OCH@/ 0/ 0D
7. Install the planetary carrier assembly and sun gear assembly to H

the front case using Tool.

I
RCH@1680D K
8. Install the new snap ring to the sun gear.
CAUTION:
• Do not reuse snap ring. L
• Do not damage sun gear.
N
OCH@/ / 88D
9. Set the L-H sleeve together with the L-H shift fork assembly onto O
the planetary carrier assembly.
RCH@1327D

TRANSFER ASSEMBLY
10. Install the control shift rod assembly to the front case.
CAUTION:
Set pin of L-H shift fork assembly into the groove of drum
cam.
11. Turn the control shift rod assembly fully counterclockwise.
V CH@/ 104D
12. Install the L-H shift rod assembly through the L-H shift fork
assembly opening to the front case.
CAUTION:
Set pin of L-H shift rod assembly into the groove of drum
cam.
13. Install the mainshaft to the sun gear assembly.
V CH@/ 105D
14. Install the drive chain to the front drive shaft and sprocket.
CAUTION:
Install with the Identification mark of drive chain on the side
of the rear bearing of front drive shaft.
OCH@/ 00/ D
15. Install the drive chain together with the front drive shaft and
sprocket to the front case.
RCH@1353D
16. Install the 2-4 sleeve and 2-4 shift fork assembly to the main-
shaft.
CAUTION:
• Install with proper orientation of 2-4 sleeve.
• Install 2-4 shift fork with engaging the grooves of 2-4 shift
fork in the retaining pin of 2-4 shift bracket.
RCH@1356D

TRANSFER ASSEMBLY
17. Install the new snap ring to the L-H shift rod assembly using suit-
able tool. A
CAUTION:
18. Install the clutch gear to the mainshaft. B
RCH@1352D
DLN
19. Install the new snap ring to the mainshaft using suitable tool.
CAUTION:
Do not reuse snap ring. E
20. Install the oil pump assembly to the mainshaft.
G
RCH@1351D
21. Install the new snap ring to the mainshaft using suitable tool. H
CAUTION:
I
RCH@1350D K
22. Install the retainer to the mainshaft.

CAUTION:
Set the projection of oil pump assembly to the identification L
hole, and then align locating hole of retainer to the L-H shift
rod assembly.
M
RCH@1357D
23. Install the mainshaft rear bearing to the mainshaft using Tool. O

P
CAUTION:
Do not push too hard in order to avoid snap rings becoming
dislodged from mainshaft.
RCH@1358D

TRANSFER ASSEMBLY
24. Install the new snap ring to the mainshaft using suitable tool.
CAUTION:
25. Install the spacer to the control shift rod.
RCH@132/ D
26. Apply liquid gasket to the mating surface of the front case.
• Use Genuine Anaerobic Liquid Gasket or equivalent.
Refer to GI-14, "Recommended Chemical Products and
Sealants".
CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
27. Install the rear case to the front case.
V CH@/ 106D
28. Tighten the bolts to the specified torque. Refer to DLN-102, "Dis-
assembly and Assembly".
CAUTION:
Be sure to install the harness brackets and air breather
hose clamp.
RCH@2311D
29. Install the retainer bolts with new gaskets. Tighten the bolts to
Assembly".
CAUTION:
• Do not reuse gasket.
• Tighten them to the specified torque again.
RCH@1678D
30. Apply petroleum jelly to the circumference of the new oil seal,
and install it to the front case using Tools.
Tool number A: ST30720000 (J-25405)

B: KV40104830 ( — )
Dimension A : 4.0 - 4.6 mm (0.157 - 0.181 in)

CAUTION:
• Apply petroleum jelly to oil seal. RCH@2080D

TRANSFER ASSEMBLY
31. Install the new rear oil seal until it is flush with the end face of the
rear case using Tool. A

CAUTION: B
C
OCH@/ 004D
DLN
32. Apply petroleum jelly to the circumference of the new dust cover.
Position the new dust cover as shown.
CAUTION: E
• Position the identification mark at the position shown.
• 1: Dust cover
• A: Protrusions F
• 2: Rear case assembly
G
@V CH@/ 44/ F A
33. Install the new dust cover to the rear case using Tool. H

CAUTION: I
• Apply petroleum jelly to dust cover.
J
OCH@/ 005D K
34. Apply sealant to the threads of the wait detection switch (gray).
Then install it to the rear case and tighten to the specified L
torque. Refer to DLN-102, "Disassembly and Assembly".
• Use Genuine Silicone RTV or equivalent. Refer to GI-14,
"Recommended Chemical Products and Sealants". M
CAUTION:
Remove old sealant and oil adhering to threads.
RCH@2278D
O

TRANSFER ASSEMBLY
35. Apply sealant to the threads of the 4LO switch (gray with green
paint) and ATP switch (black). Then install them to the front case
and tighten to the specified torque. Refer to DLN-102, "Disas-
sembly and Assembly".
"Recommended Chemical Products and Sealants".
CAUTION:
Remove old sealant and oil adhering to threads.
RCH@228/ D
36. Install the new front oil seal until it is flush with the end face of
the front case using Tool.

CAUTION:
OCH@/ 006D
37. Align the matching mark on the front drive shaft with the mark on
the companion flange, then install the companion flange.
RCH@1668D
38. Install the new companion flange self-lock nut. Tighten to the
specified torque using Tool. Refer to DLN-102, "Disassembly
and Assembly".

CAUTION:
Do not reuse self-lock nut.
V CH@/ 108D
39. Install the new O-ring to the transfer control device.

CAUTION:
• Do not reuse O-ring.
• Apply petroleum jelly to O-ring.
RCH@2267D

TRANSFER ASSEMBLY
40. Install the transfer control device to the rear case.
A
a. Turn the control shift rod fully counterclockwise using a flat-
bladed screwdriver, and then put a mark on the control shift rod.
OCH@/ 008D
DLN
b. Align the transfer control device shaft cutout with the mark on
the control shift rod, and install it.
NOTE: E
Turn the transfer control device when the transfer control device
connection does not match.
F
G
OCH@/ 01/ D
c. Tighten the bolts to the specified torque. Refer to DLN-102, "Dis- H

assembly and Assembly".
RCH@1101D K
41. Install the drain plug and filler plug with new gaskets to the rear case. Tighten to the specified torque.
Refer to DLN-102, "Disassembly and Assembly".
CAUTION: L
Do not reuse gaskets.

SHIFT CONTROL
SHIFT CONTROL
DISASSEMBLY
1. Remove the snap ring.
2. Remove the retaining pin.
3. Remove the drum cam from the control shift rod.
OCH@/ 011D
4. Remove the retaining pin from the L-H shift rod.

5. Remove the 2-4 shift bracket.
OCH@/ 014D
6. Remove the retaining ring from the 2-4 shift fork using suitable
tool.
7. Remove the fork guide collar and 2-4 shift fork spring from the 2-
4 shift fork.
V CH@/ 115D

Shift Fork
• Measure the clearance between the shift fork and sleeve. If it is out
of specification, replace it with a new one.
Standard value
2-4 : Less than 0.46 mm (0.018 in)
L-H : Less than 0.46 mm (0.018 in)
OCH@/ 023D
Shift Rod and Fork Components

SHIFT CONTROL
• Check the working face of the shift rod and fork for wear, partial
wear, abrasion, bending and other abnormality. If any is found, A
replace with a new one.
OCH@/ 024D
DLN
ASSEMBLY
1. Install clevis pin and shift collar to L-H shift fork after assembling them.
CAUTION:
E
Use caution when installing L-H shift fork, clevis pin or shift collar.
2. Install clevis pin and shift collar to 2-4 shift bracket after assembling them.
CAUTION:
Use caution when installing 2-4 shift bracket. F
3. Install guide fork collar and 2-4 shift fork spring to the 2-4 shift
fork, and then secure it with the new retaining ring.
CAUTION: G
• Do not reuse retaining ring.
• Be careful with orientation.
H
I
RCH@2280D
4. Install the 2-4shift bracket to the L-H shift rod. J

5. Install the new retaining pin evenly to the L-H shift rod.
CAUTION:
Do not reuse retaining pin. K
OCH@/ 014D
M
6. Install the drum cam to the control shift rod, and then secure it
with the new retaining pin. N
CAUTION:
Do not reuse retaining pin.
7. Install the new snap ring to the control shift rod.
O
CAUTION:
OCH@/ 011D

PLANETARY CARRIER
PLANETARY CARRIER
DISASSEMBLY
1. Remove the snap ring.
2. Remove the sun gear assembly from the planetary carrier
assembly using suitable tool.
RCH@1681D
3. Remove the snap ring from the sun gear assembly using suit-
able tool.
RCH@1242D
4. Remove the carrier bearing from the sun gear using Tools.
Tool number A: ST35300000 ( — )

B: ST30021000 (J-22912-01)
RCH@1038D
5. Remove the needle bearing from the sun gear using Tool.
Tool number : ST33710000 ( — )
RCH@1243D

PLANETARY CARRIER
6. Remove the metal bushing from the sun gear using Tools.
A
B: ST35325000 ( — )
B
C: ST33290001 (J-34286)
RCH@1057D
DLN
Bearing
Check the bearing for damage and rough rotation. If necessary, E
replace the bearing with a new one.
L SE/ / 30C H
Planetary Carrier
• Measure the end play of each pinion gear. If it is out of specifica-
tion, replace the planetary carrier assembly with new one. I
Pinion gear end play : 0.1 - 0.7 mm (0.004 - 0.028 in)

• Check the working face of each gear and bearing for damage, J
burrs, partial wear, dents and other abnormality. If any is found,
replace the planetary carrier assembly with a new one.
K
OCH@/ 035D
L
Sun Gear
• Check if the oil passage of the sun gear assembly is clogged. For
this, try to pass a 3.6 mm (0.142 in) dia. wire through the oil pas-
sage as shown. M
• Check the sliding and contact surface of each gear and bearing for
damage, burrs, partial wear, dents and other abnormality. If any is
found, replace the sun gear assembly with a new one. N
OCH@/ 036D
Internal Gear P

PLANETARY CARRIER
Check the internal gear teeth for damage, partial wear, dents or
other abnormality. If any is found, replace the internal gear with a
new one.
OCH@/ 046D
ASSEMBLY
1. Apply ATF to the new metal bushing, then install the new metal
bushing until it becomes “Dimension A” using Tool.
Dimension A : 7.7 - 8.3mm (0.303 - 0.327in)

CAUTION:
Do not reuse metal bushing.
RCH@2078D
2. Apply ATF to the new needle bearing, then install the new nee-
dle bearing until it becomes “Dimension B” using Tool.
Dimension B : 62.5 - 63.1mm (2.461 - 2.484in)

CAUTION:
Do not reuse needle bearing.
RCH@208/ D
3. Install the carrier bearing to the sun gear using Tools.

B: ST27863000 ( — )
OCH@/ 038D
4. Install the new snap ring to the sun gear assembly using suitable
tool.
CAUTION:
RCH@1242D

PLANETARY CARRIER
5. Install the sun gear assembly to the planetary carrier assembly. A

6. Install the new snap ring to the planetary carrier assembly.
CAUTION:
B
RCH@1683D
DLN

FRONT DRIVE SHAFT
FRONT DRIVE SHAFT
DISASSEMBLY
1. Remove the front bearing using Tools.

B: ST30021000 (J-22912-01)
RCH@10/ 5D
2. Remove the rear bearing using Tools.

B: ST30021000 (J-22912-01)
OCH@/ 042D

Front Drive Shaft
• Damage, peeling, dent, uneven wear and bending of the shaft.
• Excessive wear, damage and peeling of the gear.
OCH@/ 043D
Bearing
Check the bearing for damage and rough rotation. If necessary,
replace the bearing with a new one.
L SE/ / 30C
ASSEMBLY

FRONT DRIVE SHAFT
1. Install the rear bearing using Tools.
A
Tool number A: KV38100500 ( — )
B: ST30901000 (J-26010-01)
B
OCH@/ 044D
DLN
2. Install the front bearing using Tools.
Tool number A: KV38100500 ( — ) E

B: ST30901000 (J-26010-01)
G
OCH@/ 045D

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [TRANSFER: TX15B]

General Specification INFOID:0000000004095605
Engine VQ40DE
Transfer model TX15B
Fluid capacity (Approx.) (US qt, lmp qt) 2.0 (2-1/8, 1-3/4)
High 1.000
Gear ratio
Low 2.625
Planetary Sun gear 56

gear Internal gear 91
Number of teeth
Front drive sprocket 38
Front drive shaft 38
Inspection and Adjustment INFOID:0000000004095606
PINION GEAR END PLAY

Unit: mm (in)
Item Standard
Pinion gear end play 0.1 - 0.7 (0.004 - 0.028)
CLEARANCE BETWEEN SHIFT FORK AND SLEEVE

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

PREPARATION
< PREPARATION > [PROPELLER SHAFT: 2F1310]
PREPARATION A
PREPARATION
B

C
Power tool Loosening bolts and nuts
DLN
E
OAHB/ 08/ D

Symptom
×: Applicable
Reference page
Revision: October 2008

Noise
Shake
< FUNCTION DIAGNOSIS >
Possible cause and suspected parts
Vibration
NVH Troubleshooting Chart
Uneven rotation torque DLN-128, "NVH Troubleshooting Chart"
×
×
FUNCTION DIAGNOSIS
Rotation imbalance DLN-128, "NVH Troubleshooting Chart"
×
×
Excessive run out DLN-128, "NVH Troubleshooting Chart"
×
×
DLN-149, "NVH Troubleshooting Chart"
Differential
DLN-128
FAX-4, "NVH Troubleshooting Chart"

Axle RAX-19, "NVH Troubleshooting Chart"
×
×
×
RAX-19, "NVH Troubleshooting Chart"
FSU-4, "NVH Troubleshooting Chart"
×
×
Suspension
×
RSU-4, "NVH Troubleshooting Chart"
×
×
× Tires WT-43, "NVH Troubleshooting Chart"
×
Road wheel WT-43, "NVH Troubleshooting Chart"

×

×
×
×
Drive shaft RAX-7, "NVH Troubleshooting Chart"

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
×
×
Brakes BR-5, "NVH Troubleshooting Chart"

Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
×
×
Steering ST-5, "NVH Troubleshooting Chart"
2009 Xterra
[PROPELLER SHAFT: 2F1310]
INFOID:0000000004095608
PROPELLER SHAFT
< ON-VEHICLE REPAIR > [PROPELLER SHAFT: 2F1310]
ON-VEHICLE REPAIR A
PROPELLER SHAFT
On-Vehicle Service INFOID:0000000004095609
B
APPEARANCE AND NOISE INSPECTION

• Check the propeller shaft tube surface for dents or cracks. If damaged, replace the propeller shaft assembly. C
• Check the bearings for noise and damage. Repair or replace the bearings as necessary.
PROPELLER SHAFT VIBRATION
If a vibration is present at high speed, inspect the propeller shaft runout first. DLN
1. Measure the runout of the propeller shaft tube at several points
by rotating the final drive companion flange with your hands.
Refer to DLN-134, "General Specification". E
2. If the runout exceeds specifications, disconnect the propeller
shaft at the final drive companion flange; then rotate the com-
panion flange 90°, 180° and 270° and reconnect the propeller
F
shaft.
G
KCH@/ 05/ D
3. Check the runout again. If the runout still exceeds specifications, H

replace the propeller shaft assembly.
4. After installation, check for vibration by driving the vehicle.
I
KCH@/ 007D K

PROPELLER SHAFT
< REMOVAL AND INSTALLATION > [PROPELLER SHAFT: 2F1310]

PROPELLER SHAFT
COMPONENTS
Model 2F1310
V CH@/ 2/ 3D
1. Propeller shaft tube 2. Snap ring 3. Journal bearing

4. Journal 5. Flange yoke ⇐: Front
REMOVAL
1. Put matching marks on the front propeller shaft flange yoke and
the front final drive companion flange as shown.
CAUTION:
For matching marks, use paint. Never damage the flange
yoke and companion flange of the front final drive.
2. Put matching marks on the front propeller shaft flange yoke and
the transfer companion flange.
CAUTION:
For matching marks, use paint. Never damage the flange
yoke and companion flange of the front final drive.
3. Remove the bolts and then remove the front propeller shaft from RCH@1/ 35D
the front final drive and transfer.

INSPECTION

PROPELLER SHAFT
< REMOVAL AND INSTALLATION > [PROPELLER SHAFT: 2F1310]
• Inspect the propeller shaft runout. If runout exceeds the limit,
replace the propeller shaft assembly. Refer to DLN-134, "General A
Specification".
KCH@/ 007D
DLN
• While holding the flange yoke on one side, check axial play of the
joint as shown. If the journal axial play exceeds the specification,
repair or replace the journal parts. Refer to DLN-134, "General E
Specification".
• Check the propeller shaft tube surface for dents or cracks. If dam-
age is detected, replace the propeller shaft assembly.
F
G
KCH@/ 006D
INSTALLATION H
• After installation, check for vibration by driving the vehicle. Refer to DLN-128, "NVH Troubleshooting Chart".
CAUTION:
Do not reuse the bolts and nuts. Always install new ones. I

PROPELLER SHAFT
< DISASSEMBLY AND ASSEMBLY > [PROPELLER SHAFT: 2F1310]

PROPELLER SHAFT
DISASSEMBLY
Journal
1. Put matching marks on the front propeller shaft and flange yoke
as shown.
CAUTION:
For matching marks, use paint. Never damage the front pro-
peller shaft or flange yoke.
ROC017
2. Remove the snap rings.
@OC/ 00
3. Push out and remove the journal bearings by lightly tapping the
flange yoke with a hammer, taking care not to damage the jour-
nal or flange yoke hole.
NOTE:
Put marks on the disassembled parts so that they can be rein-
stalled in their original positions from which they were removed.
ROC621
4. Push out and remove the remaining journal bearings at the

opposite side by lightly tapping the flange yoke with a hammer,
taking care not to damage the journal or flange yoke hole.
NOTE:
ROC020
ASSEMBLY

PROPELLER SHAFT
< DISASSEMBLY AND ASSEMBLY > [PROPELLER SHAFT: 2F1310]
Journal
1. Assemble the journal bearings. Apply multipurpose grease on A
the bearing inner surface.
NOTE:
During assembly, use caution so that the needle bearings do not B
fall down.
V OC/ 08
DLN
2. Select new snap rings that will provide the specified play in an
axial direction of the journal, and install them. Refer to DLN-134. E
CAUTION:
Do not reuse snap rings
NOTE:
Select snap rings with a difference in thickness at both sides F
within 0.02 mm (0.0008 in).
@OC/ 01
H
3. Adjust the thrust clearance between the bearing and snap ring
to zero by tapping the yoke.
I
K
ROC621
4. Make sure that the journal moves smoothly and is below the
L
joint flex effort specification. Refer to DLN-134, "General Specifi-
cation".
KCH@/ 008D
O

< SERVICE DATA AND SPECIFICATIONS (SDS) [PROPELLER SHAFT: 2F1310]

Unit: mm (in)
4WD
Applied model VQ40DE
M/T A/T
Propeller shaft model 2F1310
Number of joints 2
Coupling method with front final drive Flange type
Coupling method with transfer Flange type
Shaft length (Spider to spider) 696 mm (27.40 in)
Shaft outer diameter 63.5 mm (2.5 in)
Propeller Shaft Runout

Unit: mm (in)
Item Limit
Propeller shaft runout 0.6 mm (0.024 in)
Propeller Shaft Joint Flex Effort

Unit: N·m (kg-m, in-lb)
Item Limit
Propeller shaft joint flex effort 1.96 N·m (0.20 kg-m, 17 in-lb) or less
Journal Axial Play

Unit: mm (in)
Item Limit
Journal axial play 0.02 mm (0.0008 in) or less
Snap Ring INFOID:0000000004095613
Model 2F1310 (4WD)

Unit: mm (in)
Thickness Color Part Number*

1.99 (0.0783) White 37146-C9400
2.02 (0.0795) Yellow 37147-C9400
2.05 (0.0807) Red 37148-C9400
2.08 (0.0819) Green 37149-C9400
2.11 (0.0831) Blue 37150-C9400
2.14 (0.0843) Light brown 37151-C9400
2.17 (0.0854) Black 37152-C9400
2.20 (0.0866) No paint 37153-C9400
*Always check with the Parts Department for the latest parts information.

PREPARATION
< PREPARATION > [PROPELLER SHAFT: 2S1330]
PREPARATION A
PREPARATION
B

C
DLN
E
OAHB/ 08/ D

Symptom
×: Applicable
Reference page

Noise
Shake
Possible cause and suspected parts
Vibration
Uneven rotation torque DLN-136, "NVH Troubleshooting Chart"
×
×
FUNCTION DIAGNOSIS
Rotation imbalance DLN-136, "NVH Troubleshooting Chart"
×
×
Excessive run out DLN-136, "NVH Troubleshooting Chart"
×
×
DLN-136
×
Differential
×
×
Axle RAX-7, "NVH Troubleshooting Chart"
×
FSU-4, "NVH Troubleshooting Chart"
×
× Suspension
×
×
×
Tires WT-43, "NVH Troubleshooting Chart"

×
×
×
Road wheel WT-43, "NVH Troubleshooting Chart"

×
×
×
Drive shaft RAX-7, "NVH Troubleshooting Chart"

×
×
Brakes BR-5, "NVH Troubleshooting Chart"

×
×
Steering ST-5, "NVH Troubleshooting Chart"
2009 Xterra
[PROPELLER SHAFT: 2S1330]
INFOID:0000000004095615
PROPELLER SHAFT
< ON-VEHICLE REPAIR > [PROPELLER SHAFT: 2S1330]
ON-VEHICLE REPAIR A
PROPELLER SHAFT
On-Vehicle Service INFOID:0000000004095616
B
APPEARANCE AND NOISE INSPECTION

• Check the propeller shaft tube surface for dents or cracks. If damaged, replace the propeller shaft assembly. C
• Check the bearings for noise and damage. Repair or replace the bearings as necessary.
PROPELLER SHAFT VIBRATION
If a vibration is present at high speed, inspect the propeller shaft runout first. DLN
1. Measure the runout of the propeller shaft tube at several points
by rotating the final drive companion flange with your hands.
Refer to DLN-142, "General Specification". E
2. If the runout exceeds specifications, disconnect the propeller
shaft at the final drive companion flange; then rotate the com-
panion flange 90°, 180° and 270° and reconnect the propeller
F
shaft.
G
KCH@/ 050D
3. Check the runout again. If the runout still exceeds specifications, H

replace the propeller shaft assembly.
4. After installation, check for vibration by driving vehicle.
I
KCH@/ 010D K

PROPELLER SHAFT
< REMOVAL AND INSTALLATION > [PROPELLER SHAFT: 2S1330]

PROPELLER SHAFT
COMPONENTS
@V CH@/ 522F A
1. Propeller shaft tube 2. Snap ring 3. Journal bearing

4. Sleeve yoke M/T 5. Sleeve yoke A/T 6. Journal
7. Flange yoke ⇐ Front
REMOVAL
1. Put the transmission in neutral and release the parking brake.
2. Put matching marks on the rear propeller shaft flange yoke and
the rear final drive companion flange as shown.
CAUTION:
For matching marks, use paint. Never damage the rear pro-
peller shaft flange yoke or the companion flange.
3. Remove the bolts, then remove the propeller shaft from the rear
final drive and transmission or transfer.
V CH@/ / 38D
INSPECTION

PROPELLER SHAFT
< REMOVAL AND INSTALLATION > [PROPELLER SHAFT: 2S1330]
• Inspect the propeller shaft runout. If runout exceeds the limit,
replace the propeller shaft assembly. Refer to DLN-142, "General A
Specification".
KCH@/ 010D
DLN
• While holding the flange yoke on one side, check axial play of the
joint as shown. If the journal axial play exceeds the specification,
repair or replace the journal parts. Refer to DLN-142, "General E
Specification".
• Check the propeller shaft tube for dents or cracks. If damage is
detected, replace the propeller shaft assembly.
F
G
KCH@/ 006D
H
INSTALLATION
• After installation, check for vibration by driving the vehicle. Refer to DLN-136, "NVH Troubleshooting Chart".
• If propeller shaft assembly or final drive assembly has been I
replaced, connect them as follows:
- Face companion flange mark (A) of the final drive (1) upward. With
the mark (A) faced upward, couple the propeller shaft and the final J
drive so that the matching mark (B) of the propeller shaft (2) can be
positioned as closest as possible with the matching mark (C) of the
final drive companion flange.
- Tighten propeller shaft and final drive bolts and nuts to specifica- K
tions. Refer to DLN-138, "Removal and Installation".
CAUTION:
Do not reuse the bolts and nuts. Always install new ones. L
OCH@/ 781I

PROPELLER SHAFT
< DISASSEMBLY AND ASSEMBLY > [PROPELLER SHAFT: 2S1330]

PROPELLER SHAFT
DISASSEMBLY
Journal
1. Put matching marks on the rear propeller shaft and flange yoke
as shown.
CAUTION:
For matching marks use paint. Never damage the rear pro-
peller shaft or flange yoke.
ROC017
2. Remove the snap rings.
@OC/ 00
3. Push out and remove the journal bearings by lightly tapping the
flange yoke with a hammer, taking care not to damage the jour-
nal or flange yoke hole.
NOTE:
ROC621
4. Push out and remove the remaining journal bearings at the

opposite side by lightly tapping the flange yoke with a hammer,
taking care not to damage the journal or flange yoke hole.
NOTE:
ROC020
ASSEMBLY

PROPELLER SHAFT
< DISASSEMBLY AND ASSEMBLY > [PROPELLER SHAFT: 2S1330]
Journal
1. Assemble the journal bearings. Apply multipurpose grease on A
the bearing inner surface.
NOTE:
During assembly, use caution so that the needle bearings do not B
fall down.
V OC/ 08
DLN
2. Select new snap rings that will provide the specified play in an
axial direction of the journal, and install them. Refer to DLN-143, E
"Snap Ring".
CAUTION:
Do not reuse snap rings
NOTE: F
Select snap rings with a difference in thickness at both sides
within 0.02 mm (0.0008 in).
G
@OC/ 01
H
3. Adjust the thrust clearance between the bearing and snap ring
to zero by tapping the yoke.
I
K
ROC621
4. Make sure that the journal moves smoothly and is below the
L
propeller joint flex effort specification. Refer to DLN-142, "Gen-
eral Specification".
KCH@/ 008D
O

< SERVICE DATA AND SPECIFICATIONS (SDS) [PROPELLER SHAFT: 2S1330]

2WD models
2WD
Applied model
VQ40DE
M/T A/T
Propeller shaft model 2S1330 (aluminum tube)
Number of joints 2
Coupling method with rear final drive Flange type
Coupling method with transmission Sleeve type
Shaft length (Spider to spider) 1151.88 mm (45.35 in) 1235.8 mm (48.65 in)
Item Limit
Propeller shaft runout 1.02 mm (0.0402 in) or less
Item Limit
Journal Axial Play
Item Limit
4WD models
Applied model 4WD
VQ40DE
M/T A/T
All Off Road S, X, SE
Propeller shaft model 2S1330 (steel tube)
Number of joints 2
Coupling method with rear final drive Flange type
Coupling method with transfer Sleeve type
806.5 mm
Shaft length (Spider to spider) 776.5 mm (30.57 in)
(31.75 in)
Item Limit
Propeller shaft runout 0.6 mm (0.024 in) or less

< SERVICE DATA AND SPECIFICATIONS (SDS) [PROPELLER SHAFT: 2S1330]
Item Limit A
Journal Axial Play

B
Item Limit
C
Snap Ring INFOID:0000000004095620
Model 2S1330 (4WD) DLN

Unit: mm (in)

1.99 (0.0783) White 37146-C9400 E
2.02 (0.0795) Yellow 37147-C9400
2.05 (0.0807) Red 37148-C9400
F
2.08 (0.0819) Green 37149-C9400
2.11 (0.0831) Blue 37150-C9400
2.14 (0.0843) Light brown 37151-C9400 G
2.17 (0.0854) Black 37152-C9400
2.20 (0.0866) No paint 37153-C9400
H
Model 2S1330 (2WD)
Unit: mm (in)
I
1.600 - 1.638 (0.0630 - 0.0645) Black 37146-EA500
1.549 - 1.588 (0.0610 - 0.0625) Black 37147-EA500 J
1.524 - 1.562 (0.0600 - 0.0615) Black 37148-EA500
1.499 - 1.537 (0.0590 - 0.0605) Black 37149-EA500
K

PRECAUTIONS
< PRECAUTION > [FRONT FINAL DRIVE: R180A]
PRECAUTION
PRECAUTIONS
Precaution for Servicing Front Final Drive INFOID:0000000004095628
• Before starting diagnosis of the vehicle, understand the symptoms well. Perform correct and systematic
operations.
• Check for the correct installation status prior to removal or disassembly. When matching marks are required,
be certain they do not interfere with the function of the parts they are applied to.
• Overhaul should be done in a clean work area, a dust proof area is recommended.
• Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from
entering into the unit during disassembly or assembly.
• Always use shop paper for cleaning the inside of components.
• Avoid using cotton gloves or a shop cloth to prevent the entering of lint.
• Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace them
with new ones if necessary.
• Gaskets, seals and O-rings should be replaced any time the unit is disassembled.
• Clean and flush the parts sufficiently and blow them dry.
• When applying sealant, remove the old sealant from the mating surface; then remove any moisture, oil, and
foreign materials from the application and mating surfaces.
• In principle, tighten nuts or bolts gradually in several steps working diagonally from inside to outside. If a
tightening sequence is specified, observe it.
• During assembly, observe the specified tightening torque.
• Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.

PREPARATION
< PREPARATION > [FRONT FINAL DRIVE: R180A]
PREPARATION A
PREPARATION
B
(Kent-Moore No.) C
Tool name
KV38108300 Removing and installing drive pinion lock nut
(J-44195) DLN
Flange wrench
MS660
KV381054S0 Removing front oil seal F

(J-34286)
Puller
G
YY@/ 5/ 0C
H
ST30720000 • Installing front oil seal

(J-25405) • Installing side oil seal
Drift a: 77 mm (3.03 in) dia. I
b: 55.5 mm (2.185 in) dia.
YY@/ 700C
ST27863000 • Installing front oil seal

K
( — ) • Installing side oil seal
Drift a: 74.5 mm (2.933 in) dia.
b: 62.5 mm (2.461 in) dia.
L
YY@0/ / 2C
M
ST3127S000 Measuring drive pinion bearing preload torque
(J-25765-A) and total preload torque
Preload gauge
1: GG91030000 N
(J-25765)
Torque wrench
2: HT62940000
( — )
O
Socket adapter (1/2″)
3: HT62900000 MS013
( — ) P

PREPARATION
(Kent-Moore No.)
Tool name
KV10111100 Removing carrier cover
(J-37228)
Seal cutter
R,MS/ 35
ST3306S001 Removing and installing side bearing inner

( — ) race
Differential side bearing puller set a: 28.5 mm (1.122 in) dia.
1: ST33051001 b: 38 mm (1.50 in) dia.
(J-22888-20)
Puller
2: ST33061000
(J-8107-2)
Base MS/ 61
ST30031000 Removing drive pinion rear bearing inner race

(J-22912-01)
Replacer
YY@/ 6/ / C
KV38100600 Installing side bearing adjusting washer

(J-25267)
Drift
RCH@/ 318I
ST30613000 Installing drive pinion rear bearing outer race

(J-25742-3) a: 72 mm (2.83 in) dia.
YY@0/ / / C

(J-25742-1) (Use with ST30613000)
Drift bar
R,MS/ 8/
KV38100200 Installing drive pinion front bearing outer race

(J-26233) a: 65 mm (2.56 in) dia.
YY@0032C

PREPARATION
(Kent-Moore No.) A
Tool name
ST30901000 Installing drive pinion rear bearing inner race
(J-26010-01) a: 79 mm (3.11 in) dia. B
c: 35.2 mm (1.386 in) dia.
YY@/ 867C
ST33200000 Installing drive pinion front bearing inner race DLN

(J-26082) a: 60 mm (2.36 in) dia.
E
YY@0/ / 1C F
ST33230000 Installing side bearing inner race
(J-35867) a: 51 mm (2.01 in) dia.
Drift b: 41 mm (1.61 in) dia. G
c: 28 mm (1.10 in) dia.
H
YY@0/ 35C
( — ) Adjusting bearing preload and drive pinion

(J-34309) height I
Differential shim selector tool
MS023
K
( — ) Selecting drive pinion height adjusting washer
(J-25269-18)
Side bearing disc (2 Req'd)
L
M
MS024
KV10112100 Tightening bolts for drive gear

(BT-8653-A)
N
Angle wrench
MS/ 03
P

PREPARATION
Power tool Loosening nuts and bolts
OAHB/ 08/ D

×: Applicable
PARTS
Symptom
Reference page

Noise
Possible cause and SUSPECTED

Gear tooth rough DLN-158
×
Gear contact improper DLN-158
×
FUNCTION DIAGNOSIS
Tooth surfaces worn DLN-158
×
×
Backlash incorrect DLN-158
×
Companion flange excessive runout DLN-158
DLN-149
×
Gear oil improper MA-11, "Fluids and Lubricants"
×
PROPELLER SHAFT
×
FRONT AXLE FAX-4, "NVH Troubleshooting Chart"
×
FRONT SUSPENSION FSU-4, "NVH Troubleshooting Chart"
×
TIRES WT-43, "NVH Troubleshooting Chart"
×
× ROAD WHEEL WT-43, "NVH Troubleshooting Chart"
DRIVE SHAFT FAX-4, "NVH Troubleshooting Chart"

×
BRAKES BR-5, "NVH Troubleshooting Chart"

STEERING ST-5, "NVH Troubleshooting Chart"

2009 Xterra
[FRONT FINAL DRIVE: R180A]
INFOID:0000000004095631
L
F
P
K
E
B
A
N
H
C
O
G
M
DLN
DESCRIPTION
< FUNCTION DIAGNOSIS > [FRONT FINAL DRIVE: R180A]
DESCRIPTION
OCH@/ 584D
1. Differential side shaft 2. Differential side shaft bearing 3. Side gear

4. Drive gear 5. Pinion mate shaft 6. Differential case
7. Side bearing 8. Pinion mate gear 9. Drive pinion
10. Collapsible spacer 11. Companion flange 12. Drive pinion front bearing
13. Drive pinion rear bearing 14. Housing spacer

DIFFERENTIAL GEAR OIL
< ON-VEHICLE MAINTENANCE > [FRONT FINAL DRIVE: R180A]
ON-VEHICLE MAINTENANCE A
Changing Differential Gear Oil INFOID:0000000004095633
B
DRAINING
1. Stop the engine. C
2. Remove the drain plug and gasket from the front final drive
assembly to drain the differential gear oil.
3. Install the drain plug with a new gasket to the front final drive DLN
assembly. Tighten to the specified torque. Refer to DLN-156,
CAUTION: E
F
KCH@/ 064D
FILLING
G
1. Remove the filler plug and gasket from the front final drive
assembly.
2. Fill the front final drive assembly with new differential gear oil H
until the level reaches the specified level near the filler plug hole.
Differential gear oil : Refer to MA-11, "Fluids

I
grade and capacity and Lubricants".
3. Install the filler plug with a new gasket on it to the front final drive
assembly. Tighten to the specified torque. Refer to DLN-156, J
"Removal and Installation". KCH@/ 065D
CAUTION:
K
Checking Differential Gear Oil INFOID:0000000004095634
DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL L

1. Make sure that differential gear oil is not leaking from the front final drive assembly or around it.
2. Check the differential gear oil level from the filler plug hole as
shown. M
CAUTION:
Do not start engine while checking differential gear oil level.
3. Install the filler plug with a new gasket on it to the front final drive N
CAUTION:
Do not reuse gasket. O
KCH@/ 065D

FRONT OIL SEAL
< ON-VEHICLE REPAIR > [FRONT FINAL DRIVE: R180A]
ON-VEHICLE REPAIR
FRONT OIL SEAL
REMOVAL
1. Remove the drive shafts from the front final drive assembly. Refer to FAX-6, "Removal and Installation".
2. Remove the front propeller shaft from the front final drive assembly. Refer to DLN-130, "Removal and
Installation".
3. Measure the total preload torque. Refer to DLN-177, "Inspection and Adjustment".
NOTE:
Record the total preload torque measurement.
4. Remove the drive pinion lock nut using Tool.

5. Put matching marks on the companion flange and drive pinion
using paint.
CAUTION:
Use paint to make the matching marks. Do not damage the
companion flange or drive pinion.
ACH@/ / / 0D
KCH@/ 060D
7. Remove the front oil seal using Tool.
Tool number : KV381054S0 (J-34286)
KCH@/ 061D
INSTALLATION

FRONT OIL SEAL
1. Apply multi-purpose grease to the lips and differential gear oil to
the circumference of the new front oil seal. Then drive the new A
front oil seal in evenly until it becomes flush with the gear carrier
using Tools.
B
B: ST27863000 ( — )
CAUTION: C
• Do not reuse front oil seal.
• Do not incline the new front oil seal when installing.
V CH@/ 036D
• Apply multi-purpose grease to the lips and differential DLN
gear oil to the circumference of the new front oil seal.
2. Install the companion flange to the drive pinion while aligning the matching marks.
3. Apply anti-corrosive oil to the threads of the drive pinion and the E
seating surface of the new drive pinion lock nut. Then adjust the
drive pinion lock nut tightening torque using Tool A, and check
the total preload torque using Tool B. F

B: ST3127S000 (J-25765-A) G
Total preload torque: Refer to DLN-177, "Inspection

and Adjustment". H
• The total preload torque should be within the total preload
torque specification. When not replacing the collapsible
spacer, it should also be equal to the measurement taken dur- I
ing removal plus an additional 0.56 N·m (0.06 Kg-m, 5 in-lb).
• If the total preload torque is low, tighten the drive pinion lock
nut in 6.8 N·m (0.69 Kg-m, 5ft-lb) increments until the total pre- J
load torque is met.
CAUTION:
• Do not reuse drive pinion lock nut.
• Apply anti-corrosive oil to the threads of the drive pinion K
and the seating surface of the new drive pinion lock nut.
• Adjust the drive pinion lock nut tightening torque to the V CH@/ 270D
lower limit first. Do not exceed the drive pinion lock nut L
specified torque. Refer to DLN-177, "Inspection and Adjustment".
• Do not loosen drive pinion lock nut to adjust the total preload torque. If the drive pinion lock nut
torque or the total preload torque exceeds the specifications, replace the collapsible spacer and
tighten it again to adjust. Refer to DLN-177, "Inspection and Adjustment". M
• After adjustment, rotate drive pinion back and forth 2 to 3 times to check for unusual noise, rota-
tion malfunction, and other malfunctions.
4. Install new side oil seals into the front final drive assembly. Refer to DLN-154, "Removal and Installation". N
5. Installation of the remaining components is in the reverse order of removal.
CAUTION:
Check the differential gear oil level after installation. Refer to DLN-151, "Checking Differential Gear O
Oil".

SIDE OIL SEAL
SIDE OIL SEAL
REMOVAL
2. Remove the side oil seal using suitable tool.
CAUTION:
Do not reuse the side oil seal.
KCH@/ 062D
INSTALLATION
the circumference of the new side oil seal. Then drive the new
side oil seal in evenly until it becomes flush with the gear carrier
using Tools.

B: ST27863000 ( — )
CAUTION:
• Do not reuse side oil seal.
• Do not incline the new side oil seal when installing.
OCH@/ 715D
• Apply multi-purpose grease to the lips and differential
gear oil to the circumference of the new side oil seal.

CAUTION:
Check the differential gear oil level after installation. Refer to DLN-151, "Checking Differential Gear
Oil".

CARRIER COVER
CARRIER COVER
A
REMOVAL B
1. Remove the front final drive assembly. Refer to DLN-156, "Removal and Installation".
2. Remove the carrier cover bolts and separate the carrier cover
from the gear carrier using Tool. C
Tool number : KV10111100 (J-37228)

CAUTION: DLN
• Do not damage the mating surface.
• Do not insert flat-bladed screwdriver, this will damage the
mating surface. E
OCH@/ 588D
F
INSTALLATION
1. Apply a 3 mm (0.12 in) bead of sealant to the mating surface of
the carrier cover as shown. G
CAUTION:
Remove any old sealant adhering to the mating surfaces. H
Also remove any moisture, oil, or foreign material adhering
to the application and mating surfaces.
2. Install the carrier cover to the gear carrier. Tighten the bolts to I
Assembly". OCH@/ 601D
3. Install the front final drive assembly. Refer to DLN-156, J

CAUTION:
Fill the front final drive assembly with recommended differential gear oil. Refer to DLN-151.
K

FRONT FINAL DRIVE ASSEMBLY
< REMOVAL AND INSTALLATION > [FRONT FINAL DRIVE: R180A]

KCH@/ 068D
1. Breather hose 2. Front final drive assembly 3. Front crossmember

4. Engine under cover
REMOVAL
1. Drain the differential gear oil. Refer to DLN-151, "Changing Differential Gear Oil".
3. Remove the front crossmember.
4. Remove the front propeller shaft from the front final drive assembly. Refer to DLN-130, "Removal and
Installation".
5. Disconnect the vent hose from the front final drive assembly.
6. Support the front final drive assembly using a suitable jack.
< REMOVAL AND INSTALLATION > [FRONT FINAL DRIVE: R180A]
7. Remove the front final drive assembly bolts, then remove the
front final drive assembly. A
CAUTION:
Support the front final drive assembly while removing using
a suitable jack.
B
V CH@/ 034D
DLN
INSTALLATION
• Install new side oil seals into the front final drive assembly. Refer to DLN-154, "Removal and Installation".
CAUTION: E
• Make sure there are no pinched or restricted areas on the breather hose caused by folding or bend-
ing when installing it.
• Fill the front final drive assembly with differential gear oil after installation. Refer to DLN-151, F
"Checking Differential Gear Oil".

FRONT FINAL DRIVE
< DISASSEMBLY AND ASSEMBLY > [FRONT FINAL DRIVE: R180A]

FRONT FINAL DRIVE
COMPONENTS
V CH@/ 154D
1. Drive pinion lock nut 2. Companion flange 3. Front oil seal

4. Drive pinion front bearing 5. Gear carrier 6. Side oil seal
7. Bushing 8. Differential side shaft 9. Differential side shaft bearing
10. Snap ring 11. Snap ring 12. Gasket
13. Drain plug 14. Collapsible spacer 15. Drive pinion rear bearing
16. Drive pinion height adjusting washer 17. Drive pinion 18. Side bearing adjusting washer
19. Side bearing 20. Side gear thrust washer 21. Side gear
22. Pinion mate shaft 23. Lock pin 24. Pinion mate gear
25. Pinion mate thrust washer 26. Drive gear 27. Differential case

FRONT FINAL DRIVE
28. Housing spacer 29. Side bearing cap 30. Filler plug
31. Carrier cover A
ASSEMBLY INSPECTION AND ADJUSTMENT

• Drain the differential gear oil before inspection and adjustment. Refer to DLN-151, "Changing Differential B
Gear Oil".
• Remove and install the carrier cover as necessary for inspection and adjustment. Refer to DLN-155,
C
Total Preload Torque
1. Install the differential side shaft if necessary.
CAUTION: DLN
The differential side shaft must be installed in order to measure total preload torque.
2. Rotate the drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings. E
4. Measure total preload torque using Tool.
Tool number : ST3127S000 (J-25765-A) F
Total preload torque:

1.67 - 2.74 N·m (0.17 - 0.27 kg-m, 15 - 24 in-lb) G
NOTE:
Total preload torque = Drive pinion bearing preload torque +
Side bearing preload torque H
OCH@/ 586D
• If the measured value is out of the specification, check and adjust each part. Adjust the drive pinion I
bearing preload torque first, then adjust the side bearing preload torque.
If the total preload torque is greater than specification J

On drive pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same
amount on each side. Refer to DLN-177, "Inspection and Adjust- K
ment".
If the total preload torque is less than specification L

On drive pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Use thicker side bearing adjusting washers by the same
amount on each side. Refer to DLN-177, "Inspection and Adjust- M
ment".
CAUTION:
N
Select a side bearing adjusting washer for right and left individually.
Drive Gear Runout
1. Fit a dial indicator to the drive gear back face. O
2. Rotate the drive gear to measure runout.
Runout limit: 0.08 mm (0.0031 in) or less P

• If the runout is outside of the limit, check the condition of the drive
gear assembly. Foreign material may be caught between the drive
gear and differential case, or the differential case or drive gear may
be deformed.
CAUTION:
Replace drive gear and drive pinion as a set. ROC775

FRONT FINAL DRIVE
Tooth Contact
1. Apply red lead to the drive gear.
NOTE:
Apply red lead to both faces of three to four gears, at four loca-
tions evenly spaced on the drive gear.
ROC246
2. Rotate the drive gear back and forth several times. Then check
for correct drive pinion to drive gear tooth contact as shown.
CAUTION:
Check tooth contact on drive side and reverse side.
RCH@/ 46/ D
• If the tooth contact is improperly adjusted, adjust the drive pin-

ion height (dimension X).
RCH@/ 406D
- If the tooth contact is near the face (face contact), or near the
heel (heel contact), use a thicker drive pinion height adjusting
washer to move drive pinion closer to the drive gear.
Refer to DLN-177, "Inspection and Adjustment".
OCH@/ 33/ D

FRONT FINAL DRIVE
- If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), use a thinner drive pinion height adjusting A
washer to move the drive pinion farther from the drive gear.
B
OCH@/ 330D
DLN
Backlash
1. Fit a dial indicator to the drive gear face to measure the back-
lash.
E
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
• If the backlash is outside of the specification, change the thick-
F
ness of the side bearing adjusting washers.
If the backlash is greater than specification:

G
Make side bearing adjusting washer thicker on drive
gear back side, and side bearing adjusting washer ROC402
thinner on drive gear tooth side by the same amount.
Refer to DLN-177, "Inspection and Adjustment". H
If the backlash is less than specification:

Make side bearing adjusting washer thinner on drive I
gear back side, and side bearing adjusting washer
thicker on drive gear tooth side by the same amount.
J
CAUTION:
Do not change the total thickness of side bearing adjusting washers as it will change the side
bearing preload torque.
K
Companion Flange Runout
1. Rotate companion flange and check for runout on the compan-
ion flange face (inner side of the bolt holes) and companion L
flange inner side (socket diameter) using suitable tool.
Runout limit: 0.1 mm (0.004 in) or less M

2. If the runout is outside the runout limit, follow the procedure
below to adjust.
a. Rotate the companion flange on the drive pinion by 90°, 180° N
and 270° while checking for the position where the runout is
minimum. RCH@1/ 67D
b. If the runout is still outside of the runout limit after the companion O
flange has been rotated on the drive pinion, possible cause could be an assembly malfunction of drive pin-
ion and drive pinion bearing or a malfunctioning drive pinion bearing.
c. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion P
bearing or drive pinion bearing, replace the companion flange.
DISASSEMBLY
Differential side shaft
1. Drain the differential gear oil if necessary.

FRONT FINAL DRIVE
from the gear carrier using Tool.
Tool number : KV10111100 (J-37228)

CAUTION:
mating surface.
OCH@/ 588D
3. Remove side oil seal.

CAUTION:
Do not damage gear carrier.
OCH@/ 602D
4. Remove snap ring (hole side) using suitable tool.
OCH@/ 603D
5. Remove differential side shaft assembly out of gear carrier using

suitable tool.
NOTE:
Tap on differential side shaft assembly from side gear side.
6. Remove snap ring (differential side shaft side).
OCH@/ 604D
7. Press differential side shaft out of differential side shaft bearing.

CAUTION:
Do not drop differential side shaft.
OCH@/ 607D

FRONT FINAL DRIVE
Differential Assembly
1. Remove differential side shaft assembly. A
2. Remove side seal from gear carrier using suitable tool.
3. For proper reinstallation, paint matching marks on one side of
the side bearing cap and gear carrier. B
CAUTION:
• For matching marks, use paint. Do not damage side bear-
ing cap or gear carrier. C
• Side bearing caps are line-board during manufacture. The
matching marks are used to reinstall them in their original
positions.
DLN
OCH@/ 6/ / D
E
4. Remove the side bearing caps.
H
OCH@/ 6/ 0D
5. Lift the differential case assembly out of the gear carrier. I

CAUTION:
• Keep side bearing outer races together with side bearing
inner races. Do not mix them up.
J
• Keep side bearing adjusting washers together with side
bearings.
ROC808 L
6. Remove housing spacer.

7. Remove side bearing inner race using Tools as shown. M
Tool number A: ST33051001 (J-22888-20)

B: ST33061000 (J-8107-2) N
CAUTION:
• Do not remove side bearing inner race unless it is being
replaced. O
• Place copper plates between the vise and the side bearing
inner race and drive gear to prevent damage.
OCH@/ 716D P

FRONT FINAL DRIVE
• Keep side bearing outer races together with side bearing
inner races. Do not mix them up.
ROC/ 11
8. For proper reinstallation, paint matching marks on the differential

case and drive gear.
CAUTION:
Use paint for matching marks. Do not damage differential
case or drive gear.
9. Remove the drive gear bolts.
10. Tap the drive gear off the differential case using suitable tool.
CAUTION:
Tap evenly all around to keep drive gear from bending.
OCH@/ 385D
11. Remove the lock pin of the pinion mate shaft from the drive gear
side using suitable tool.
ROC/ 14
12. Remove the pinion mate shaft.
RCH@/ / 20I
13. Turn the pinion mate gear, then remove the pinion mate gear,
pinion mate thrust washer, side gear and side gear thrust
washer from the differential case.
RCH@/ / 21I

FRONT FINAL DRIVE
Drive Pinion Assembly
1. Remove the differential assembly. Refer to "Differential Assembly" in disassembly. A
Tool number : KV38108300 (J-44195) B

using paint.
C
CAUTION:
DLN
OCH@/ 6/ 1D
4. Remove the companion flange using suitable tool. E
OCH@/ 6/ 2D H
5. Press the drive pinion assembly (with rear inner bearing race
and collapsible spacer) out of the gear carrier. I
CAUTION:
Do not drop drive pinion assembly.
J
OCH@/ 6/ 3D
L
6. Remove the drive pinion rear bearing inner race and drive pinion
height adjusting washer using Tool.
Tool number : ST30031000 (J-22912-01) M
O
R,OC068

FRONT FINAL DRIVE
7. Remove the front oil seal using suitable tool.
CAUTION:
OCH@/ 605D
8. Remove the drive pinion front bearing inner race.

9. Remove the drive pinion front and rear bearing outer races by
tapping them uniformly using suitable tool.
CAUTION:
OCH@/ 6/ 4D

Clean the disassembled parts. Then inspect the parts for wear or damage. If wear or damage are found, follow
the measures below.
Drive Pinion and Drive Gear
• If the drive pinion and drive gear teeth do not mesh or line-up correctly, determine the cause and adjust,
repair, or replace as necessary.
• If the drive pinion or drive gear are worn, cracked, damaged, pitted or chipped (by friction) noticeably,
replace with new drive pinion and drive gear.
• Drive pinion and drive gear are supplied in matched sets only. Matching numbers on both drive pinion and
drive gear are etched for verification. If a new drive pinion and drive gear set are being used, verify the num-
bers of each drive pinion and drive gear before proceeding with assembly.
Bearing
• If bearings are chipped (by friction), pitted, worn, rusted, scratched, or unusual noise is coming from bearing,
replace with new bearing assembly (as a new set).
• Bearing must be replaced with a new one whenever disassembled.
Side Gear and Pinion Mate Gear
• If any cracks or damage are found on the surface of the teeth, replace with new one.
• If any worn or chipped marks are found on the side of the side gear and pinion mate gear which contact the
thrust washer, replace with new one.
• Replace both side gear and pinion mate gear as a set when replacing side gear or pinion mate gear.
Side Gear Thrust Washer and Pinion Mate Thrust Washer
• If any chips (by friction), damage, or unusual wear are found, replace with new one.
Gear Carrier
• If any wear or cracks are found on the contact sides of gear carrier, replace with new one.
Companion Flange
• If any chips (about 0.1mm, 0.004 in) or other damage on the companion flange surface which contacts the
front oil seal lips are found, replace with new one.
ADJUSTING AND SELECTING WASHERS
Side Gear Back Clearance
• Assemble the differential parts if they are disassembled. Refer to "Differential Assembly" in disassembly.

FRONT FINAL DRIVE
1. Place the differential case straight up so that the side gear to be
measured is upward. A
OCH@/ 35/ D
DLN
2. Using feeler gauges, measure the clearance between the side
gear back and differential case at three different points, while
rotating the side gear. Average the three readings to calculate
E
the clearance. (Measure the clearance of the other side as well.)
Side gear back clearance: 0.1 mm (0.004 in) or less.

F
• If the side gear back clearance is outside of the specification,
use a thicker or thinner side gear thrust washer to adjust.
G
If the side gear back clearance is greater than
specification:
Use a thicker side gear thrust washer. H
If the side gear back clearance is less than spec-
ification:
I
Use a thinner side gear thrust washer.
CAUTION:
• Insert feeler gauges with the same thickness on both J
sides to prevent side gear from tilting.
• Each gear should rotate smoothly without excessive
resistance during differential motion. OCH@/ 465D
• Select a side gear thrust washer for right and left individu- K
ally.
NOTE:
Side gear back clearance is clearance between side gear and differential case for adjusting side gear L
backlash.
Drive Pinion Height
1. Make sure all parts are clean and that the bearings are well lubricated. M
2. Assemble the drive pinion bearings onto the Tool.
Tool number : — (J-34309) N
P
ROC658

FRONT FINAL DRIVE
• Drive pinion front bearing; make sure the J-34309-3 drive
pinion front bearing seat is secured tightly against the J-
34309-2 gauge anvil. Then turn the J-34309-7 drive pinion
front bearing pilot to secure the drive pinon front bearing in its
proper position.
• Drive pinion rear bearing; the J-34309-8 drive pinion rear
bearing pilot is used to center the drive pinion rear bearing
only. The J-34309-4 drive pinion rear bearing locking seat is
used to lock the drive pinion rear bearing to the assembly.
• Installation of J-34309-9 and J-34309-16; place a suitable
2.5 mm (0.098 in) thick plain washer between J-34309-9 and
ROC086@
J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must
be parallel with a clearance of 2.5 mm (0.098 in).
3. Install the drive pinion rear bearing inner race into the gear car-
rier. Then insert the drive pinion height adjusting washer selec-
tor tool, J-34309-1, gauge screw assembly.
ROC782
4. Assemble the drive pinion front bearing inner race and the J-
34309-2 gauge anvil. Assemble them together with the J-34309-
1 gauge screw in the gear carrier. Make sure that the drive pin-
ion height gauge plate, J-34309-16, will turn a full 360°. Tighten
the two sections together by hand.
ROC088@
5. Turn the assembly several times to seat the drive pinon bear-
ings.
ROC66/

FRONT FINAL DRIVE
6. Measure the turning torque at the end of the J-34309-2 gauge
anvil using Tool. A
Tool number : ST3127S000 (J-25765- A)

B
Turning torque specification:
1.0 - 1.6 N·m (0.11 - 0.16 kg-m, 9 - 14 in-lb)
C
OCH@/ 455D
DLN
7. Place the J-34309-10 “R180A” drive pinion height adapter onto
the gauge plate and tighten it by hand.
CAUTION:
Make sure all machined surfaces are clean. E
G
ROC1/ 7@
8. Position the side bearing discs, Tool, and arbor firmly into the
side bearing bores. Install the side bearing caps and tighten the H
side bearing cap bolts to the specified torque. Refer to "COM-
PONENTS".
I
Tool number : — (J-25269-18)
ROC100@
K
9. Select the correct standard drive pinion height adjusting washer
thickness. Select by using a standard gauge of 3 mm (0.12 in)
and your J-34309-101 feeler gauge. Measure the distance L
between the J-34309-10 drive pinion height adapter, including
the standard gauge and the arbor.
N
ROC1/ 3@
10. Write down the exact measurement (the value of feeler gauge). O
ROC664

FRONT FINAL DRIVE
11. Correct the drive pinion height adjusting washer size by referring
to the drive pinion “head number”.
There are two numbers painted on the drive pinion. The first
one refers to the drive pinion and drive gear as a matched
set. This number should be the same as the number on the
drive gear. The second number is the drive pinion “head
number”. It refers to the ideal drive pinion height from stan-
dard for quietest operation. Use the following chart to
determine the correct drive pinion height adjusting washer.
Add or remove from the standard drive pinion ROC431

Head number
height adjusting washer thickness measurement
-6 Add 0.06 mm (0.0024 in)
-5 Add 0.05 mm (0.0020 in)
-4 Add 0.04 mm (0.0016 in)
-3 Add 0.03 mm (0.0012 in)
-2 Add 0.02 mm (0.0008 in)
-1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)
12. Select the correct drive pinion height adjusting washer. Refer to DLN-177, "Inspection and Adjustment".
13. Remove the Tool from the gear carrier and disassemble to
retrieve the drive pinion bearings.
Tool number : — (J-34309)
ROC1/ 4@
ASSEMBLY

FRONT FINAL DRIVE
1. Install drive pinion rear bearing outer race and drive pinion front
bearing outer race using Tools. A
Tool number A: ST30611000 (J-25742-1)

B: ST30613000 (J-25742-3) B
C: KV38100200 (J-26233)
CAUTION:
• First tap the drive pinion bearing outer race until it C
becomes flush with the gear carrier.
• Do not reuse drive pinion front and rear bearing outer
race. DLN
G
OCH@/ 6/ 6D
2. Select drive pinion height adjusting washer. Refer to DLN-177, "Inspection and Adjustment".
H
3. Install the selected drive pinion height adjusting washer to the
drive pinion. Press the drive pinion rear bearing inner race to it
using Tool.
I
Tool number : ST30901000 (J-26010-01)
CAUTION:
• Install the drive pinion height adjusting washer in the J
proper direction as shown.
• Do not reuse drive pinion rear bearing inner race.
K
RCH@/ / 37D
4. Install the collapsible spacer to the drive pinion.

CAUTION: L
Do not reuse collapsible spacer.
5. Apply differential gear oil to the drive pinion rear bearing, and
install the drive pinion assembly to the gear carrier. M
6. Apply differential gear oil to the drive pinion front bearing, and
install the drive pinion front bearing inner race to the drive pinion
assembly. N
CAUTION:
Do not reuse drive pinion front bearing inner race.
OCH@/ 6/ 7D
O

FRONT FINAL DRIVE
7. Press the drive pinion front bearing inner race to the drive pinion
as far as drive pinion lock nut can be tightened using Tool.
Tool number : ST33200000 (J-26082)
OCH@/ 6/ 8D

the circumference of the new front oil seal. Then drive the new
using Tools.

B: ST27863000 ( — )
CAUTION:
OCH@/ 606D
10. Apply anti-corrosive oil to the threads of the drive pinion and the
seating surface of the new drive pinion lock nut. Then adjust the
the drive pinion bearing preload torque using Tool B.
Tool number A: KV38108300 (J-44195)

B: ST3127S000 (J-25765-A)
Drive pinion bearing preload torque:

1.08 - 1.66 N·m (0.11 - 0.16 kg-m, 10 - 14 in-lb)
CAUTION:
• Apply anti-corrosive oil to the threads of the drive pinion
• Adjust the drive pinion lock nut tightening torque to the
lower limit first. Do not exceed the drive pinion lock nut
specified torque. Refer to DLN-158, "Disassembly and
Assembly".
• If the drive pinion bearing preload torque exceeds the
specified value, replace collapsible spacer and tighten it
again to adjust. Do not loosen drive pinion lock nut to
adjust the drive pinion bearing preload torque. V CH@/ 271D
• After adjustment, rotate drive pinion back and forth 2 to 3

times to check for unusual noise, rotation malfunction, and other malfunctions.
11. Check companion flange runout. Refer to "companion flange runout" in disassembly.
12. Install the differential case assembly. Refer to "differential case assembly" in assembly.

FRONT FINAL DRIVE
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly, or reinstall the old ones on A
the side gears.
RCH@/ 082I
DLN
2. Install the side gears and side gear thrust washers into the dif-
ferential case.
3. Install the pinion mate thrust washers to the two pinion mate E
gears. Then install the pinion mate gears with the pinion mate
thrust washers by aligning them in diagonally opposite positions
and rotating them into the differential case.
F
G
RCH@1/ 14D
4. Install the pinion mate shaft and align the lock pin hole on the
H
pinion mate shaft with the lock pin hole on the differential case.
5. Measure the side gear end play. If necessary, select the appro-
priate side gear thrust washers. Refer to "side gear end play" in
disassembly. I
RCH@/ 084I
K
6. Drive a new lock pin into the pinion mate shaft until it is flush
with the differential case using suitable tool.
CAUTION: L
Do not reuse lock pin.
N
ROC/ 2/
7. Align the matching mark of the differential case with the mark of O
the drive gear, then place the drive gear onto the differential
case.
P
RCH@1482D

FRONT FINAL DRIVE
8. Apply thread locking sealant into the threaded holes of the drive
gear and install the new drive gear bolts.
• Use Genuine High Strength Thread Locking Sealant or equiv-
alent. Refer to GI-14, "Recommended Chemical Products and
Sealants".
CAUTION:
Make sure the drive gear back and threaded holes are
clean.
RCH@1483D
9. Tighten the new drive gear bolts to the specified torque. Refer to
DLN-158, "Disassembly and Assembly". After tightening the
new drive gear bolts to the specified torque, tighten an additional
34° to 39° using Tool.
Tool number : KV10112100-A (BT-8653-A)

CAUTION:
• Always use Tool. Avoid tightening based on visual check
alone.
• Tighten new drive gear bolts in a crisscross pattern.
@V AH@/ 611YY
10. Press the new side bearing inner races to the differential case
using Tools.

B: ST33061000 (J-8107-2)
CAUTION:
Do not reuse side bearing inner races.
ROC242
11. Install housing spacer into gear carrier.

12. Apply differential gear oil to the side bearings, and install the dif-
ferential case assembly with the side bearing outer races into
the gear carrier.
CAUTION:
Do not reuse side bearing outer race when replacing side
bearing inner race (replace as a set).
ROC416

FRONT FINAL DRIVE
13. Insert left and right original side bearing adjusting washers in
place between side bearings and gear carrier using Tool. A
Tool number : KV38100600 (J-25267)

B
OCH@/ 6/ 5D
DLN
14. Install the side bearing caps with the matching marks aligned
and tighten the side bearing cap bolts to the specified torque.
E
G
OCH@/ 6/ / D
the circumference of the new side oil seal. Then drive the new H
using Tools.
I
B: ST27863000 ( — )
CAUTION: J
OCH@/ 600D
• Apply multi-purpose grease to the lips and differential K
16. Check and adjust tooth contact, backlash, drive gear runout and total preload torque. Refer to DLN-158,
"Disassembly and Assembly"". L
Recheck above items.
17. Apply a 3 mm (0.12 in) bead of sealant to the mating surface of
the carrier cover as shown.
M
CAUTION:
Remove any old sealant adhering to the mating surfaces. N
18. Install the carrier cover to the gear carrier. Tighten the bolts to O
Assembly". OCH@/ 601D
Differential side shaft P

FRONT FINAL DRIVE
1. Press differential side shaft bearing to differential side shaft.
CAUTION:
Do not reuse differential side shaft bearing.
2. Install snap ring (differential side shaft side).
3. Install differential side shaft assembly into gear carrier.
4. Install snap ring (hole side).
OCH@/ 608D

the circumference of the new side oil seal. Then drive the new
using Tools.

B: ST27863000 ( — )
CAUTION:
OCH@/ 717D

< SERVICE DATA AND SPECIFICATIONS (SDS) [FRONT FINAL DRIVE: R180A]
SERVICE DATA AND SPECIFICATIONS (SDS) A

B
Applied model VQ40DE

C
Final drive model R180A
Transmission type A/T M/T
Grade S, X, SE Off Road S, X Off Road DLN
Gear ratio 3.133 3.357 3.538 3.962
Number of teeth (Drive gear/Drive pinion) 47/15 47/14 46/13 48/13
E
Differential gear oil capacity (Approx.) 0.85 (1-3/4 US pt, 1-1/2 lmp pt)
Number of pinion gears 2
Drive pinion adjustment spacer type Collapsible F
G
DRIVE GEAR RUNOUT
Unit: mm (in)
Item Runout limit H

Drive gear back face 0.08 (0.0031) or less
SIDE GEAR CLEARANCE

Unit: mm (in)
I
Item Specification
0.1 (0.004) or less J
Side gear back clearance (Clearance between side gear and differ-
(Each gear should rotate smoothly without excessive resistance
ential case for adjusting side gear backlash)
during differential motion.)
PRELOAD TORQUE K
Item Specification
Drive pinion bearing preload torque 1.08 - 1.66 (0.11 - 0.16, 10 - 14) L
Side bearing preload torque 0.59 - 1.08 (0.06 - 0.11, 6 - 9)
Total preload torque
(Total preload torque = drive pinion bearing preload torque + side 1.67 - 2.74 (0.17 - 0.27, 15 - 24)
M
bearing preload torque).
BACKLASH N
Unit: mm (in)
Item Specification
Drive gear to drive pinion backlash 0.10 - 0.15 (0.0039 - 0.0059) O
COMPANION FLANGE RUNOUT
Unit: mm (in)
P
Item Runout limit
Companion flange face 0.1 (0.004) or less
Companion flange inner side 0.1 (0.004) or less
SELECTIVE PARTS
Drive Pinion Height Adjusting Washer

< SERVICE DATA AND SPECIFICATIONS (SDS) [FRONT FINAL DRIVE: R180A]
Unit: mm (in)
Thickness Part number* Thickness Part number*

3.09 (0.1217) 38154 EA000 3.39 (0.1335) 38154 EA010
3.12 (0.1228) 38154 EA001 3.42 (0.1346) 38154 EA011
3.15 (0.1240) 38154 EA002 3.45 (0.1358) 38154 EA012
3.18 (0.1252) 38154 EA003 3.48 (0.1370) 38154 EA013
3.21 (0.1264) 38154 EA004 3.51 (0.1382) 38154 EA014
3.24 (0.1276) 38154 EA005 3.54 (0.1394) 38154 EA015
3.27 (0.1287) 38154 EA006 3.57 (0.1406) 38154 EA016
3.30 (0.1299) 38154 EA007 3.60 (0.1417) 38154 EA017
3.33 (0.1311) 38154 EA008 3.63 (0.1429) 38154 EA018
3.36 (0.1323) 38154 EA009 3.66 (0.1441) 38154 EA019
*: Always check with the Parts Department for the latest parts information.
Side Gear Thrust Washer

Unit: mm (in)

0.75 (0.0295) 38424 W2010 0.87 (0.0343) 38424 W2014
0.78 (0.0307) 38424 W2011 0.90 (0.0354) 38424 W2015
0.81 (0.0319) 38424 W2012 0.93 (0.0366) 38424 W2016
0.84 (0.0331) 38424 W2013 0.96 (0.0378) 38424 W2017
Side Bearing Adjusting Washer

Unit: mm (in)
1.95 (0.0768) 38453 EA000 2.35 (0.0925) 38453 EA008
2.00 (0.0787) 38453 EA001 2.40 (0.0945) 38453 EA009
2.05 (0.0807) 38453 EA002 2.45 (0.0965) 38453 EA010
2.10 (0.0827) 38453 EA003 2.50 (0.0984) 38453 EA011
2.15 (0.0846) 38453 EA004 2.55 (0.1004) 38453 EA012
2.20 (0.0866) 38453 EA005 2.60 (0.1024) 38453 EA013
2.25 (0.0886) 38453 EA006 2.65 (0.1043) 38453 EA014
2.30 (0.0906) 38453 EA007

PRECAUTIONS
< PRECAUTION > [C200]
PRECAUTION A
PRECAUTIONS
Precaution for Servicing Rear Final Drive INFOID:0000000004095642
B
operations.
• Check for the correct installation status prior to removal or disassembly. When matching marks are required, C
• Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from DLN
• Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace them E
• Clean and flush the parts sufficiently and blow them dry. F
• In principle, tighten nuts or bolts gradually in several steps working diagonally from inside to outside. If a G
• Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified. H

PREPARATION
< PREPARATION > [C200]
PREPARATION
PREPARATION
(Kent-Moore No.)
Tool name
KV38108300 Removing and installing drive pinion lock nut
( — )
Flange wrench
MS660
KV38100500 Installing front oil seal

(J-25273) a: 80 mm (3.15 in) dia.
YY@/ 700C
ST3127S000 Measuring drive pinion bearing preload torque

(J-25765-A) and total preload torque
Preload gauge
1: GG91030000
(J-25765)
Torque wrench
2: HT62940000
( — )
3: HT62900000 MS013
( — )
(J-37228)
Seal cutter
R,MS/ 35
ST3306S001 Removing and installing side bearing inner

( — ) race
Differential side bearing puller set a: 28.5 mm (1.122 in) dia.
1: ST33051001 b: 38 mm (1.50 in) dia.
(J-22888-20)
Puller
2: ST33061000
(J-8107-2)
Base MS/ 61

PREPARATION
(Kent-Moore No.) A
Tool name
ST30031000 Removing drive pinion rear bearing inner race
(J-22912-01) B
Puller
YY@/ 6/ / C
KV38100600 Installing side bearing adjusting washer DLN

(J-25267) a: 8 mm (0.31 in)
Drift b: R42.5 mm (1.673 in)
E
MS417 F
(J-25742-5) a: 79 mm (3.11 in) dia.
Drift b: 59 mm (2.32 in) dia. G
H
YY@0/ / / C
ST30613000 Installing drive pinion front bearing outer race

(J-25742-3) a: 72 mm (2.83 in) dia. I
YY@0/ / / C
K
ST30611000 Installing drive pinion front bearing outer race
(J-25742-1) [Use with ST30613000 (J-25742-3) and
Drift bar ST30621000 (J-25742-5)]
L
M
R,MS/ 8/
ST30901000 Installing drive pinion rear bearing inner race

(J-26010-01) a: 79 mm (3.11 in) dia.
N
c: 35.2 mm (1.386 in) dia.
YY@/ 867C
ST3323 0000 Installing side bearing inner race P

(J-25805-01) a: 51 mm (2.01 in) dia.
c: 28.5 mm (1.122 in) dia.
MS/ 74

PREPARATION
(Kent-Moore No.)
Tool name
— Measuring turning torque
(J-8129)
Spring gauge
MS016
— Adjusting bearing preload and pinion gear

(J-34309) height
Differential shim selector tool
MS023
— Selecting pinion height adjusting washer

(J-25269-4)
Side bearing disc (2 Req'd)
MS025

Spacer Installing pinion front bearing inner race
a: 60 mm (2.36 in) dia.
b: 36 mm (1.42 in) dia.
c: 30 mm (1.18 in)
YY@0022C
Power tool Loosening nuts and bolts
OAHB/ 08/ D

Symptom
×: Applicable
Reference page

Noise
Possible cause and SUSPECTED PARTS

Gear tooth rough DLN-158, "Disassembly and Assembly"
×
FUNCTION DIAGNOSIS
Gear contact improper DLN-158, "Disassembly and Assembly"
×
Tooth surfaces worn DLN-158, "Disassembly and Assembly"
×
×
Backlash incorrect DLN-158, "Disassembly and Assembly"
DLN-183
×
Companion flange excessive runout DLN-158, "Disassembly and Assembly"
×
Gear oil improper MA-11, "Fluids and Lubricants"
×
PROPELLER SHAFT DLN-128, "NVH Troubleshooting Chart"
REAR AXLE RAX-19, "NVH Troubleshooting Chart"
×
REAR SUSPENSION RSU-4, "NVH Troubleshooting Chart"
×
×
ROAD WHEEL WT-43, "NVH Troubleshooting Chart"

×
DRIVE SHAFT

2009 Xterra
[C200]
INFOID:0000000004095645
L
F
P
K
E
B
A
N
H
C
O
G
M
DLN
DESCRIPTION
< FUNCTION DIAGNOSIS > [C200]
DESCRIPTION
KCH@/ 080D
1. Companion flange 2. Pinion front bearing 3. Collapsible spacer

4. Pinion rear bearing 5. Differential case 6. Side bearing
7. Drive gear 8. Pinion mate gear 9. Side gear
10. Pinion mate shaft 11. Drive pinion

< ON-VEHICLE MAINTENANCE > [C200]
B
DRAINING
1. Stop engine. C
2. Remove the drain plug from the rear final drive assembly to
drain the differential gear oil.
3. Install the drain plug with a new gasket to the rear final drive DLN
"Disassembly and Assembly".
CAUTION: E
F
KCH@/ 076D
FILLING
G
1. Remove the filler plug from the rear final drive assembly.
2. Fill the rear final drive assembly with new differential gear oil
until the level reaches the specified level near the filler plug hole. H

grade and capacity and Lubricants". I
3. Install the filler plug with sealant applied on the threads to the
rear final drive assembly. Tighten to the specified torque. Refer
to DLN-190, "Disassembly and Assembly". J
• Use High Performance Thread Sealant or equivalent. Refer to
GI-14, "Recommended Chemical Products and Sealants".
KCH@/ 016D

K
DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL

L
1. Make sure that differential gear oil is not leaking from the rear final drive assembly or around it.
shown.
CAUTION: M
rear final drive assembly. Tighten to the specified torque. Refer N
to DLN-190, "Disassembly and Assembly".
GI-14, "Recommended Chemical Products and Sealants". O
KCH@/ 016D

FRONT OIL SEAL
< ON-VEHICLE REPAIR > [C200]
ON-VEHICLE REPAIR
FRONT OIL SEAL
REMOVAL
1. Remove the propeller shaft. Refer to DLN-130, "Removal and Installation".
2. Put matching mark on the end of the drive pinion. The matching
mark should be in line with the matching mark A on companion
flange.
CAUTION:
For matching mark, use paint. Do not damage drive pinion.
NOTE:
The matching mark A on the final drive companion flange indi-
cates the maximum vertical runout position.
OCH@/ 564D
V CH@/ 130D
ROC626
5. Remove the front oil seal using suitable tool.
V OC/ 02
INSTALLATION
1. Apply multi-purpose grease to the front oil seal lips.

FRONT OIL SEAL
2. Install the new front oil seal using Tool.
A
Tool number : KV38100500 (J-25273)
CAUTION:
• Do not reuse oil seal. B
• Do not incline oil seal when installing.
V CH@/ 123D
DLN
3. Align the matching mark of drive pinion with the matching mark
A of companion flange, then install the companion flange.
E
G
OCH@/ 564D
4. Apply gear oil on the screw part of drive pinion and the seating
H
surface of drive pinion lock nut.
5. Install the new drive pinion lock nut and tighten to the specified
torque using Tool. Refer to DLN-190, "Disassembly and Assem-
bly". I

J
CAUTION:
Do not reuse drive pinion lock nut.
6. Install the propeller shaft. Refer to DLN-130, "Removal and
Installation".
V CH@/ 130D
K

CARRIER COVER
CARRIER COVER
REMOVAL
2. Disconnect the parking brake cable and brake tube from the car-
rier cover.
Tool number : KV10111100 (J-37228)

CAUTION:
mating surface.
KCH@/ 015D
INSTALLATION
1. Apply a bead of sealant to the mating surface of the carrier
cover as shown.
CAUTION:
Remove any old sealant adhering to the mating surfaces.
2. Install the carrier cover to the gear carrier. Tighten the bolts to
Assembly". V CH@/ 171D
3. Connect the parking brake cable and brake tube to the carrier
cover.
4. Fill the rear final drive assembly with recommended differential gear oil. Refer to DLN-185, "Checking Dif-
ferential Gear Oil".

REAR FINAL DRIVE
< REMOVAL AND INSTALLATION > [C200]
REMOVAL AND INSTALLATION A

REAR FINAL DRIVE
B
REMOVAL
CAUTION: C
• Do not damage spline, companion flange and front oil seal when removing propeller shaft.
• Before removing final drive assembly or rear axle assembly, disconnect ABS sensor harness con-
nector from the assembly and move it away from final drive/rear axle assembly area. Failure to do so
may result in sensor wires being damaged and sensor becoming inoperative. DLN
E
3. Remove the axle shaft. Refer to RAX-9, "Removal and Installation".
4. Remove the stabilizer bar. Refer to RSU-13, "Removal and Installation".
5. Disconnect the following components from the rear final drive. F
• ABS sensor wire harness
• Parking brake cable
• Brake hoses and tubes
G
I
KCH@/ 015D
6. Support rear final drive assembly using a suitable jack. J

7. Remove rear shock absorber lower bolts. Refer to RSU-9, "Removal and Installation".
8. Remove leaf spring U-bolt nuts. Refer to RSU-10, "Removal and Installation".
K
9. Remove rear final drive assembly
CAUTION:
Secure rear final drive assembly to the jack while removing it.
L
INSTALLATION
CAUTION:
• Fill the rear final drive assembly with differential gear oil after installation. Refer to DLN-185, "Check- M
ing Differential Gear Oil".
• Bleed the air from brake system. Refer to BR-17, "Bleeding Brake System".
N

REAR FINAL DRIVE
< DISASSEMBLY AND ASSEMBLY > [C200]

REAR FINAL DRIVE
COMPONENTS
V CH@/ 170D

REAR FINAL DRIVE
1. Gear carrier 2. Drive pinion lock nut 3. Companion flange A

4. Front oil seal 5. Drive pinion front bearing 6. Drain plug
7. Collapsible spacer 8. Side bearing cap 9. Drive pinion rear bearing
10. Drive pinion height adjusting washer 11. Drive pinion 12. Drive gear B
13. Differential case 14. Carrier cover 15. Filler plug
16. Pinion mate shaft 17. Lock pin 18. Side bearing
19. Side bearing adjusting washer 20. Side gear thrust washer 21. Side gear C
22. Pinion mate gear 23. Pinion mate thrust washer 24. Gasket
25. Breather
DLN
• Drain the differential gear oil before inspection and adjustment. Refer to DLN-185, "Changing Differential
Gear Oil".
• Remove and install the carrier cover as necessary for inspection and adjustment. Refer to DLN-188, E
F
1. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
2. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
3. Measure total preload torque using Tool. G
Tool number : ST3127S000 (J-25765-A)

H
: 1.4 - 2.9 N·m (0.15 - 0.29 kg-m, 13 - 25 in-lb)
NOTE: I
Side bearing preload torque
• If the measured value is out of the specification, check and adjust OCH@/ 2/ 8D J
each part. Adjust the drive pinion bearing preload torque first, then
adjust the side bearing preload torque.
K
If the total preload torque is greater than specification
On drive pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same L
amount to each side. Refer to DLN-209, "Inspection and Adjust-
ment".
M
If the total preload torque is less than specification
On drive pinion bearings: Tighten the drive pinion nut.
On side bearings: Use thicker side bearing adjusting washers by the same N
amount to each side. Refer to DLN-209, "Inspection and Adjust-
ment".
O
Drive Gear Runout

REAR FINAL DRIVE
1. Fit a dial indicator to the drive gear back face.
2. Rotate the drive gear to measure runout.
Runout limit : 0.08 mm (0.0031 in) or less

• If the runout is outside of the limit, check the condition of the drive
gear assembly. Foreign material may be caught between the drive
gear and differential case, or the differential case or drive gear may
be deformed.
CAUTION:
Replace drive gear and drive pinion as a set. ROC775
Tooth Contact
Checking gear tooth contact pattern is necessary to verify correct relationship between drive gear and drive
pinion. Gears which are not positioned in proper arrangement may be noisy and/or have a short life. Check
gear tooth contact pattern to obtain the best contact for low noise and long life.
1. Apply red lead to drive gear.
NOTE:
ROC088
2. Rotate the drive gear back and forth several times. Then check
for correct drive pinion to drive gear tooth contact as shown.
CAUTION:
Check tooth contact on drive side and reverse side.
RCH@/ 46/ D
3. If the tooth contact is improperly adjusted, follow the procedure

below to adjust the pinion height (dimension X).
RCH@/ 406D

REAR FINAL DRIVE
• If the tooth contact is near the face (face contact), or near the heel
(heel contact), use a thicker drive pinion height adjusting washers A
to move the drive pinion closer to the drive gear.
B
OCH@/ 33/ D
DLN
• If the tooth contact is near the flank (flank contact), or near the toe
(toe contact), use a thinner drive pinion height adjusting washers to
move the drive pinion farther from the drive gear. E
G
OCH@/ 330D
Backlash
H
lash.
I
Backlash: 0.10 - 0.15 mm (0.0039 - 0.0059 in)
• If the backlash is outside of the specification, change the thickness
of each side bearing adjusting washer. J

Make drive gear back side adjusting washer thicker, K
and drive gear tooth side adjusting washer thinner by ROC085
the same amount. Refer to DLN-209, "Inspection and

Adjustment". L
Make drive gear back side adjusting washer thinner,
and drive gear tooth side adjusting washer thicker by M
the same amount. Refer to DLN-209, "Inspection and
Adjustment".
CAUTION: N
Do not change the total thickness of side bearing adjusting washers as it will change the side bearing
preload torque.
Companion Flange Runout O

REAR FINAL DRIVE
ion flange face (inner side of the bolt holes) and companion
Runout limit: 0.08 mm (0.0031 in) or less

below to adjust.
a. Rotate the companion flange on the drive pinion by 90°, 180°
and 270° while checking for the position where the runout is
minimum. RCH@1/ 67D
b. If the runout is still outside of the runout limit after the companion
flange has been rotated on the drive pinion, possible cause could be an assembly malfunction of drive pin-
ion and drive pinion bearing or a malfunctioning drive pinion bearing.
c. If the runout is still outside of the runout limit after repair of the assembly of drive pinion and drive pinion
DISASSEMBLY
1. Remove carrier cover bolts.
2. Remove carrier cover using Tool.
Tool number : KV10111100 (J-37228)

CAUTION:
mating surface.
RCH@1470D
3. For proper reinstallation, paint matching marks on one side of

side bearing cap.
CAUTION:
• Side bearing caps are line-board for initial assembly. The
positions.
• For matching mark, use paint. Do not damage side bear-
ing cap.
ROC603
4. Remove side bearing caps.
ROC1/ 1

REAR FINAL DRIVE
5. Remove differential case assembly using suitable tool.
A
ROC082
DLN
• Keep side bearing outer races together with inner races. Do
not mix them up. Also, keep side bearing adjusting washers
together with bearings. E
G
ROC634
6. Remove side bearing inner race using Tools. H
Tool number A: ST33051001 (J-22888-20)

B: ST33061000 (J-8107-2) I
CAUTION:
• Engage puller jaws in groove to prevent damage.
• To prevent damage to the side bearing and drive gear, J
place copper plates between these parts and vise.
• It is not necessary to remove side bearing inner race
except if it is replaced. K
ROC81/
7. For proper reinstallation, paint matching mark on one differential O

case assembly.
CAUTION:
Use paint for matching marks. Do not damage differential P
case or drive gear.
8. Remove drive gear bolts.
9. Tap the drive gear off the differential case assembly using suit-
able tool.
CAUTION:
Tap evenly all around to keep drive gear from binding.
OCH@/ 385D

REAR FINAL DRIVE
10. Remove the lock pin of pinion mate shaft from the drive gear
side using suitable tool.
ROC/ 14
11. Remove pinion mate shaft.
RCH@/ / 20I
washer from differential case.
RCH@/ / 21I

1. Remove differential case assembly. Refer to "differential case assembly" in disassembly.
2. Remove drive pinion lock nut using Tool.

using paint.
CAUTION:
V CH@/ 130D

REAR FINAL DRIVE
4. Remove companion flange using suitable Tool.
A
ROC/ 03
DLN
5. Remove drive pinion assembly from gear carrier using suitable
tool.
CAUTION:
E
6. Remove front oil seal.
7. Remove drive pinion front bearing inner race.
F
8. Remove collapsible spacer.
G
ROC1/ 5
9. Remove drive pinion rear bearing inner race and drive pinion
H
Tool number : ST30031000 (J-22912-01)

I
R,OC068
K
10. Tap drive pinion front and rear bearing outer races uniformly with
a brass bar or equivalent to remove.
CAUTION: L
N
RCH@/ 706D

O
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.
Drive Pinion and Drive Gear P

REAR FINAL DRIVE
Bearing
Gear Carrier
Companion Flange
ADJUSTING AND SELECTING WASHERS
• Assemble the differential parts if they are disassembled. Refer to "Differential Assembly" in assembly.
measured is upward.
OCH@/ 35/ D

gear back and differential case at three different points, while
Side gear back clearance: 0.1 - 0.2 mm (0.004 - 0.008 in)

or less.
use a thicker or thinner side gear thrust washer to adjust.
If the side gear back clearance is greater than

specification:
Use a thicker side gear thrust washer.
If the side gear back clearance is less than spec-
ification:
CAUTION:
• Insert feeler gauges with the same thickness on both
sides to prevent side gear from tilting.
• Each gear should rotate smoothly without excessive OCH@/ 465D
resistance during differential motion.

• Select a side gear thrust washer for right and left individually.

REAR FINAL DRIVE
NOTE:
Side gear back clearance is clearance between side gear and differential case for adjusting side gear A
backlash.
Side Bearing Preload Torque
• A selection of side bearing adjusting washers is required for successful completion of this procedure. B
1. Apply differential gear oil to the side bearings, and install the dif-
ferential case assembly with the side bearing outer races into
the gear carrier. C
CAUTION:
Do not reuse side bearing outer race when replacing side
bearing inner race (replace as a set).
DLN
E
ROC416
2. Insert the left and right original side bearing adjusting washers in F
place between side bearings and gear carrier using Tool.
Tool number : KV38100600 (J-25267)

G
ROC6/ 8 I
3. Align the matching mark on the side bearing cap with the match-
ing mark on the gear carrier.
J
4. Install the side bearing caps and tighten the side bearing cap
bolts to the specified torque. Refer to DLN-190, "Disassembly
and Assembly".
5. Turn the differential assembly several times to seat the side K
bearings.
RCH@0684D
6. To determine side bearing preload torque, measure the pulling M

force of the differential assembly at the drive gear bolt using
Tool.
N
Specification : 34.2 - 39.2 N (3.5 - 4.0 kg, 7.7 - 8.8 lb) O

of pulling force at the drive gear bolt
NOTE:
If pulling force of the differential assembly at the drive gear bolt ROC083@
P
is within specification, side bearing preload torque will also be
within specification. Refer to DLN-209, "Inspection and Adjustment".

REAR FINAL DRIVE
7. If the pulling force is outside the specification, use a thicker or
thinner side bearing adjusting washer to adjust. Refer to DLN-
209, "Inspection and Adjustment".
If the pulling force is less than the specification:

Use a thicker side bearing adjusting washer.
If the pulling force is greater than the specification:
Use a thinner side bearing adjusting washer.
CAUTION:
Select a side bearing adjusting washer for right and left ROC661
individually.
8. Record the total amount of washer thickness required for the correct side bearing preload torque.
Drive Pinion Height
1. Make sure all parts are clean and that the bearings are well
lubricated.
2. Assemble the drive pinion bearings onto the Tool.
ROC658
• Drive pinion front bearing; make sure the J-34309-3 drive

pinion front bearing seat is secured tightly against the J-
34309-2 gauge anvil. Then turn the J-34309-5 drive pinion
front bearing pilot to secure the drive pinion bearing in its
proper position.
• Drive pinion rear bearing; the J-34309-8 drive pinion rear
bearing pilot is used to center the drive pinion rear bearing
only. The J-34309-4 drive pinion rear bearing locking seat is
used to lock the drive pinion rear bearing to the assembly.
• Installation of J-34309-9 and J-34309-16; place a suitable
2.5 mm (0.098 in) thick plain washer between J-34309-9 and
ROC086@
J-34309-16. Both surfaces of J-34309-9 and J-34309-16 must
be parallel with a clearance of 2.5 mm (0.098 in).
3. Install the drive pinion rear bearing inner race into the gear car-
rier. Then insert the drive pinion height adjusting washer selec-
tor tool, J-34309-1, gauge screw assembly.
ROC782

REAR FINAL DRIVE
4. Assemble the drive pinion front bearing inner race and the J-
34309-2 gauge anvil. Assemble them together with the J-34309- A
1 gauge screw in the gear carrier. Make sure that the drive pin-
ion height gauge plate, J-34309-16, will turn a full 360°. Tighten
the two sections together by hand.
B
ROC088@
DLN
5. Turn the assembly several times to seat the drive pinion bear-
ings.
E
G
ROC66/
6. Measure the turning torque at the end of the J-34309-2 gauge

H
anvil using Tool.
Tool number : ST3127S000 (J-25765- A)

I
Turning torque: 1.0 - 1.3 N·m (0.11 - 0.13 kg-m,
9 - 11 in-lb)
J
OCH@/ 455D
K
7. Place the J-34309-11 drive pinion height adapter onto the gauge
plate and tighten it by hand.
CAUTION: L
Make sure all machined surfaces are clean.
N
ROC1/ 7@
8. Position the side bearing discs, Tool, and arbor firmly into the O
side bearing bores. Install the side bearing caps and tighten the
side bearing cap bolts to the specified torque. Refer to "DLN-
190, "Disassembly and Assembly".
P
Tool number : — (J-25269-4)
ROC100@

REAR FINAL DRIVE
9. Select the correct standard drive pinion height adjusting washer
thickness. Select by using a standard gauge of 3 mm (0.12 in)
and your J-34309-101 feeler gauge. Measure the distance
between the J-34309-11 drive pinion height adapter, including
the standard gauge and the arbor.
ROC1/ 3@
10. Write down the exact measurement (the value of feeler gauge).
ROC664
11. Correct the drive pinion height adjusting washer size by referring
to the drive pinion “head number”.
There are two numbers painted on the drive pinion. The first
one refers to the drive pinion and drive gear as a matched
set. This number should be the same as the number on the
drive gear. The second number is the drive pinion “head
number”. It refers to the ideal drive pinion height from stan-
dard for quietest operation. Use the following chart to
determine the correct drive pinion height adjusting washer.
Add or remove from the standard drive pinion ROC431

Head number
height adjusting washer thickness measurement
-6 Add 0.06 mm (0.0024 in)
-5 Add 0.05 mm (0.0020 in)
-4 Add 0.04 mm (0.0016 in)
-3 Add 0.03 mm (0.0012 in)
-2 Add 0.02 mm (0.0008 in)
-1 Add 0.01 mm (0.0004 in)
0 Use the selected washer thickness
+1 Subtract 0.01 mm (0.0004 in)
+2 Subtract 0.02 mm (0.0008 in)
+3 Subtract 0.03 mm (0.0012 in)
+4 Subtract 0.04 mm (0.0016 in)
+5 Subtract 0.05 mm (0.0020 in)
+6 Subtract 0.06 mm (0.0024 in)
12. Select the correct drive pinion height adjusting washer. Refer to DLN-209, "Inspection and Adjustment".

REAR FINAL DRIVE
13. Remove the Tool from the gear carrier and disassemble to
retrieve the drive pinion bearings. A

B
ROC1/ 4@
DLN
ASSEMBLY
1. Install the new drive pinion front and rear bearing outer races E
using Tools.
Tool number A: ST30611000 (J-25742-1) F

B: ST30621000 (J-25742-5)
C: ST30613000 (J-25742-3)
G
CAUTION:
• First tap the drive pinion bearing outer race until it
becomes flush with the gear carrier.
• Do not reuse drive pinion front and rear bearing outer H
race.
ROC568
L
2. Select a drive pinion height adjusting washer. Refer to DLN-209, "Inspection and Adjustment".
3. Install the selected drive pinion height adjusting washer to the
drive pinion. Press the new drive pinion rear bearing inner race
to it using Tool. M
Tool number : ST30901000 (J-26010-01)

CAUTION: N
• Install the drive pinion height adjusting washer in the
proper direction as shown.
• Do not reuse drive pinion rear bearing inner race. O
RCH@/ / 37D

REAR FINAL DRIVE
4. Assemble the new collapsible spacer to the drive pinion.
CAUTION:
Do not reuse collapsible spacer.
5. Apply differential gear oil to the drive pinion rear bearing, and
install the drive pinion assembly to the gear carrier.
6. Apply differential gear oil to the drive pinion front bearing, and
install the new drive pinion front bearing inner race to the drive
pinion assembly.
CAUTION:
Do not reuse drive pinion front bearing inner race.
ROC111
7. Press the drive pinion front bearing inner race to the drive pinion
as far as drive pinion lock nut can be tightened using suitable
spacer.
ROC785

the circumference of the new front oil seal. Then drive the new
using Tool.
Tool number : KV38100500 (J-25273)

CAUTION:
gear oil to the circumference of the new front oil seal. OCH@/ 452D

REAR FINAL DRIVE
seating surface of the new drive pinion lock nut. Then adjust the A
the drive pinion bearing preload torque using Tool B.
B
B: ST3127S000 (J-25765-A)
C
1.1 - 1.4 N·m (0.12 - 0.14 kg-m, 10 - 12 in-lb)
CAUTION: DLN
and the seating surface of the new drive pinion lock nut. E
Assembly". F
specified value, replace collapsible spacer and tighten it
again to adjust. Do not loosen drive pinion lock nut to G
adjust the drive pinion bearing preload torque. V CH@/ 268D
• After adjustment, rotate drive pinion back and forth 2 to 3

times to check for unusual noise, rotation malfunction, and other malfunctions. H
11. Check companion flange runout. Refer to "companion flange runout" in disassembly.
12. Install differential case assembly. Refer to "differential case assembly" in assembly.
Differential Assembly I
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly, or reinstall the old ones on
the side gears. J
L
RCH@/ 082I
2. Install the side gears and side gear thrust washers into the dif- M
ferential case.
CAUTION:
Make sure that the circular clip is installed to side gears. N
3. Install the pinion mate thrust washers to the two pinion mate
gears. Then install the pinion mate gears with the pinion mate
thrust washers by aligning them in diagonally opposite positions
and rotating them into the differential case. O
RCH@1/ 14D P

REAR FINAL DRIVE
4. Align the lock pin hole on the differential case with the lock pin
hole on the pinion mate shaft, and install the pinion mate shaft.
5. Measure the side gear end play. If necessary, select the appro-
priate side gear thrust washers. Refer to DLN-209, "Inspection
and Adjustment".
RCH@/ 084I
6. Drive a new lock pin into the pinion mate shaft until it is flush
with the differential case using suitable tool.
CAUTION:
ROC/ 2/
7. Align the matching mark of the differential case with the mark of
the drive gear, then place the drive gear onto the differential
case.
RCH@1482D
gear and install the bolts.
• Use Genuine Medium Strength Thread Locking Sealant or
equivalent. Refer to GI-14, "Recommended Chemical Prod-
ucts and Sealants".
CAUTION:
clean.
RCH@1483D
9. Tighten the drive gear bolts to the specified torque. Refer to

DLN-190, "Disassembly and Assembly". After tightening the
drive gear bolts to the specified torque, tighten an additional 31°
to 36° using Tool.
Tool number : KV10112100-A (BT-8653-A)

CAUTION:
• Always use Tool. Avoid tightening based on visual check
alone.
• Tighten drive gear bolts in a crisscross pattern.
@V AH@/ 611YY

REAR FINAL DRIVE
10. Press the new side bearing inner races to the differential case
using Tools. A
Tool number A: ST33230000 (J-25805-01)

B: ST33061000 (J-8107-2) B
CAUTION:
Do not reuse side bearing inner race.
C
ROC242
DLN
11. Install the differential case assembly with the side bearing outer
races into gear carrier.
12. Measure the side bearing preload torque. If necessary, select E
the appropriate side bearing adjusting washers. Refer to DLN-
209, "Inspection and Adjustment".
F
G
ROC416
13. Insert the selected left and right side bearing adjusting washers H
in place between the side bearings and gear carrier using Tool.
Tool number : KV38100600 (J-25267)

I
ROC6/ 8 K
14. Install the side bearing caps with the matching marks aligned
and tighten the side bearing cap bolts to the specified torque.
Refer to DLN-190, "Disassembly and Assembly". L
N
ROC778
15. Check and adjust the drive gear runout, tooth contact, drive gear to drive pinion backlash, and total pre- O
load torque. Refer to "disassembly".
Recheck above items.
P

REAR FINAL DRIVE
16. Apply sealant to the mating surface of the carrier cover.
CAUTION:
Assembly".
V CH@/ 171D

< SERVICE DATA AND SPECIFICATIONS (SDS) [C200]

B
C200
C
VQ40DE
Applied model 5A/T
2WD 4WD DLN
Final drive model C200
Gear ratio 2.937 3.133
E
Number of teeth (Drive gear/Drive pinion) 47/16 47/15
Oil capacity (Approx.) 1.6 (3-3/8 US pt, 2-7/8 lmp pt)
Number of pinion gears 2 F
Drive pinion adjustment spacer type Collapsible

G
DRIVE GEAR RUNOUT

Unit: mm (in) H
Item Runout limit
Drive gear back face 0.08 (0.0031) or less
I
SIDE GEAR CLEARANCE
Unit: mm (in)
Item Specification
J
Side gear back clearance 0.1 - 0.2 (0.004 - 0.008) or less
(Clearance between side gear and differential case for adjusting (Each gear should rotate smoothly without excessive resistance
side gear backlash) during differential motion.)
K
PRELOAD TORQUE
Item Specification L
Drive pinion bearing preload torque 1.1 - 1.4 (0.12 - 0.14, 10 - 12)
Side bearing preload torque (reference value determined by drive
0.3 - 1.5 (0.03 - 0.15, 3 - 13) M
gear bolt pulling force)
Drive gear bolt pulling force (by spring gauge) 34.2 − 39.2 N (3.5 − 4 kg, 7.7 − 8.8 lb)
N
(Total preload torque = drive pinion bearing preload torque + Side 1.4 - 2.9 (0.15 - 0.29, 13 - 25)
bearing preload torque)
BACKLASH O
Unit: mm (in)
Item Specification
Drive gear to drive pinion gear 0.10 - 0.15 (0.0039 - 0.0059) P
Unit: mm (in)
Item Runout limit

Companion flange Inner side 0.08 (0.0031) or less

< SERVICE DATA AND SPECIFICATIONS (SDS) [C200]
SELECTIVE PARTS
Unit: mm (in)
0.75 (0.0295) 38424 EC000 0.87 (0.0343) 38424 EC004
0.78 (0.0307) 38424 EC001 0.90 (0.0350) 38424 EC005
0.81 (0.0319) 38424 EC002 0.93 (0.0366) 38424 EC006
0.84 (0.0331) 38424 EC003

Unit: mm (in)
3.05 (0.1201) 38154 0C000 3.29 (0.1295) 38154 0C008
3.08 (0.1213) 38154 0C001 3.32 (0.1307) 38154 0C009
3.11 (0.1224) 38154 0C002 3.35 (0.1319) 38154 0C010
3.14 (0.1236) 38154 0C003 3.38 (0.1331) 38154 0C011
3.17 (0.1248) 38154 0C004 3.41 (0.1343) 38154 0C012
3.20 (0.1260) 38154 0C005 3.44 (0.1354) 38154 0C013
3.23 (0.1272) 38154 0C006 3.47 (0.1366) 38154 0C014
3.26 (0.1283) 38154 0C007 3.50 (0.1378) 38154 0C015
Side Bearing Adjusting Washer

Unit: mm (in)
2.00 (0.0787) 38453 N3100 2.35 (0.0925) 38453 N3107
2.05 (0.0807) 38453 N3101 2.40 (0.0945) 38453 N3108
2.10 (0.0827) 38453 N3102 2.45 (0.0965) 38453 N3109
2.15 (0.0846) 38453 N3103 2.50 (0.0984) 38453 N3110
2.20 (0.0866) 38453 N3104 2.55 (0.1004) 38453 N3111
2.25 (0.0886) 38453 N3105 2.60 (0.1024) 38453 N3112
2.30 (0.0906) 38453 N3106 2.65 (0.1043) 38453 N3113

PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: M226 ]
PRECAUTION A
PRECAUTIONS
B
operations.
• Check for the correct installation status prior to removal or disassembly. When matching marks are required, C
• Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from DLN
• Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace them E
• Clean and flush the parts sufficiently and blow them dry. F
• In principle, tighten nuts or bolts gradually in several steps working diagonally from inside to outside. If a G
• Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified. H

PREPARATION
< PREPARATION > [REAR FINAL DRIVE: M226 ]
PREPARATION
PREPARATION
(Kent-Moore No.)
Tool name
KV40104000 Removing and installing drive pinion nut
( — ) a: 85 mm (3.35 in) dia.
Flange wrench b: 65 mm (2.56 in) dia.
MS548
ST33290001 Removing front oil seal

(J-34286)
Puller
YY@/ 5/ 0C
ST15310000 Installing front oil seal

( — ) a: 96mm (3.77 in) dia.
MS004
ST3127S000 Inspecting drive pinion bearing preload

(J-25765-A) and total preload
Preload gauge set
1. GG91030000
(J-25765)
Torque wrench
2. HT62940000 (1/2″)
( — )
Socket adapter
3. HT62900000 (3/8″) MS013
( — )
Socket adapter
— Removing and installing side bearing ad-
(C-4164) juster
Adjuster tool
V CH@/ 081D

PREPARATION
(Kent-Moore No.) A
Tool name
(J-37228) B
Seal cutter
R,MS/ 35
ST30021000 Removing drive pinion rear bearing inner DLN

(J-22912-01) race
Puller
E
YY@/ 6/ / C F
ST33081000 Removing and installing side bearing in-
( — ) ner race
Adapter a: 43 mm (1.69 in) dia. G
b: 33.5 mm (1.32 in) dia.
H
YY@0/ / / C
ST23550000 Removing and installing lock pin

( — ) a: 4.5 mm (0.177 in) dia. I
Pin punch
MS30/
K
— Adjusting pinion gear height
(8144)
Pinion block
L
M
RCH@1488D

(6740)
N
Cone
RCH@15/ 0D
— Adjusting pinion gear height P

(6741)
Screw
RCH@15/ 1D

PREPARATION
(Kent-Moore No.)
Tool name
(6739)
Pinion height lock
RCH@15/ 2D

(D-115-2)
Scooter block
RCH@15/ 3D

(8541A-1)
Arbor disc
RCH@15/ 4D

(D-115-3)
Arbor
RCH@15/ 5D
ST01500001 Installing drive pinion rear bearing outer

( — ) race
Drift a: 89mm (3.50 in) dia.
b: 79 mm (3.11 in) dia.
YY@/ 700C

( — ) race
b: 110 mm (4.33 in) dia.
MS55/
ST33022000 Installing drive pinion front bearing outer

( — ) race
b: 67 mm (2.63 in) dia.
MS55/

PREPARATION
(Kent-Moore No.) A
Tool name
— Installing drive pinion rear bearing inner
(C-4040) race B
Installer
RCH@15/ 6D
KV38100300 Installing side bearing inner race DLN

(J-25523) a: 54 mm (2.13 in) dia.
c: 32mm (1.26 in) dia.
E
YY@0/ 35C F

Puller Removing companion flange and side H
bearing inner race
MS/ 66
J
Puller Removing side bearing inner race
L
YYA/ 712C

M
OAHB/ 08/ D

DESCRIPTION
< FUNCTION DIAGNOSIS > [REAR FINAL DRIVE: M226 ]
FUNCTION DIAGNOSIS
DESCRIPTION
RCH@1525D
1. Companion flange 2. Drive pinion 3. Drive gear

4. Differential case 5. Pinion mate gear 6. Axle shaft
7. Side gear 8. Pinion mate shaft

Symptom
×: Applicable
Reference page

< SYMPTOM DIAGNOSIS >
Noise

SYMPTOM DIAGNOSIS
Gear tooth rough —
×
Gear contact improper DLN-223
×
Tooth surfaces worn —
×
×
Backlash incorrect DLN-223
DLN-217
×
Companion flange excessive runout DLN-223
×
Gear oil improper DLN-218
×
PROPELLER SHAFT
RAX-19, "NVH Troubleshooting Chart",
×
AXLE AND SUSPENSION
× TIRES
WT-43, "NVH Troubleshooting Chart"
×
ROAD WHEEL
×
AXLE SHAFT RAX-19, "NVH Troubleshooting Chart"


2009 Xterra
[REAR FINAL DRIVE: M226 ]
INFOID:0000000004095659
L
F
P
K
E
B
A
N
H
C
O
G
M
DLN
< ON-VEHICLE MAINTENANCE > [REAR FINAL DRIVE: M226 ]
ON-VEHICLE MAINTENANCE
DRAINING
1. Stop engine.
3. Install the drain plug with sealant applied on the threads to the
KCH@/ 072D
FILLING
until the level reaches the specified level near the filler plug hole.

grade and capacity and Lubricants".
KCH@/ 016D

shown.
CAUTION:
KCH@/ 016D

FRONT OIL SEAL
< ON-VEHICLE REPAIR > [REAR FINAL DRIVE: M226 ]
ON-VEHICLE REPAIR A
FRONT OIL SEAL
B
REMOVAL
1. Remove rear propeller shaft. Refer to DLN-138, "Removal and Installation". C
2. Remove brake calipers and rotors. Refer to BR-38, "Removal and Installation of Brake Caliper and Disc
Rotor".
3. Measure the total preload torque. Refer to DLN-223, "Disassembly and Assembly". DLN
NOTE:
Record the total preload torque measurement.
4. Remove the drive pinion lock nut using Tool. E

5. Put matching marks on the companion flange and drive pinion F
using paint.
CAUTION:
Use paint to make the matching marks. Do not damage the G
KCH@/ 011D H

I
V CH@/ 138D
L
Tool number : ST33290001 (J-34286)

M
O
KCH@/ 013D
INSTALLATION
P

FRONT OIL SEAL
1. Apply multi-purpose grease to the lips of the new front oil seal.
Then drive the new front oil seal in evenly until it becomes flush
with the gear carrier using Tool.

CAUTION:
KCH@/ 014D
seating surface of the new drive pinion lock nut and new drive
pinion lock nut washer. Then adjust the drive pinion lock nut
tightening torque using Tool A, and check the total preload
torque using Tool B.

B: ST3127S000 (J-25765-A)
Total preload torque: Refer to DLN-239, "Inspection

and Adjustment".
spacer, it should also be equal to the measurement taken dur-
nut in 6.8 N·m (0.69 Kg-m, 5ft-lb) increments until the total pre-
load torque is met.
CAUTION:
• Do not reuse drive pinion lock nut or drive pinion lock nut
washer.
• Apply anti-corrosive oil to the threads of the drive pinion V CH@/ 27/ D
• Adjust the drive pinion lock nut tightening torque to the lower limit first. Do not exceed the drive
pinion lock nut specified torque. Refer to DLN-223, "Disassembly and Assembly".
• Do not loosen drive pinion lock nut to adjust the total preload torque. If the total preload torque
exceeds the specifications, replace the collapsible spacer and tighten it again to adjust. Refer to
DLN-223, "Disassembly and Assembly".
CAUTION:
Oil".

CARRIER COVER
CARRIER COVER
A
REMOVAL B
rier cover. C
DLN
Tool number : KV10111100 (J-37228)
CAUTION:
• Do not damage the mating surface. E
mating surface.
KCH@/ 015D
F
INSTALLATION
cover as shown. G
CAUTION:
Assembly". OCH@0/ 50D
3. Connect the parking brake cable and brake tube to the carrier J
cover.
ferential Gear Oil". K

REAR FINAL DRIVE ASSEMBLY
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: M226 ]

REMOVAL
CAUTION:
may result in sensor wires being damaged and sensor becoming inoperative.
5. Disconnect the following components from the rear final drive assembly.
• ABS sensor wire harness. Refer to BRC-207, "Removal and Installation".
• Parking brake cable
• Brake hoses and tubes
KCH@/ 015D
6. Support rear final drive assembly using a suitable jack.

9. Remove rear final drive assembly.
CAUTION:
INSTALLATION
CAUTION:
• Fill the rear final drive assembly with differential gear oil after installation. Refer to DLN-218, "Check-

< DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: M226 ]
DISASSEMBLY AND ASSEMBLY A

B
COMPONENTS
C
DLN
V CH@/ 236D
O
1. Drive pinion lock nut 2. Drive pinion nut washer 3. Companion flange
4. Front oil seal 5. Drive pinion front bearing thrust 6. Drive pinion front bearing
washer
P
7. Gear carrier 8. Drain plug 9. Side bearing cap
10. Adjuster lock plate 11. Carrier cover 12. Filler plug
13. Drive pinion 14. Drive pinion height adjusting washer 15. Drive pinion rear bearing
16. Collapsible spacer 17. Side bearing adjuster 18. Side bearing
19. Differential case 20. Drive gear 21. Pinion mate thrust washer
22. Pinion mate gear 23. Pinion mate shaft 24. Lock pin
25. Side gear thrust washer 26. Side gear 27. Breather

• Drain the differential gear oil before inspection and adjustment. Refer to DLN-218.
• Remove and install the carrier cover as necessary for inspection and adjustment. Refer to DLN-221.
2. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.
Total preload torque : 2.49 - 4.57 N·m (0.26 - 0.46 kg-m,

22- 40 in-lb)
NOTE:
• If the measured value is out of the specification, check and OCH@/ 2/ 8D
adjust each part. Adjust the drive pinion bearing preload
torque first, then adjust the side bearing preload torque.

On drive pinion bearings: Replace collapsible spacer.
On side bearings: Loosen side bearing adjuster.

On drive pinion bearings: Tighten drive pinion lock nut.
On side bearings: Tighten side bearing adjuster.
Tooth Contact
1. Thoroughly clean drive gear and drive pinion teeth.
2. Apply red lead to drive gear.
NOTE:
OCH@/ 210D
3. Hold companion flange steady by hand and rotate drive gear in

both directions.
OCH@/ 211D

DLN
RCH@1480D
F
4. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer to DLN-223, "Dis-
assembly and Assembly" and DLN-239, "Inspection and Adjustment".
Backlash G
lash.
H
Backlash: 0.12 - 0.20 mm (0.0050 - 0.0079 in)
2. If the backlash is outside of the specification, adjust each side
bearing side bearing adjuster. I
a. Remove adjuster lock plate.
b. Loosen side bearing cap bolts.
J
RCH@153/ D
c. Tighten or loosen each side bearing adjuster using Tool. K
Tool number : — (C - 4164)

L
OCH@/ 226D N

O
Loosen side bearing adjuster A and tighten side bear-
ing adjuster B by the same amount.
If the backlash is less than specification: P
Loosen side bearing adjuster B and tighten side bear-
ing adjuster A by the same amount.
CAUTION:
Do not change the side bearing side bearing adjusters by
different amounts as it will change the side bearing preload OCH@/ 22/ D
torque.

d. Tighten side bearing cap bolts to the specified torque. Refer to
e. Install adjuster lock plate and tighten to the specified torque.
CAUTION:
Check tooth contact and total preload torque after adjusting
side bearing adjuster. Refer to "Tooth Contact" and "Total Pre-
load Torque".
OCH@/ 220D

Runout limit
Companion flange face: 0.10 mm (0.0039 in)
Companion flange inner side: 0.13 mm (0.0051 in)
below to adjust.
a. Rotate the companion flange on the drive pinion by 90°, 180° RCH@1/ 67D
and 270° while checking for the position where the runout is minimum.
b. If the runout is still outside of the runout limit after the companion flange has been rotated on the drive pin-
ion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a mal-
functioning drive pinion bearing.
DISASSEMBLY
Tool number : KV10111100 (J-37228)

CAUTION:
mating surface.
RCH@1470D
3. For proper reinstallation, paint matching mark on one side of

side bearing cap.
CAUTION:
positions.
• For matching mark, use paint. Do not damage side bear-
ing cap.
4. Remove adjuster lock plates.
OCH@/ 20/ D

A
OCH@/ 200D
DLN
6. Remove side bearing adjusters using Tool.
Tool number : — (C - 4164) E
G
OCH@/ 226D
7. Keep side bearing outer races together with inner races. Do not
mix them up. Also, keep side bearing adjusters together with H
bearing.
8. Remove side bearing adjusters from gear carrier.
I
OCH@/ 201D
K
9. Remove side bearing inner races using Tool.
Tool number : ST33081000 ( — ) L

CAUTION:
Do not damage differential case.
M
N
RCH@1524D
10. For proper reinstallation, paint matching mark on differential O

CAUTION:
case or drive gear. P
CAUTION:
RCH@1127D

13. Remove the lock pin of the pinion mate shaft from the drive gear
side using Tool.
OCH@/ / 51D
14. Remove pinion mate shaft.
RCH@/ / 20I
washer from differential case.
RCH@/ / 21I

1. Remove differential case assembly. Refer to DLN-223, "Disassembly and Assembly".
2. Remove drive pinion lock nut and washer using Tool.

using paint.
CAUTION:
OCH@/ 203D

4. Remove companion flange using suitable tool.
A
OCH@/ 204D
DLN
5. Remove front oil seal using Tool.
Tool number : ST33290001 (J-34286) E

CAUTION:
6. Remove drive pinion front bearing thrust washer. F
G
RCH@1475D
7. Remove drive pinion assembly (with rear inner bearing race and
H
collapsible spacer) out of gear carrier.
CAUTION:
8. Remove drive pinion front bearing inner race from gear carrier. I
OCH@/ 205D
K
9. Tap drive pinion front bearing outer race uniformly with a brass
bar or equivalent to remove.
CAUTION: L
10. Tap drive pinion rear bearing outer race uniformly with a brass
bar or equivalent for removal. M
CAUTION:
N
RCH@1530D
11. Remove drive pinion rear bearing inner race and drive pinion O
Tool number : ST30021000 (J-22912-01) P
RCH@1125D

Bearing
Gear Carrier
Companion Flange
SELECTION ADJUSTING WASHERS
• Assemble the differential parts if they are disassembled. Refer to DLN-223, "Disassembly and Assembly".
measured is upward.
OCH@/ 35/ D

gear back and differential case at three different points, while A
B
Side gear back clearance: 0.305 mm (0.0120 in) or less.
use a thicker or thinner side gear thrust washer to adjust. C
If the side gear back clearance is greater than DLN

specification:
Use a thicker side gear thrust washer.
If the side gear back clearance is less than spec- E
ification:
CAUTION: F
• Insert feeler gauges with the same thickness on both sides to
prevent side gear from tilting.
• Each gear should rotate smoothly without excessive resis- G
tance during differential motion. OCH@/ 465D
• Select a side gear thrust washer for right and left individually.
NOTE: H
Side gear back clearance is clearance between side gear and differential case for adjusting side gear back-
lash.
I
• Drive gear and drive pinion are supplied in matched sets only.
Matching numbers on both drive pinion and drive gear are etched
for verification. If a new gear set is being used, verify the numbers
of each drive pinion and drive gear before proceeding with assem- J
bly.
L
RCH@1130D
• The mounting distance from the center line of drive gear to the back face of drive pinion for the Model 226 M
final drive assembly is 109.5 mm (4.312 in).
On the button end of each drive pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0),
which indicates the best running position for each particular gear set. This dimension is controlled by a
selective drive pinion height adjusting washer between drive pinion inner bearing race and drive pinion. N
For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 in) less drive pinion height
adjusting washer than a drive pinion etched “0”. This means decreasing drive pinion height adjusting washer
thickness; increases the mounting distance of drive pinion to 109.6 mm (4.315 in). If a drive pinion is etched O
m-8 (-3), it would require adding 0.08 mm (0.003 in) more to drive pinion height adjusting washer than would
be required if drive pinion were etched “0”. By adding 0.08 mm (0.003 in), the mounting distance of drive pin-
ion was decreased to 109.4 mm (4.309 in) which is just what m-8 (a-3) etching indicated.
• To change drive pinion adjustment, use different drive pinion height adjusting washers which come in differ- P
ent thickness.
• Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness to
add or subtract from the old drive pinion height adjusting washer.

OLD DRIVE NEW DRIVE PINION MARKING mm (in)

PINION
MARKING -10 (-4) -8 (-3) -5 (-2) -3 (-1) 0 (0) +3 (+1) +5 (+2) +8 (+3) +10 (+4)
+0.20 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0

+10 (+4)
(+0.008) (+0.007) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0)
+0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02
+8 (+3)
(+0.007) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001)
+0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05
+5 (+2)
(+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002)
+0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08
+3 (+1)
(+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003)
+0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10
0 (0)
(+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004)
+0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13
-3 (-1)
(+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005)
+0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15
-5 (-2)
(+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006)
+0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18
-8 (-3)
(+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006) (-0.007)
0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18 -0.20
-10 (-4)
(0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006) (-0.007) (-0.008)
1. Make sure all parts are clean and that drive pinion bearings are
well lubricated.
2. Assemble drive pinion bearings into Tools.
Tool number A: — (8144)

B: — (6740)
C: — (6741)
RCH@1131D
3. Install drive pinion bearing inner race and drive pinion height
adjusting washer to gear carrier using Tool as shown.
OCH@/ 207D
4. Turn the assembly several times to seat drive pinion bearings.
OCH@/ 208D

5. Measure the turning torque using Tool.
A
Turning torque specification: B

1.2 - 2.8 N-m (0.13 - 0.28 kg-m, 11 - 24 in-lb)
OCH@/ 21/ D
DLN
6. Tighten side bearing caps to the specified torque installing Tools
as shown.
Tool number A: — (6739) E

B: — (D-115-2)
C: — (8541A-1) F
D: — (D-115-3)
G
RCH@1535D
7. Put scooter block on pinion height block. Make sure that dial
indicator is level adjusting pressure with a hand. Dial indicator H
indicates “0”.
8. Slide dial indicator along arbor. Record the maximum.
9. Adjust drive pinion height adjusting washer so that the maximum I
will be “0”.
RCH@1536D
K
ASSEMBLY
1. Press a new drive pinion rear bearing outer race into gear car- L
rier using Tools.
Tool number A: ST01500001 ( — ) M

B: ST30022000 ( — )
CAUTION:
Do not reuse drive pinion rear bearing. N
OCH@/ 212D
O

2. Press a new drive pinion front bearing outer race into gear car-
rier using Tool.

CAUTION:
Do not reuse drive pinion front bearing.
3. Select drive pinion height adjusting washer. Refer to DLN-223,
"Disassembly and Assembly".
OCH@/ 213D
4. Press a new drive pinion rear bearing inner race and drive pin-
ion height adjusting washer to drive pinion using Tool.

CAUTION:
Do not reuse drive pinion rear bearing.
5. Apply gear oil to drive pinon rear bearing and drive pinon front
bearing.
6. Install a new drive pinion front bearing inner race in gear carrier.
7. Install drive pinion front bearing thrust washer to gear carrier. RCH@1481D
8. Apply multi-purpose grease to new front oil seal lip. Install new
front oil seal into gear carrier using Tool.

CAUTION:
• Apply multi-purpose grease to the lip of the new front oil
seal.
OCH@/ 215D
9. Install new collapsible spacer to drive pinion. And then install

drive pinion assembly in gear carrier.
CAUTION:
• Do not reuse collapsible spacer.
• Do not damage front oil seal.
RCH@1484D
10. Install the companion flange onto the drive pinion while aligning
the matching marks. Then tap the companion flange using suit-
able tool.
CAUTION:
Do not damage companion flange or front oil seal.
OCH@/ 217D

seating surface of the new drive pinion lock nut and new drive A
tightening torque using Tool A, and check the drive pinion bear-
ing preload torque using Tool B. B

B: ST3127S000 (J-25765-A) C

1.7 - 3.1 N·m (0.18 - 0.31 kg-m, 15 - 27 in-lb) DLN
CAUTION:
washer. E
• Adjust the drive pinion lock nut tightening torque to the F
Assembly".
• If the drive pinion bearing preload torque exceeds the G
specified value, replace collapsible spacer and tighten it V CH@/ 268D

adjust the drive pinion bearing preload torque. H
Differential Assembly I
1. Assemble side gear thrust washers with the same thickness as
the ones installed prior to disassembly or reinstall the old ones
on side gears. J
2. Assemble side gear and side gear thrust washer into differential
case.
K
L
RCH@/ 082I
3. Align 2 pinion mate gears in diagonally opposite positions, then M

rotate and assemble them into differential case after assembling
pinion mate thrust washer to pinion mate gear.
N
RCH@/ / 25I P

4. Align lock pin holes on differential case and shaft, and assemble
pinion mate shaft.
5. Measure side gear end play. If necessary, select the appropriate
side gear thrust washers. Refer to DLN-223, "Disassembly and
Assembly".
RCH@/ / 26I
6. Drive a new lock pin into pinion mate shaft, using Tool.

CAUTION:
OCH@/ / 51D
7. Apply gear oil to gear tooth surfaces and thrust surfaces and
check to see they turn properly.
ROC211
8. Apply thread locking sealant to the back face of drive gear as

shown.
• Use Genuine High Strength Thread Locking Sealant, Loctite
648 or equivalent. Refer to GI-14, "Recommended Chemical
Products and Sealants".
CAUTION:
clean.
OCH@0/ 48D
9. Align the matching mark of differential case with the mark of

drive gear, then install drive gear.
RCH@1482D

gear and install the bolts. A
Products and Sealants". B
CAUTION:
clean.
C
RCH@1483D
DLN
11. Install new drive gear bolts, and then tighten to the specified
CAUTION: E
• Do not reuse the bolts.
• Tighten bolts in a crisscross fashion.
F
G
RCH@/ 136I
12. Press new side bearing inner races to differential case using H
Tools.

I
B: ST33081000 ( — )
CAUTION:
Do not reuse side bearing. J
RCH@113/ D K
13. Install side bearing adjusters into gear carrier.

L
OCH@/ 270D
14. Apply gear oil to side bearings. Install differential case assembly O
with side bearing outer races into gear carrier.
OCH@/ 201D

15. Align paint matching mark on side bearing caps with that on
gear carrier and install side bearing caps on gear carrier.
CAUTION:
Do not tighten at this point. This allows further tightening of
side bearing adjusters.
OCH@/ 218D
16. Tighten each side bearing adjusters using Tool.

17. Adjusting backlash of drive gear and drive pinion. Refer to DLN-
18. Check total preload. Refer to DLN-223, "Disassembly and
Assembly".
19. Check tooth contact. Refer to DLN-223, "Disassembly and
Assembly".
OCH@/ 226D

cover as shown.
CAUTION:

< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR FINAL DRIVE: M226 ]

B
VQ40DE
Applied model C
6M/T
Final drive model M226
Gear ratio 3.538 DLN
Number of teeth (Drive gear / drive pinion) 46/13
E

F
DIFFERENTIAL SIDE GEAR CLEARANCE

Unit: mm (in) G
Item Standard
Side gear back clearance 0.305 (0.0120) or less.
(Clearance between side gear and differential case (Each gear should rotate smoothly without excessive resistance during differ- H
for adjusting side gear backlash) ential motion.)
PRELOAD TORQUE I
Item Specification
Drive pinion bearing preload torque 1.7 - 3.1 (0.18 - 0.31, 15 - 27) J
(Total preload torque = drive pinion bearing preload 2.49 - 4.57 (0.26 - 0.46, 22 - 40)
torque + Side bearing preload torque) K
BACKLASH
Unit: mm (in)
L
Item Standard
Drive gear to drive pinion gear 0.12 - 0.20 (0.0050 - 0.0079)
COMPANION FLANGE RUNOUT M

Unit: mm (in)
Item Runout limit

N
SELECTIVE PARTS O

P

< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR FINAL DRIVE: M226 ]
Unit: mm (in)
Thickness Package part number*

0.076 (0.030)
0.079 (0.031)
0.081 (0.032) 38151 8S101
0.084 (0.033)
0.086 (0.034)
0.089 (0.035)
0.091 (0.036)
0.094 (0.037) 38151 8S102
0.097 (0.038)
0.099 (0.039)
0.102 (0.040)
0.104 (0.041)
0.107 (0.042) 38151 8S103
0.109 (0.043)
0.112 (0.044)
0.114 (0.045)
0.117 (0.046)
0.119 (0.047) 38151 8S104
0.122 (0.048)
0.124 (0.049)
0.127 (0.050)
0.130 (0.051)
0.132 (0.052) 38151 8S105
0.135 (0.053)
0.137 (0.054)

Unit: mm (in)

0.76 (0.030)
0.79 (0.031)
0.81 (0.032) 38424 8S101
0.84 (0.033)
0.86 (0.034)
0.89 (0.035)
0.91 (0.036)
0.94 (0.037) 38424 8S102
0.97 (0.038)
0.99 (0.039)
*Always check with the parts department for the latest parts information.

< BASIC INSPECTION > [REAR FINAL DRIVE: M226 (ELD) ]
BASIC INSPECTION A
Work Flow INFOID:0000000004095668
B
OVERALL SEQUENCE
C
DLN
@KDH@/ / 30F A
DETAILED FLOW

< BASIC INSPECTION > [REAR FINAL DRIVE: M226 (ELD) ]
1.INTERVIEW FOR MALFUNCTION

Interview the customer about the symptom.
>> GO TO 2
2.SYMPTOM CHECK
Verify the symptom from the customer's information.
>> GO TO 3
3.BASIC INSPECTION
Check the operation of each part. Check that no symptoms occur other than those specified by the customer.
>> GO TO 4
4.SELF-DIAGNOSIS WITH CONSULT-III
Perform the self diagnosis with CONSULT-III. Check that any DTC is detected.
Is any DTC detected?
YES >> GO TO 5
NO >> GO TO 6
5.TROUBLE DIAGNOSIS BY DTC
Perform the trouble diagnosis for the detected DTC. Specify the malfunctioning part.
>> GO TO 7
6.SYMPTOM DIAGNOSIS
Perform the symptom diagnosis. Specify the malfunctioning part.
>> GO TO 7
7.MALFUNCTIONING PART REPAIR
Repair or replace the malfunctioning part.
>> GO TO 8
8.REPAIR CHECK (SELF-DIAGNOSIS WITH CONSULT-III)
Perform the self diagnosis with CONSULT-III. Verfied that no DTCs are detected. Erase all DTCs detected
prior to the repair. Verify that DTC is not detected again.
Is any DTC detected?
YES >> GO TO 5
NO >> GO TO 9
9.REPAIR CHECK (OPERATION CHECK)
Check the operation of each part.
Does it operate normally?
NO >> GO TO 3

DIFFERENTIAL LOCK SYSTEM
< FUNCTION DIAGNOSIS > [REAR FINAL DRIVE: M226 (ELD) ]
FUNCTION DIAGNOSIS A
B
DLN
OCH@0/ 51D K
1. Companion flange 2. Drive pinion 3. Drive gear

4. Differential case 5. Pinion mate gear 6. Axle shaft L
7. Side gear 8. Spring 9. Differential lock solenoid
10. Pinion mate shaft 11. Pressure plate 12. Differential lock position switch
13. Cam ring M

System Diagram INFOID:0000000004095669
RCH@14/ / D
System Description INFOID:0000000004095670
The differential lock system consists of the following components

• Differential lock control unit
• Differential lock mode switch
• Differential lock position switch
• Differential lock solenoid
• ABS actuator and electric unit (control unit)
• Transfer control unit
DIFFERENTIAL LOCK SYSTEM OPERATION
When the differential lock mode switch is in the LOCK position, a signal is sent to the differential lock control
unit. The differential lock control unit monitors input from the ABS actuator and electric unit (vehicle speed and
VDC operation) and the transfer control unit (4WD shift switch). If conditions are set, the differential lock con-
trol unit provides power and ground to the differential lock solenoid to lock the differential. The differential lock
position switch provides feedback to the differential lock control unit as to whether the lock is engaged based
on pressure plate position. The differential lock control unit provides ground to the DIFF LOCK indicator lamp
to activate the lamp. Refer to the Owner’s Manual for differential lock system operating instructions.
As a fail-safe function, the differential lock disengages when a malfunction is detected in the differential lock
system. Self-diagnostics can be performed using CONSULT-III. Refer to DLN-247, "DIFFERENTIAL LOCK
CONTROL UNIT : CONSULT-III Function (DIFF LOCK)".
DIFFERENTIAL LOCK OPERATION
RCH@1387D

1. Differential lock solenoid operates pressure plate. A

2. Pressure plate presses cam ring.
3. Engage cam ring and side gear, and the differential is locked.
DIFFERENTIAL LOCK INDICATOR LAMP OPERATION B
Condition DIFF LOCK indicator lamp

Differential lock/unlock ON/OFF C
Differential lock standby condition Flashing once every 2 seconds
Differential lock system malfunction OFF (even if differential lock mode switch is in LOCK position)
DLN
Turns ON when ignition switch is turned ON.
Lamp check
Turns OFF after engine start.
NOTE:
The differential lock standby condition is the time where the differential lock mode switch is in the LOCK posi- E
tion and the differential is unlocked.
Component Parts Location INFOID:0000000004095671
F
@V CH@/ 2/ 3YY
1. Combination meter M24 2. Differential lock mode switch M149 3. Differential lock control unit M70
4. Steering column 5. Differential lock position switch C116 6. Differential lock solenoid C117

Component Description INFOID:0000000004095672
Component Function
• Controls differential lock solenoid to lock/unlock the differential.
Differential lock control unit • As a fail-safe function, the differential lock disengages when a malfunction is detected
within the differential lock system.
Controls pressure plate operation when provided power and ground from the differential
Differential lock solenoid
lock control unit.
Differential lock position switch Detects differential lock/unlock condition based on the position of the pressure plate.
Differential lock mode switch Allows driver input for differential LOCK/UNLOCK to the differential lock control unit.
DIFF LOCK indicator lamp Illuminates to indicate the differential lock is locked or in standby condition.
Transmits the following signals via CAN communication to the differential lock control
unit.
ABS actuator and electric unit (control unit)
• Vehicle speed signal
• VDC operation signal
Transmits the 4WD shift switch signal via CAN communication to the differential lock
Transfer control unit
control unit.

DIAGNOSIS SYSTEM (DIFFERENTIAL LOCK CONTROL UNIT)
DIAGNOSIS SYSTEM (DIFFERENTIAL LOCK CONTROL UNIT)
A
DIFFERENTIAL LOCK CONTROL UNIT
DIFFERENTIAL LOCK CONTROL UNIT : CONSULT-III Function (DIFF LOCK)
INFOID:0000000004095673 B
CONSULT-III can display each diagnostic item using the following diagnostic test modes
C
DIFF LOCK
Function
Diagnostic test mode
Self-Diagnostic Result Displays differential lock control unit self-diagnostic results.
DLN
Data Monitor Displays differential lock control unit input/output data in real time.
CAN Diagnostic Support Monitor The results of transmit/receive diagnosis of CAN communication can be read.
ECU Identification The part number of the differential lock control unit can be checked E
SELF-DIAGNOSTIC RESULTS
Display Item List
Refer to DLN-275, "DTC Index". F
DATA MONITOR
Display Item List G
Monitor item [Unit] Description
BATTERY VOLT [V] Displays power supply voltage for the differential lock control unit. H
4WD MODE [2H/4H/4Lo] Displays 4WD shift switch position.
Displays average of right wheel speed sensor. Value is approximately equal to the indi-
VHCL S/SEN-R [km/h] or [mph]
cation of vehicle speed on the speedometer (inside ±10%). I
Displays average of left wheel speed sensor. Value is approximately equal to the indica-
VHCL S/SEN-L [km/h] or [mph]
tion of vehicle speed on the speedometer (inside ±10%).
VHCL S/SEN-RL [km/h] or [mph]

Displays average of rear wheel speed sensors (left and right). Value is approximately J
equal to the indication of vehicle speed on the speedometer (inside ±10%).
D-LOCK SW SIG [ON/OFF] Displays differential lock mode switch position.
D-LOCK SIG [ON/OFF] Displays control status of differential lock. K
Displays operating condition of differential lock solenoid relay (integrated in differential
RELAY ON [ON/OFF]
lock control unit).
Displays control status of differential lock solenoid relay (integrated in differential differ- L
RELAY MTR [ON/OFF]
ential lock control unit).
SOL MTR [ON/OFF] Displays control status of differential lock solenoid.
IND MTR [ON/OFF] Displays control status of DIFF LOCK indicator lamp.
M
D-LOCK POS SW [ON/OFF] Displays condition of differential lock position switch.

Symptom
×: Applicable
Reference page

Noise

Gear tooth rough DLN-295, "Disassembly and Assembly"
×
Gear contact improper DLN-295, "Disassembly and Assembly"
×
Tooth surfaces worn DLN-295, "Disassembly and Assembly"
×
×
Backlash incorrect DLN-295, "Disassembly and Assembly"
×
Companion flange excessive runout DLN-295, "Disassembly and Assembly"
DLN-248
×
Gear oil improper MA-5, "General Maintenance"
×
PROPELLER SHAFT
×
REAR AXLE
×
× REAR SUSPENSION RSU-4, "NVH Troubleshooting Chart"

×
ROAD WHEEL WT-43, "NVH Troubleshooting Chart"

×
AXLE SHAFT

2009 Xterra
[REAR FINAL DRIVE: M226 (ELD) ]
INFOID:0000000004095674
U1000 CAN COMM CIRCUIT
< COMPONENT DIAGNOSIS > [REAR FINAL DRIVE: M226 (ELD) ]
COMPONENT DIAGNOSIS A
U1000 CAN COMM CIRCUIT
B
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 elec-
tronic control units are equipped onto a vehicle and each control unit shares information and links with other C
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN-H, CAN-L) allowing a high rate of information transmission with less wiring. Each
control unit transmits/receives data but selectively reads required data only. DLN
CAN Communication Signal Chart. Refer to LAN-46, "CAN Communication Signal Chart".
E
DTC DETECTION LOGIC
Display contents of CON- F

DTC Diagnostic item is detected when ... Probable malfunction location
SULT-III
When differential lock control unit is not trans-
U1000 CAN COMM CIRCUIT mitting or receiving CAN communication signal CAN communication system G
for 2 seconds or more.

H
1.PERFORM SELF DIAGNOSTIC
1. Turn ignition switch ON and wait for 2 seconds or more.
I
2. Check “Self Diagnostic Result” of differential lock control unit.
Is “CAN COMM CIRCUIT” displayed?
YES >> Refer to LAN-14, "Trouble Diagnosis Flow Chart". J
NO >> Refer to GI-37, "Intermittent Incident".

P1833 INITIAL START
P1833 INITIAL START
Self-diagnosis memory function was suspended due to low battery voltage at the differential lock control unit.
DTC Display contents of CONSULT-III DTC Detection Condition Action to take

Check differential lock con-
Low battery voltage available to the differential lock control unit power supply and
P1833 INITIAL START [P1833]
trol unit. ground circuit. Refer to DLN-
250, "Diagnosis Procedure".
1.CHECK DIFFERENTIAL LOCK CONTROL UNIT POWER SUPPLY

1. Turn ignition switch OFF.
2. Disconnect differential lock control unit harness connector.

4. Check voltage between differential lock control unit harness
connector M70 terminals 1, 2, 15 and ground.
(+)
(-) Voltage (Approx.)
Connector Terminal
1
M70 2 Ground Battery voltage
15
RCH@1452D
YES >> GO TO 2.
NO >> Check fuse. Repair harness or connectors.
2.CHECK DIFFERENTIAL LOCK CONTROL UNIT GROUND CIRCUIT
2. Check continuity between differential lock control unit harness
connector M70 terminals 3, 10 and ground.
Connector Terminal — Continuity

3
M70 Ground Yes
10
YES >> Power and ground supply is normal.
NO >> Repair harness or connectors. RCH@1453D

P1834 CONTROL UNIT 1
A
Replace the differential lock control unit if this DTC is displayed. Refer to DLN-286, "Removal and Installation". B
C
Replace differential lock
CONTROL UNIT 1 A malfunction is detected in the memory (RAM) of the dif- control unit. Refer to DLN- DLN
P1834
[P1834] ferential lock control unit. 286, "Removal and Installa-
tion".

Replace the differential lock control unit if this DTC is displayed. Refer to DLN-286, "Removal and Installation".

CONTROL UNIT 2 A malfunction is detected in the memory (ROM) of the dif- control unit. Refer to DLN-
P1835
[P1835] ferential lock control unit. 286, "Removal and Installa-
tion".

A
Replace the differential lock control unit if this DTC is displayed. Refer to DLN-286, "Removal and Installation". B
C
CONTROL UNIT 3 A malfunction is detected in the memory (EEPROM) of control unit. Refer to DLN- DLN
P1836
[P1836] the differential lock control unit. 286, "Removal and Installa-
tion".

Replace the differential lock control unit if this DTC is displayed. Refer to DLN-286, "Removal and Installation".

CONTROL UNIT 4 The AD converter system of the differential lock control control unit. Refer to DLN-
P1837
[P1837] unit is malfunctioning. 286, "Removal and Installa-
tion".

P1838 ON SWITCH
P1838 ON SWITCH
A
The differential lock mode switch sends differential lock ON/OFF request signals to the differential lock control B
unit.

Inspect the differential lock DLN
ON SW Two switch inputs were simultaneously detected due to a
P1838 mode switch. Refer to DLN-
[P1838] short circuit in the differential lock mode switch.
255, "Diagnosis Procedure".

E
1.CHECK DIFFERENTIAL LOCK MODE SWITCH OPERATION

F
2. Using CONSULT-III, select “D-LOCK SW SIG” of DIFF LOCK data monitor items.
3. While operating the differential lock mode switch, check that the display value changes between ON/OFF.
G
Switch ON Display item ON
Switch OFF Display item OFF
H
YES >> Differential lock mode switch is operating properly.
NO >> GO TO 2.
I
2.CHECK DIFFERENTIAL LOCK MODE SWITCH POWER SUPPLY CIRCUIT
1. Disconnect differential lock mode switch harness connector.
2. Turn ignition switch ON. J
3. Check voltage between differential lock mode switch harness
connector M149 terminal 3 and ground.
K
(+)
Connector Terminal
M149 3 Ground Battery voltage L
RCH@1423D
M
YES >> GO TO 3.
NO >> Repair harness or connector. N
3.CHECK DIFFERENTIAL LOCK MODE SWITCH SIGNAL
O
2. Connect differential lock mode switch harness connector.
P
(+) Differential lock mode
Connector Terminal switch
RCH@1457D

P1838 ON SWITCH
ON Battery voltage
9
OFF 0V
M70 Ground
ON 0V
22
OFF Battery voltage
YES >> Replace the differential lock control unit. Refer to DLN-286, "Removal and Installation".
NO >> GO TO 4.
4.CHECK DIFFERENTIAL LOCK MODE SWITCH
2. Disconnect differential lock mode switch harness connector.
3. Operate differential lock mode switch and check continuity
between differential lock mode switch terminals.
Terminals Differential lock mode switch Continuity

ON No
1-3
OFF Yes
ON Yes
2-3
OFF No
Is the inspection result normal? RCH@1424D
YES >> GO TO 5.
NO >> Replace differential lock mode switch.
5.CHECK HARNESS BETWEEN DIFFERENTIAL LOCK CONTROL UNIT AND DIFFERENTIAL LOCK
MODE SWITCH
connector M70 (A) terminals 9, 22 and differential lock mode
switch harness connector M149 (B) terminals 2, 1.
Connector Terminal Connector Terminal Continuity

9 2
M70 (A) M149 (B) Yes
22 1
connector M70 (A) terminals 9, 22 and ground.
@KCH@/ 054YY
Connector Terminal Continuity

9 Ground
M70 (A) No
22
NO >> Repair harness or connector.

P1839 POSITION SWITCH ON
A
The differential lock position switch sends a signal to the differential lock control unit when the differential lock B
is engaged. The differential lock control unit monitors the left and right rear wheel speed sensor signals to
determine wheel slippage. When the differential lock is engaged the left and right rear wheel speed sensor sig-
nals should match.
C
DLN
The differential lock position switch is ON indicating the Inspect the differential lock
POSI SW ON differential is locked, but the differential lock control unit position switch. Refer to
P1839 E
[P1839] detects a difference between left and right rear wheel DLN-257, "Diagnosis Proce-
speeds. dure".

F
1.CHECK DIFFERENTIAL LOCK POSITION SWITCH SIGNAL

1. Start engine. G
2. Using CONSULT-III, select “D-LOCK POS SW SIG” of DIFF LOCK data monitor.
3. Activate the differential lock according to the directions listed in the table and monitor the display value.
H
Monitor item Condition Display value
• Vehicle stopped Differential lock mode switch: ON

ON
• Engine running (DIFF LOCK indicator lamp: ON)
D-LOCK POS SW SIG I
• VDC OFF switch: ON Differential lock mode switch: OFF
• 4WD shift switch: 4LO OFF
(DIFF LOCK indicator lamp: OFF)
J
YES >> Differential lock position switch is operating normally.
NO >> GO TO 2.
K
2.CHECK DIFFERENTIAL LOCK POSITION SWITCH
1. Disconnect differential lock position switch harness connector.
2. Turn ignition switch ON. L
3. Select “D-LOCK POS SW SIG” of DIFF LOCK data monitor.
4. Monitor the display value while connecting and disconnecting a
jumper wire between differential lock position switch harness
M
connector C116 terminals 1 and 3.
Monitor item Condition Display value

N
Jumper wire connected ON
D-LOCK POS SW SIG
Jumper wire disconnected OFF
@V CH@/ 2/ 4YY
Is the inspection result normal? O
YES >> Check the mechanical operation of the differential lock. Replace the differential lock position
switch. Refer to DLN-287, "Removal and Installation".
NO >> GO TO 3. P
3.CHECK DIFFERENTIAL LOCK POSITION SWITCH VOLTAGE

Check voltage between differential lock position switch harness con-
nector C116 terminal 3 and ground.
(+)
Connector Terminal
C116 3 Ground Battery voltage
YES >> GO TO 4.
NO >> GO TO 5.
@V CH@/ 2/ 5YY

2. Check continuity between differential lock position switch har-
ness connector C116 terminal 1 and ground.

C116 1 Ground Yes
YES >> Replace the differential lock control unit. Refer to DLN-
286, "Removal and Installation".
NO >> Repair harness or connector. @V CH@/ 2/ 6YY
5.CHECK HARNESS BETWEEN DIFFERENTIAL LOCK CONTROL UNIT AND DIFFERENTIAL LOCK PO-
SITION SWITCH
connector M70 (A) terminal 20 and differential lock position
switch harness connector C116 (B) terminal 3.
Connector Terminal Connector Terminal Continuity

M70 (A) 20 C116 (B) 3 Yes
connector M70 (A) terminal 20 and ground. @V CH@/ 2/ 7YY
Connector Terminal Continuity

Ground
M70 (A) 20 No
YES >> Replace differential lock control unit. Refer to DLN-286, "Removal and Installation".

P1844 RELAY
P1844 RELAY
A
The differential lock solenoid relay is an integral part of the differential lock control unit. B
C
Inspect differential lock con-
trol unit relay power and DLN
RELAY The differential lock control unit relay monitor did not de-
P1844 ground supply circuit. Refer
[P1844] tect expected voltage at the relay.
to DLN-259, "Diagnosis Pro-
cedure".
E
1.CHECK DIFFERENTIAL LOCK CONTROL UNIT POWER SUPPLY F

G
connector M70 terminals 1, 2, 15 and ground. H
(+)
Connector Terminal I
1
M70 2 Ground Battery voltage
J
15
RCH@1452D
YES >> GO TO 2. K
NO >> Check fuse. Repair harness or connectors.
2.CHECK DIFFERENTIAL LOCK CONTROL UNIT GROUND CIRCUIT
L
M
3
M70 Ground Yes N
10
YES >> Power and ground supply is normal. O
NO >> Repair harness or connectors. RCH@1453D

P1847 SOLENOID CIRCUIT
P1847 SOLENOID CIRCUIT
Replace the differential lock control unit if this DTC is displayed. Refer to DLN-286, "Removal and Installation"
.

SOL CIRCUIT A malfunction is detected in the differential lock control control unit. Refer to DLN-
P1847
[P1847] unit internal circuit. 286, "Removal and Installa-
tion".

P1848 SOLENOID DISCONNECT
A
When power and ground is supplied from the differential lock control unit, the differential lock solenoid will B
actuate to move the pressure plate against the cam ring to lock the differential. By reversing polarity at the dif-
ferential lock control unit, the differential lock solenoid moves the pressure plate away from the cam ring to
unlock the differential.
C
DLN
Inspect differential lock sole-
SOL DISCONNECT An open was detected in the differential lock solenoid or
P1848 noid. Refer to DLN-261, "Di-
[P1848] circuit. E
agnosis Procedure".
F
1.CHECK DIFFERENTIAL SOLENOID CONTROL
G
1. Start engine.
2. Using CONSULT-III, select “RELAY ON”, “RELAY MTR”, “SOL MTR” of DIFF LOCK data monitor.
3. Observe the display values while operating the differential lock system.
H
Monitor item Condition Differential lock mode switch Display value
ON ON
RELAY ON I
OFF OFF
• Vehicle stopped
• Engine running ON ON
RELAY MTR
• VDC OFF switch: ON OFF OFF J
• 4WD shift switch: 4LO
ON ON
SOL MTR
OFF OFF
K
YES >> Differential lock solenoid control system is operating normally.
NO >> GO TO 2.
L
2.CHECK DIFFERENTIAL LOCK SOLENOID RESISTANCE
2. Disconnect differential lock solenoid harness connector C117. M
3. Check resistance between differential lock solenoid terminals 2
and 4.
N
2-4 : Approx. 3.4Ω
YES >> GO TO 3. O
NO >> Replace differential solenoid. Refer to DLN-295, "Disas-
@V CH@/ 2/ 8YY
3.CHECK DIFFERENTIAL LOCK SOLENOID OPERATION P

Check operation by applying power and ground to the differential
lock solenoid terminals.
(+) (-)
Component Solenoid operation
Terminal Terminal
Differential lock
4 2 Yes
solenoid
YES >> GO TO 4.
NO >> Check for a mechanical malfunction with the differential @V CH@/ 20/ YY
lock system. Replace differential solenoid. Refer to

4.CHECK DIFFERENTIAL LOCK SOLENOID CIRCUIT
connector M70 (A) terminals 11, 12 and differential lock solenoid
harness connector C117 (B) terminals 4, 2.
A B
Continuity
Connector Terminal Connector Terminal
11 4
M70 C117 Yes
12 2
@V CH@/ 200YY
A
— Continuity
Connector Terminal
11
M70 Ground No
12

P1849 SOLENOID SHORT
A
When power and ground is supplied from the differential lock control unit, the differential lock solenoid will B
actuate to move the pressure plate against the cam ring to lock the differential. By reversing polarity at the dif-
ferential lock control unit, the differential lock solenoid moves the pressure plate away from the cam ring to
unlock the differential.
C
DLN
Inspect the differential lock
SOL SHORT A short was detected in the differential lock solenoid inter-
P1849 solenoid. Refer to DLN-263,
[P1849] nal circuit or in the harness. E
"Diagnosis Procedure".
F
1.CHECK DIFFERENTIAL SOLENOID CONTROL
G
1. Start engine.
2. Using CONSULT-III, select “RELAY ON”, “RELAY MTR”, “SOL MTR” of DIFF LOCK data monitor.
H
ON ON
RELAY ON I
OFF OFF
• Vehicle stopped
• Engine running ON ON
RELAY MTR
• VDC OFF switch: ON OFF OFF J
ON ON
SOL MTR
OFF OFF
K
YES >> Differential lock solenoid control system is operating normally.
NO >> GO TO 2.
L
2. Disconnect differential lock solenoid harness connector C117. M
and 4.
N
2-4 : Approx. 3.4Ω
YES >> GO TO 3. O
@V CH@/ 2/ 8YY
3.CHECK DIFFERENTIAL LOCK SOLENOID OPERATION P

(+) (-)
Terminal Terminal
Differential lock
4 2 Yes
solenoid
YES >> GO TO 4.

A B
Continuity
11 4
M70 C117 Yes
12 2
@V CH@/ 200YY
A
— Continuity
Connector Terminal
11
M70 Ground No
12

P1850 SOLENOID CURRENT
A
The differential lock control unit supplies power and ground to the differential lock solenoid via the differential B
lock solenoid relay (integral to the differential lock control unit).

Inspect the differential lock DLN
SOL CURRENT The differential lock relay does not switch to OFF or there
P1850 solenoid. Refer to DLN-265,
[P1850] is a short to power in the harness.
"Diagnosis Procedure".

E
1.CHECK DIFFERENTIAL SOLENOID CONTROL F
1. Start engine.
2. Using CONSULT-III, select “RELAY ON”, “RELAY MTR”, “SOL MTR” of DIFF LOCK data monitor. G

H
ON ON
RELAY ON
OFF OFF
• Vehicle stopped
• Engine running ON ON I
RELAY MTR
• VDC OFF switch: ON OFF OFF
ON ON
SOL MTR J
OFF OFF
YES >> Differential lock solenoid control system is operating normally. K
NO >> GO TO 2.
1. Turn ignition switch OFF. L
2. Disconnect differential lock solenoid harness connector C117.
and 4. M
2-4 : Approx. 3.4Ω

Is the inspection result normal? N
YES >> GO TO 3.
sembly and Assembly". O
@V CH@/ 2/ 8YY
3.CHECK DIFFERENTIAL LOCK SOLENOID OPERATION

P

(+) (-)
Terminal Terminal
Differential lock
4 2 Yes
solenoid
YES >> GO TO 4.

A B
Continuity
11 4
M70 C117 Yes
12 2
@V CH@/ 200YY
A
— Continuity
Connector Terminal
11
M70 Ground No
12

C1203 ABS SYSTEM
C1203 ABS SYSTEM
A
The differential lock control unit and the ABS actuator and electric unit (control unit) are in communication via B
the CAN communication network. Vehicle speed and wheel slippage information is used by the differential lock
control unit to determine if conditions are met to actuate the differential lock solenoid.
DTC Logic INFOID:0000000004095710 C

DLN
Check for proper ABS oper-
A malfunction related to wheel speed sensors has been ation. Refer to BRC-23,
ABS SYSTEM
C1203 detected by the ABS actuator and electric unit (control "CONSULT-III Function
[C1203] E
unit). (ABS)" or BRC-126, "CON-
SULT-III Function (ABS)".

LOCK INDICATOR LAMP
LOCK INDICATOR LAMP
The DIFF LOCK indicator lamp has power available to it any time the ignition switch is in the ON or START
position. The differential lock control unit supplies ground to activate the DIFF LOCK indicator lamp. The DIFF
LOCK indicator lamp will go through a prove out at initial key ON. The DIFF LOCK will flash while the differen-
tial lock system is activating or while waiting for conditions to be met to activate. Once the differential lock has
been engaged, the DIFF LOCK indicator lamp will remain ON. For more information about the DIFF LOCK
indicator lamp, refer to the Owner’s Manual.
Component Function Check INFOID:0000000004095712
1.CHECK DIFF LOCK INDICATOR LAMP OPERATION

1. Turn the ignition switch ON.
2. Observe the DIFF LOCK indicator lamp.
Ignition switch ON Indicator prove out

Does the DIFF LOCK indicator lamp prove out normally?
YES >> DIFF LOCK indicator lamp is operating normally.
NO, ALWAYS ON>> Perform self diagnostics on differential lock control unit. Refer to DLN-247, "DIFFEREN-
TIAL LOCK CONTROL UNIT : CONSULT-III Function (DIFF LOCK)".
NO, ALWAYS OFF>>Check DIFF LOCK indicator lamp control circuit. Refer to DLN-268, "Diagnosis Proce-
dure".
1.CHECK DIFFERENTIAL LOCK CONTROL UNIT POWER AND GROUND SUPPLY

Check the differential lock control unit power and ground supply. Refer to DLN-250, "Diagnosis Procedure".
YES >> GO TO 2.
NO >> Repair or replace malfunctioning component.
2.CHECK HARNESS BETWEEN DIFFERENTIAL LOCK CONTROL UNIT AND COMBINATION METER
2. Disconnect differential lock control unit harness connector and
combination meter harness connector.
connector M70 (A) terminal 21 and combination meter harness
connector M24 (B) terminal 25.
A B
Continuity
M70 21 M24 25 Yes @V CH@/ 201YY

connector M70 (A) terminal 21 and ground.
A
— Continuity
Connector Terminal
M70 21 Ground No
YES >> Replace combination meter. Refer to MWI-90, "Removal and Installation".

< ECU DIAGNOSIS > [REAR FINAL DRIVE: M226 (ELD) ]
ECU DIAGNOSIS A
Reference Value INFOID:0000000004095714
B
DIFFERENTIAL LOCK CONTROL UNIT TERMINAL CONNECTOR LAYOUT

C
DLN
RCH@1462D
Data are reference value and are measured between each terminal and ground.
Terminal No. F
Description
(Wire color) Voltage (V) (Ap-
Condition
Input/ prox.)
+ - Signal name
Output G
1
Ground Ign power supply Input Ignition ON or START Battery voltage
(W/G)
2 H
Ground Ign power supply Input Ignition ON or START Battery voltage
(W/G)
3
Ground Ground Input Ignition ON Less than 0.2V
(B) I
4
– CAN-L – –
(P)
5 J
– CAN-H – –
(L)
9 Differential lock mode switch Differential lock mode switch: ON Battery voltage
Ground Input
(Y) (ON) Differential lock mode switch: OFF 0V K
10
Ground Ground Input Ignition ON Less than 0.2V
(B)
L
11 Differential lock solenoid Differential lock mode switch: ON 0V
Ground Output
(GR) (LO) Differential lock mode switch: OFF Battery voltage
12 Differential lock solenoid Differential lock mode switch: ON 0V M

Ground Output
(L) (HIGH) Differential lock mode switch: OFF Battery voltage
13
– K-LINE – – –
(SB) N
15 Battery power supply
Ground Input Ignition OFF Battery voltage
(R/Y) (Memory back-up)
Differential lock mode switch: ON
0V
O
20 Differential lock position (DIFF LOCK indicator lamp: ON)
Ground Input
(BR) switch Differential lock mode switch: OFF
Battery voltage
(DIFF LOCK indicator lamp: OFF) P
21 DIFF LOCK indicator lamp: ON 0V
Ground DIFF LOCK indicator lamp Output
(SB) DIFF LOCK indicator lamp: OFF Battery voltage
22 Differential lock mode switch Differential lock mode switch: ON 0V

Ground Input
(G) (OFF) Differential lock mode switch: OFF Battery voltage
CAUTION:
When using a circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals.

Wiring Diagram INFOID:0000000004095715
@ACV @/ / 53F A

DLN
@ACH@/ 050F A

@ACH@/ 051F A

DLN
@ACH@/ 052F A

@ACH@/ 053F A

DTC Index INFOID:0000000004095716
Items (CONSULT-III screen

Diagnostic item is detected when... Check item
terms)
B
INITIAL START Due to removal of battery which cuts off power supply to differential
DLN-250, "Description"
[P1833] control unit, self-diagnosis memory function is suspended.
CONTROL UNIT 1 Malfunction is detected in the memory (RAM) system of differential C
[P1834] lock control unit.
CONTROL UNIT 2 Malfunction is detected in the memory (ROM) system of differential
[P1835] lock control unit.
DLN
CONTROL UNIT 3 Malfunction is detected in the memory (EEPROM) system of differ-
[P1836] ential lock control unit.
CONTROL UNIT 4 E
AD converter system of differential lock control unit is malfunctioning. DLN-254, "Description"
[P1837]
ON SW More than two switch inputs are simultaneously detected due to
[P1838] short circuit of differential lock mode switch.
F
POSI SW ON When differential lock position switch is ON, rotation difference oc-
[P1839] curs in wheel speed (rear wheel right and left).
RELAY Differential lock control unit detects as irregular by comparing target
[P1844] value with monitor value.
DLN-259, "Description" G
SOL CIRCUIT
Malfunction is detected in differential lock control unit internal circuit. DLN-260, "Description"
[P1847]
H
SOL DISCONNECT • Differential lock solenoid internal circuit or harness is open.
[P1848] • Differential lock solenoid relay does not switch to ON position.
SOL SHORT
Differential lock solenoid internal circuit or harness is shorted. DLN-263, "Description" I
[P1849]
SOL CURRENT
Differential lock solenoid relay does not switch to OFF position. DLN-265, "Description"
[P1850]
J
ABS SYSTEM Malfunction related to wheel sensor has been detected by ABS ac-
[C1203] tuator and electric unit (control unit).
CAN COMM CIRCUIT
Malfunction has been detected from CAN communication line. DLN-249, "Description" K
[U1000]
NO DTC IS DETECTED.
FURTHER TESTING MAY No malfunction has been detected. —
BE REQUIRED. L
CAUTION:
If “CAN COMM CIRCUIT [U1000]” is displayed with other DTCs, first perform the trouble diagnosis for CAN communication
line. M

DIFF LOCK INDICATOR LAMP INOPERATIVE
< SYMPTOM DIAGNOSIS > [REAR FINAL DRIVE: M226 (ELD) ]
SYMPTOM DIAGNOSIS
DIFF LOCK INDICATOR LAMP INOPERATIVE
Inspection Procedure INFOID:0000000004095718
SYMPTOM:
DIFF LOCK indicator lamp does not turn ON for approx. 1 second when turning ignition switch to
“ON”.
1.PERFORM DIFFERENTIAL LOCK CONTROL UNIT SELF DIAGNOSIS
Perform self-diagnosis. Refer to DLN-247, "DIFFERENTIAL LOCK CONTROL UNIT : CONSULT-III Function
(DIFF LOCK)".
Were any DTC’s displayed?
YES >> Refer to DLN-275, "DTC Index".
NO >> GO TO 2.
2.CHECK DIFFERENTIAL LOCK CONTROL UNIT POWER SUPPLY AND GROUND CIRCUIT
Check the differential lock control unit for proper power and ground. Refer to DLN-250, "Diagnosis Procedure".
YES >> GO TO 3.
3.CHECK DIFF LOCK INDICATOR LAMP POWER SUPPLY
Check power supply to the combination meter (DIFF LOCK indicator lamp). Refer to MWI-29, "COMBINATION
METER : Diagnosis Procedure".
YES >> GO TO 4.
NO >> Repair harness or connectors.
4.CHECK DIFF LOCK INDICATOR LAMP CONTROL
Check the DIFF LOCK indicator lamp control circuit. Refer to DLN-268, "Description".
NO >> Repair malfunctioning component.

DIFF LOCK INDICATOR LAMP DOES NOT TURN ON WITH DIFFERENTIAL
LOCK SWITCHED ON
DIFF LOCK INDICATOR LAMP DOES NOT TURN ON WITH DIFFEREN-
A
TIAL LOCK SWITCHED ON
B
SYMPTOM:
DIFF LOCK indicator lamp does not turn ON when turning differential lock mode switch to “ON” after
engine start. C
1.CHECK DIFF LOCK INDICATOR LAMP DLN
Confirm the DIFF LOCK indicator lamp proves out when ignition switch is turned ON.
YES >> GO TO 2. E
NO >> Refer to DLN-276, "Inspection Procedure".
2.CHECK SELF-DIAGNOSTIC RESULTS
F
(DIFF LOCK)".
Is any DTC detected by self-diagnosis?
G
YES >> Check the malfunctioning system. Refer to DLN-275, "DTC Index".
NO >> GO TO 3.
3.CHECK DIFFERENTIAL LOCK MODE SWITCH OPERATION H
Check differential lock mode switch. Refer to DLN-255, "Description".
YES >> GO TO 4. I
NO >> Repair component, harness or connector.
4.CHECK DIFFERENTIAL LOCK CONTROL UNIT POWER SUPPLY AND GROUND CIRCUIT J
Check differential lock control unit power supply and ground circuit. Refer to DLN-250, "Diagnosis Procedure".
YES >> Replace the differential lock control unit. Refer to DLN-286, "Removal and Installation". K

DIFF LOCK INDICATOR LAMP FLASHES WHILE DRIVING
DIFF LOCK INDICATOR LAMP FLASHES WHILE DRIVING
The DIFF LOCK indicator lamp will flash once every 2 seconds when the differential lock system is in standby
condition. Standby condition is the time between when the differential lock mode switch is turned ON and
when the differential lock control unit see’s all conditions are met to engage the differential lock. The DIFF
LOCK indicator lamp should be OFF if there has been a malfunction detected. For more information regarding
the differential lock system operation, refer to the Owner’s Manual.
SYMPTOM:
DIFF LOCK indicator lamp sometimes flashes while driving.
1.CHECK SELF-DIAGNOSTIC RESULTS
(DIFF LOCK)".
YES >> Check the malfunctioning system. Refer to DLN-275, "DTC Index".
NO >> GO TO 2.
2.CHECK DIFFERENTIAL LOCK MODE SWITCH
Perform trouble diagnosis for differential lock mode switch. Refer to DLN-255, "Description".
YES >> Condition is intermittent. Refer to GI-37, "Intermittent Incident".
NO >> Repair or replace malfunctioning component.

PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: M226 (ELD) ]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000004095722
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. DLN
Information necessary to service the system safely is included in the SR and SB section of this Service Man-
ual.
WARNING: E
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
F
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the SR section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this G
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
Precaution INFOID:0000000004095723
H
• Before connecting or disconnecting differential lock control

unit harness connector, turn ignition switch “OFF” and dis- I
connect the battery cable from the negative terminal. Because
battery voltage is applied to differential lock control unit even
if ignition switch is turned “OFF”.
J
RDE178G
L
• When connecting or disconnecting pin connectors into or
from differential lock control unit, take care not to damage pin
terminals (bend or break). M
When connecting pin connectors make sure that there are not
any bends or breaks on differential lock control unit pin termi-
nal.
N
O
RDE180G

PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: M226 (ELD) ]
• Before replacing differential lock control unit, perform differ-
ential lock control unit input/output signal inspection and
make sure whether differential lock control unit functions
properly or not. Refer to DLN-269, "Reference Value".
RCH@0737D
operations.
• Check for the correct installation status prior to removal or disassembly. When matching marks are required,
• Before disassembly, completely remove sand and mud from the exterior of the unit, preventing them from
• Check appearance of the disassembled parts for damage, deformation, and abnormal wear. Replace them
• Clean and flush the parts sufficiently and blow them dry.
• In principle, tighten nuts or bolts gradually in several steps working diagonally from inside to outside. If a
• Add new differential gear oil, petroleum jelly, or multi-purpose grease, as specified.

PREPARATION
< PREPARATION > [REAR FINAL DRIVE: M226 (ELD) ]
PREPARATION A
PREPARATION
B
(Kent-Moore No.) C
Tool name
KV40104000 Removing and installing drive pinion lock
( — ) nut DLN
Flange wrench a: 85 mm (3.35 in) dia.
b: 65 mm (2.56 in) dia.
MS548
ST33290001 Removing front oil seal F

(J-34286)
Puller
G
YY@/ 5/ 0C
H
ST15310000 Installing front oil seal

( — ) a: 96mm (3.77 in) dia.
Drift b: 84 mm (3.30 in) dia. I
MS004
ST3127S000 Inspecting drive pinion bearing preload

K
(J-25765-A) torque and total preload torque
Preload gauge set
1. GG91030000
(J-25765) L
Torque wrench
2. HT62940000 (1/2″)
( — )
Socket adapter M
3. HT62900000 (3/8″) MS013
( — )
Socket adapter
N
— Removing and installing side bearing ad-
(C-4164) juster
Adjuster tool
O
P
V CH@/ 081D

PREPARATION
(Kent-Moore No.)
Tool name
(J-37228)
Seal cutter
R,MS/ 35
ST30021000 Removing drive pinion rear bearing inner

(J-22912-01) race
Puller
YY@/ 6/ / C
ST33081000 Removing and installing side bearing in-

( — ) ner race
Adapter a: 43 mm (1.69 in) dia.
b: 33.5 mm (1.32 in) dia.
YY@0/ / / C
— Adjusting drive pinion height

(8144)
Drive pinion block
RCH@1488D

(6740)
Cone
RCH@15/ 0D

(6741)
Screw
RCH@15/ 1D

(6739)
Drive pinion height lock
RCH@15/ 2D

PREPARATION
(Kent-Moore No.) A
Tool name
(D-115-2) B
Scooter block
RCH@15/ 3D
— Adjusting drive pinion height DLN

(8541A-1)
Arbor disc
E
RCH@15/ 4D F
(D-115-3)
Arbor G
H
RCH@15/ 5D

( — ) race I
Drift a: 89mm (3.50 in) dia.
b: 79 mm (3.11 in) dia.
J
YY@/ 700C
K
( — ) race
b: 110 mm (4.33 in) dia. L
M
MS55/
ST33022000 Installing drive pinion front bearing outer

( — ) race
N
b: 67 mm (2.63 in) dia.
MS55/

PREPARATION
(Kent-Moore No.)
Tool name
— Installing drive pinion rear bearing inner
(C-4040) race
Installer
RCH@15/ 6D
KV38100300 Installing side bearing inner race

(J-25523) a: 54 mm (2.13 in) dia.
c: 32mm (1.26 in) dia.
YY@0/ 35C

Puller Removing companion flange and side
bearing inner race
MS/ 66
Puller Removing side bearing inner race
YYA/ 712C
OAHB/ 08/ D

< ON-VEHICLE MAINTENANCE > [REAR FINAL DRIVE: M226 (ELD) ]
B
DRAINING
1. Stop engine. C
3. Install the drain plug with sealant applied on the threads to the DLN
• Use High Performance Thread Sealant or equivalent. Refer to E
F
KCH@/ 072D
FILLING
G
until the level reaches the specified level near the filler plug hole. H

grade and capacity and Lubricants". I
to DLN-295, "Disassembly and Assembly". J
KCH@/ 016D

K

L
shown.
CAUTION: M
rear final drive assembly. Tighten to the specified torque. Refer N
GI-14, "Recommended Chemical Products and Sealants". O
KCH@/ 016D

< ON-VEHICLE REPAIR > [REAR FINAL DRIVE: M226 (ELD) ]
ON-VEHICLE REPAIR
REMOVAL
1. Disconnect the battery cable from the negative terminal.
2. Disconnect the differential lock control unit connector.
3. Remove the two bolts and remove the differential lock control
unit.
V CH@/ 143D
INSTALLATION
• When installing differential lock control unit, tighten bolts to the specified torque.
Differential lock control unit bolts : 5.1 N·m (0.52 kg-m, 45 in-lb)
• After the installation, check DIFF LOCK indicator lamp. Refer to DLN-280, "Precaution for Servicing Rear
Final Drive".

DIFFERENTIAL LOCK POSITION SWITCH
A
REMOVAL B
Differential Lock Position Switch
CAUTION:
• Do not damage spline, companion flange and front oil seal when removing propeller shaft. C
may result in sensor wires being damaged and sensor becoming inoperative. DLN
1. Drain rear final drive gear oil. Refer to DLN-285, "Changing Differential Gear Oil".
2. Remove rear propeller shaft. Refer to DLN-138, "Removal and Installation".
• Plug rear end of transfer. E
3. Remove both RH and LH axle shafts. Refer to RAX-21, "Removal and Installation".
4. Remove the rear stabilizer bar. Refer to RSU-13, "Removal and Installation".
5. Disconnect the following components from the rear final drive. F
• ⇐ : Vehicle front
• Parking brake cable (1)
• Brake hoses and tubes (2) G
• Differential lock position switch connector (4)
6. Remove the bolt from the differential lock solenoid (3) and
remove the solenoid from the axle housing. H
KCH@/ 083D
I
7. Remove the carrier cover bolts. Then separate the carrier cover
from the axle housing using Tool. J
Tool number : KV10111100 (J-37228)

CAUTION: K
mating surface. L
KCH@/ 081D
M
8. For installation, apply a paint matching mark on one side of side
bearing cap.
CAUTION:
• Side bearing caps are line-board for initial assembly. The N
matching marks are used to install them in their original
positions.
• For matching mark, use paint. Do not damage side bear- O
ing cap.
P
RCH@1472D

RCH@1476D
11. Loosen the side bearing adjusters using Tool.
OCH@/ 226D
12. Keep side bearing outer races together with inner races. Do not
mix them up. Also, keep side bearing adjusters together with
bearing.
RCH@1477D
13. Remove side bearing adjusters from axle housing.
OCH@/ 270D
14. Remove the differential lock position switch harness from the bracket.
15. Remove differential lock position switch.
INSTALLATION
1. Apply sealant to threads of differential lock position switch and install it to the axle housing with the speci-
fied torque. Refer to DLN-295, "Disassembly and Assembly".
• Use Genuine Silicone RTV or equivalent. Refer to GI-14, "Recommended Chemical Products and
Sealants".
CAUTION:

Remove old sealant adhering to axle housing and differential lock position switch. Also remove
any moisture, oil, or foreign material adhering to application and axle housing and differential lock A
position switch.
2. Install differential lock position switch harness to the bracket on axle housing.
3. Install side bearing adjusters into axle housing. B
DLN
OCH@/ 270D E
4. Apply gear oil to side bearings. Install differential case assembly

with side bearing outer races into axle housing.
F
5. Apply multi-purpose grease to differential lock position connec-
tor.
CAUTION:
Do not reuse sensor connector. G
RCH@1477D
I
• ⇐: Front
6. Install the differential lock solenoid (3) to axle housing and
tighten bolt with specified torque. Refer to DLN-295, "Disassem-
bly and Assembly". J
7. Connect the differential lock position switch connector (4).
K
L
KCH@/ 083D
8. Align paint matching mark on side bearing caps with that on axle
housing and install side bearing caps on axle housing without M
tightening to specification.
CAUTION:
Do not tighten at this point. This allows further tightening of N
RCH@1521D
P

9. Tighten each side bearing adjusters using adjuster tool.

10. Adjusting backlash of drive gear and drive pinion. Refer to DLN-
Assembly".
Assembly".
OCH@/ 226D
13. Apply sealant to mating surface of carrier cover.

CAUTION:
Remove old sealant adhering to mating surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mating surfaces.
14. Install carrier cover on axle housing and tighten carrier cover
bolts with the specified torque. Refer to DLN-295, "Disassembly
and Assembly".
OCH@0/ 50D
• ⇐: Front
15. Connect the brake tube (2) and parking brake cable (4) to the
carrier cover and tighten to the specified torque. Refer to DLN-
16. Install the rear stabilizer bar. Refer to RSU-13, "Removal and
Installation".
17. Install both RH and LH axle shafts. Refer to RAX-21, "Removal
and Installation".
18. Install propeller shaft. Refer to DLN-138, "Removal and Installa-
tion" . KCH@/ 083D
19. Refill rear final drive oil. Refer to DLN-285, "Checking Differen-
tial Gear Oil".

FRONT OIL SEAL
FRONT OIL SEAL
A
REMOVAL B
2. Remove the brake calipers and rotors. Refer to BR-38, "Removal and Installation of Brake Caliper and
Disc Rotor". C
3. Measure the total preload torque. Refer to DLN-295, "Disassembly and Assembly".
NOTE:
Record the total preload torque measurement. DLN
4. Remove the drive pinion nut using Tool.
Tool number : KV40104000 ( — ) E

using paint.
CAUTION: F
G
KCH@/ 011D
6. Remove the companion flange using suitable tool. H
KCH@/ 012D K

L
Tool number : ST33290001 (J-34286)
KCH@/ 013D
INSTALLATION O

FRONT OIL SEAL
1. Apply multi-purpose grease to the lips of the new front oil seal.
Then drive the new front oil seal in evenly until it becomes flush
with the gear carrier using Tool.

CAUTION:
KCH@/ 014D
tightening torque using Tool A, and check the total preload
torque using Tool B.

B: ST3127S000 (J-25765-A)
Total preload torque: Refer to DLN-295, "Disassem-

bly and Assembly".
spacer, it should also be equal to the measurement taken dur-
nut in 6.8 N·m (0.69 Kg-m, 5ft-lb) increments until the total pre-
load torque is met.
CAUTION:
washer.
• Apply anti-corrosive oil to the threads of the drive pinion V CH@/ 27/ D
• Adjust the drive pinion lock nut tightening torque to the lower limit first. Do not exceed the drive
pinion lock nut specified torque. Refer to DLN-295, "Disassembly and Assembly".
• Do not loosen drive pinion lock nut to adjust the total preload torque. If the total preload torque
exceeds the specifications, replace the collapsible spacer and tighten it again to adjust. Refer to
CAUTION:
Oil".

CARRIER COVER
CARRIER COVER
A
REMOVAL B
rier cover. C
DLN
Tool number : KV10111100 (J-37228)
CAUTION:
• Do not damage the mating surface. E
mating surface.
KCH@/ 015D
F
INSTALLATION
cover as shown. G
CAUTION:
3. Connect the parking brake cable and brake tube to the carrier J
cover.
ferential Gear Oil". K

< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: M226 (ELD) ]

REMOVAL
CAUTION:
may result in sensor wires being damaged and sensor becoming inoperative.
5. Disconnect the following components from the rear final drive assembly.
• ⇐: Vehicle front
• ABS sensor wire harness
• Parking brake cable (1)
• Brake hoses and tubes (2)
• Differential lock solenoid connector (3)
• Differential lock position switch connector (4)
KCH@/ 083D
6. Support the rear final drive assembly using a suitable jack.

9. Remove rear final drive assembly.
CAUTION:
INSTALLATION
CAUTION:
• Fill the rear final drive assembly with differential gear oil after installation. Refer to DLN-285, "Check-
• After the installation, check DIFF LOCK indicator lamp. Refer to DLN-280, "Precaution for Servicing
Rear Final Drive".

REAR FINAL DRIVE
< DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: M226 (ELD) ]
DISASSEMBLY AND ASSEMBLY A

REAR FINAL DRIVE
B
COMPONENTS
C
DLN
V CH@/ 235D
O
1. Drive pinion lock nut 2. Drive pinion lock nut washer 3. Companion flange
4. Front oil seal 5. Drive pinion front bearing thrust 6. Drive pinion front bearing
washer
P
7. Gear carrier 8. Differential lock position switch 9. Breather
10. Sensor connector 11. Drain plug 12. Side bearing cap
13. Adjuster lock plate 14. Carrier cover 15. Filler plug
16. Drive pinion 17. Drive pinion height adjusting washer 18. Drive pinion rear bearing
19. Collapsible spacer 20. Side bearing adjuster 21. Side bearing
22. Differential case assembly 23. Drive gear 24. Differential lock solenoid
25. Solenoid washer

REAR FINAL DRIVE
• Drain the differential gear oil before inspection and adjustment. Refer to DLN-285, "Changing Differential
Gear Oil" .
• Remove and install the carrier cover as necessary for inspection and adjustment. Refer to DLN-293,
2. Rotate the drive pinion at least 20 times to check for smooth operation of the bearings.
Total preload torque:

2.38 - 4.46 N·m (0.25 - 0.45 kg-m, 21 - 39 in-lb)
NOTE:
• If the measured value is out of the specification, check and OCH@/ 2/ 8D
adjust each part. Adjust the drive pinion bearing preload

torque first, then adjust the side bearing preload torque.

On drive pinion bearings: Replace collapsible spacer.
On side bearings: Loosen side bearing adjuster.

On drive pinion bearings: Tighten drive pinion lock nut.
On side bearings: Tighten side bearing adjuster.
Tooth Contact
1. Thoroughly clean drive gear and drive pinion teeth.
2. Apply red lead to the drive gear.
NOTE:
RCH@1512D

REAR FINAL DRIVE
3. Hold companion flange steady by hand and rotate drive gear in
both directions. A
OCH@/ 211D
DLN
I
RCH@1480D
4. If outside the standard, adjust drive pinion height adjusting washer and backlash. Refer to DLN-295, "Dis- J
assembly and Assembly" and DLN-310, "Inspection and Adjustment".
Backlash
1. Fit a dial indicator to the drive gear face to measure the back- K
lash.
Backlash: 0.12 - 0.20 mm (0.0050 - 0.0079 in) L

2. If the backlash is outside of the specification, adjust each side
bearing side bearing adjuster.
M
a. Remove adjuster lock plate.
b. Loosen side bearing cap bolts.
RCH@153/ D
N
c. Tighten or loosen each side bearing adjusters using Tool.

O
OCH@/ 226D

REAR FINAL DRIVE

Loosen side bearing adjuster A and tighten side bear-
ing adjuster B by the same amount.
Loosen side bearing adjuster B and tighten side bear-
ing adjuster A by the same amount.
CAUTION:
Do not change the side bearing side bearing adjusters by
different amounts as it will change the side bearing preload OCH@/ 22/ D
torque.
d. Tighten side bearing cap bolts to the specified torque. Refer to
e. Install adjuster lock plate and tighten to the specified torque.
CAUTION:
Check tooth contact and total preload torque after adjusting
side bearing adjuster. Refer to DLN-295, "Disassembly and
Assembly".
OCH@/ 220D

Runout limit
Companion flange face: 0.10 mm (0.0039 in)
Companion flange inner side: 0.13 mm (0.0051 in)
below to adjust.
a. Rotate the companion flange on the drive pinion by 90°, 180° RCH@1/ 67D
and 270° while checking for the position where the runout is minimum.
b. If the runout is still outside of the runout limit after the companion flange has been rotated on the drive pin-
ion, possible cause could be an assembly malfunction of drive pinion and drive pinion bearing or a mal-
functioning drive pinion bearing.
DISASSEMBLY
Tool number : KV10111100 (J-37228)

CAUTION:
mating surface.
RCH@1470D

REAR FINAL DRIVE
3. Remove differential sensor connector bolt and differential lock
solenoid connector. A
RCH@1474D
DLN
4. For proper reinstallation, paint matching mark on one side of
side bearing cap.
CAUTION: E
positions.
• For matching mark, use paint. Do not damage side bear- F
ing cap.
G
RCH@1472D
6. Remove side bearing caps. H
RCH@1476D K
7. Remove side bearing adjusters using Tool.

L
OCH@/ 226D
8. Keep side bearing outer races together with inner races. Do not O
mix them up. Also, keep side bearing adjusters together with
bearing.
9. Remove side bearing adjusters from gear carrier. P
RCH@1477D

REAR FINAL DRIVE
10. Remove bracket of differential lock position switch connector and bolts.
11. Remove differential lock position switch.
12. Remove side bearing inner race and washer using Tool.

CAUTION:
Do not damage differential case assembly and differential
lock solenoid.
13. Remove differential lock solenoid and solenoid washer.
RCH@1473D
14. Remove side bearing inner race using Tool.

CAUTION:
Do not damage differential case assembly.
RCH@1478D
15. For proper reinstallation, paint matching mark on differential

CAUTION:
case or drive gear.
CAUTION:
RCH@1127D

1. Remove differential case assembly. Refer to DLN-294, "Removal and Installation".
2. Remove drive pinion lock nut and washer using Tool.

using paint.
CAUTION:
OCH@/ 203D

REAR FINAL DRIVE
4. Remove companion flange using suitable tool.
A
OCH@/ 204D
DLN
5. Remove front oil seal using Tool.
Tool number : ST33290001 (J-34286) E

CAUTION:
6. Remove drive pinion front bearing thrust washer. F
G
RCH@1475D
7. Remove drive pinion assembly (with rear inner bearing race and
H
collapsible spacer) out of gear carrier.
CAUTION:
8. Remove drive pinion front bearing inner race from gear carrier. I
OCH@/ 205D
K
9. Tap drive pinion front bearing outer race uniformly with a brass
bar or equivalent to remove.
CAUTION: L
10. Tap drive pinion rear bearing outer race uniformly with a brass
bar or equivalent for removal. M
CAUTION:
N
RCH@1530D
11. Remove drive pinion rear bearing inner race and drive pinion O
Tool number : ST30021000 (J-22912-01) P
RCH@1125D

REAR FINAL DRIVE
• If the gear teeth do not mesh or line-up correctly, determine the cause and adjust, repair, or replace as nec-
essary.
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new gears.
• Drive gear and drive pinion are supplied in matched sets only. Matching numbers on both drive pinion and
drive gear are etched for verification. If a new gear set is being used, verify the numbers of each pinion gear
and drive gear before proceeding with assembly.
Bearing
• If found any chipped (by friction), pitted, worn, rusted, scratched mark, or unusual noise from the bearing,
Differential Case Assembly
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new differen-
tial case assembly.
• If the movement is not smooth when pushing cam ring of differential case assembly with a hand.
Differential Lock Solenoid
• If the operating part of differential lock solenoid is not smooth, perform component inspection. Refer to DLN-
SELECTION ADJUSTING WASHERS
• Drive gear and drive pinion are supplied in matched sets only.
Matching numbers on both drive pinion and drive gear are etched
for verification. If a new gear set is being used, verify the numbers
of each drive pinion and drive gear before proceeding with assem-
bly.
RCH@1130D
• The mounting distance from the center line of drive gear to the back face of drive pinion for the Model 226
final drive assembly is 109.5 mm (4.312 in).
On the button end of each drive pinion, there is etched a plus (+) number, a minus (-) number, or a zero (0),
which indicates the best running position for each particular gear set. This dimension is controlled by a
selective drive pinion height adjusting washer between drive pinion inner bearing race and drive pinion.
For example: If a drive pinion is etched m+8 (+3), it would require 0.08 mm (0.003 in) less drive pinion height
adjusting washer than a drive pinion etched “0”. This means decreasing drive pinion height adjusting washer
thickness; increases the mounting distance of drive pinion to 109.6 mm (4.315 in). If a drive pinion is etched
m-8 (-3), it would require adding 0.08 mm (0.003 in) more to drive pinion height adjusting washer than would
be required if drive pinion were etched “0”. By adding 0.08 mm (0.003 in), the mounting distance of drive pin-
ion was decreased to 109.4 mm (4.309 in) which is just what m-8 (a-3) etching indicated.
• To change drive pinion adjustment, use different drive pinion height adjusting washers which come in differ-
ent thickness.
• Use the following tables as a guide for selecting the correct drive pinion height adjusting washer thickness to
add or subtract from the old drive pinion height adjusting washer.

PINION
MARKING -10 (-4) -8 (-3) -5 (-2) -3 (-1) 0 (0) +3 (+1) +5 (+2) +8 (+3) +10 (+4)
+0.20 +0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0

+10 (+4)
(+0.008) (+0.007) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0)
+0.18 +0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02
+8 (+3)
(+0.007) (+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001)

REAR FINAL DRIVE
PINION A
MARKING -10 (-4) -8 (-3) -5 (-2) -3 (-1) 0 (0) +3 (+1) +5 (+2) +8 (+3) +10 (+4)
+0.15 +0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05

+5 (+2)
(+0.006) (+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) B
+0.13 +0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08
+3 (+1)
(+0.005) (+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003)
0 (0)
+0.10 +0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10 C
(+0.004) (+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004)
+0.08 +0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13
-3 (-1)
(+0.003) (+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) DLN
+0.05 +0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15
-5 (-2)
(+0.002) (+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006)
+0.02 0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18 E
-8 (-3)
(+0.001) (0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006) (-0.007)
0 -0.02 -0.05 -0.08 -0.10 -0.13 -0.15 -0.18 -0.20
-10 (-4)
(0) (-0.001) (-0.002) (-0.003) (-0.004) (-0.005) (-0.006) (-0.007) (-0.008)
F
1. Make sure all parts are clean and that drive pinion bearings are
well lubricated.
2. Assemble drive pinion bearings into the tools. G

B: — (6740) H
C: — (6741)
I
RCH@1131D
3. Install drive pinion bearing inner race and drive pinion height
adjusting washer to gear carrier using tool as shown. J
OCH@/ 207D
M
4. Turn the assembly several times to seat drive pinion bearings.
P
OCH@/ 208D

REAR FINAL DRIVE
5. Measure the turning torque, using Tool.
Turning torque specification:

1.2 - 2.8 N-m (0.13 - 0.28 kg-m, 11 - 24 in-lb)
OCH@/ 21/ D
6. Tighten side bearing caps to the specified torque installing Tools

as shown.

B: — (D-115-2)
C: — (8541A-1)
D: — (D-115-3)
RCH@1535D
7. Put scooter block on pinion height block. Make sure that dial
indicator is level adjusting pressure with a hand. Dial indicator
indicates “0”.
8. Slide dial indicator along arbor. Record the maximum.
9. Adjust drive pinion height adjusting washer so that the maximum
will be “0”.
RCH@1536D
ASSEMBLY
1. Press a drive pinion rear bearing outer race into gear carrier
using Tool.

B: ST30022000 ( — )
CAUTION:
Do not reuse drive pinion rear bearing.
OCH@/ 212D

REAR FINAL DRIVE
2. Press a drive pinion front bearing outer race into gear carrier
using Tool. A

CAUTION: B
Do not reuse drive pinion front bearing.
3. Select drive pinion height adjusting washer. Refer to DLN-295,
"Disassembly and Assembly". C
OCH@/ 213D
DLN
4. Press a drive pinion rear bearing inner race and drive pinion
height adjusting washer to drive pinion, using Tool.
E
CAUTION:
Do not reuse drive pinion rear bearing. F
5. Apply gear oil to the drive pinon rear bearing and drive pinon
front bearing.
6. Install drive pinion front bearing inner race in gear carrier. G
7. Install drive pinion front bearing thrust washer to gear carrier. RCH@1481D
8. Apply multi-purpose grease to new front oil seal lip. Install new H
front oil seal into gear carrier using Tool.

I
CAUTION:
• Apply multi-purpose grease to the lip of the new front oil J
seal.
OCH@/ 215D
K
9. Install new collapsible spacer to drive pinion. And then install
drive pinion assembly in gear carrier.
CAUTION: L
• Do not reuse collapsible spacer.
• Do not damage front oil seal.
M
N
RCH@1484D
10. Install the companion flange onto the drive pinion while aligning O
the matching marks. Then tap the companion flange using suit-
able tool.
CAUTION: P
Do not damage companion flange or front oil seal.
OCH@/ 217D

REAR FINAL DRIVE
tightening torque using Tool A, and check the drive pinion bear-
ing preload torque using Tool B.

B: ST3127S000 (J-25765-A)

1.7 - 3.1 N·m (0.18 - 0.31 kg-m, 15 - 27 in-lb)
CAUTION:
washer.
Assembly".
specified value, replace collapsible spacer and tighten it V CH@/ 268D

adjust the drive pinion bearing preload torque.
1. Apply thread locking sealant to back face of drive gear.
CAUTION:
clean.
OCH@0/ 48D
2. Align the matching mark of differential case assembly with the

mark of drive gear, then install drive gear.
RCH@1482D

REAR FINAL DRIVE
gear and install the bolts. A
B
CAUTION:
clean.
C
RCH@1483D
DLN
4. Install new drive gear bolts, and then tighten to the specified
CAUTION:
E
• Do not reuse the bolts.
• Tighten bolts in a crisscross fashion.
G
RCH@/ 136I
5. Press side bearing inner races to differential case assembly

H
using Tool.

I
CAUTION:
Do not reuse side bearing.
J
RCH@152/ D
K
6. Install differential lock solenoid and washer.
7. Press side bearing inner races to differential case assembly
using Tool. L

B: ST33081000 ( — ) M
N
RCH@1520D
8. Apply sealant to threads of differential lock position switch. O

• Use Genuine Silicone RTV or equivalent. Refer to GI-14, "Recommended Chemical Products and Seal-
ants".
CAUTION:
Remove old sealant adhering to gear carrier and differential lock position switch. Also remove any P
moisture, oil, or foreign material adhering to application and gear carrier and differential lock posi-
tion switch.

REAR FINAL DRIVE
9. Install differential lock position switch on gear carrier and tighten
differential lock position switch bolts with the specified torque.
RCH@1522D
10. Install side bearing adjusters into gear carrier.
OCH@/ 270D
11. Apply gear oil to side bearings. Install differential case assembly
with side bearing outer races into gear carrier.
12. Apply multi-purpose grease to sensor connector.
CAUTION:
Do not reuse sensor connector.
RCH@1477D
13. Connect differential lock solenoid harness and sensor connec-

tor. Then install it to gear carrier, tighten to the specified torque.
RCH@1474D
14. Align paint matching mark on side bearing caps with that on
gear carrier and install side bearing caps on gear carrier.
CAUTION:
Do not tighten at this point. This allows further tightening of
RCH@1521D

REAR FINAL DRIVE
15. Tighten each side bearing adjusters using adjuster tool.
A
16. Adjusting backlash of drive gear and drive pinion. Refer to DLN- B
Assembly".
C
Assembly".
OCH@/ 226D
DLN
cover as shown.
• Use Genuine Silicone RTV or equivalent. Refer to GI-14, E
CAUTION:
Also remove any moisture, oil, or foreign material adhering F
the specified torque. Refer to DLN-295, "Disassembly and G

< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR FINAL DRIVE: M226 (ELD) ]

VQ40DE
Applied model 4WD
5A/T 6M/T
Final drive model M226
Gear ratio 3.357 3.692
Number of teeth (Drive gear / drive pinion) 47/14 48/13
PRELOAD TORQUE
Item Specification
Drive pinion bearing preload torque 1.7 - 3.1 (0.18 - 0.31, 15 - 27)
(Total preload torque = drive pinion bearing preload 2.38 - 4.46 (0.25 - 0.45, 21 - 39)
torque + Side bearing preload torque)
BACKLASH
Unit: mm (in)
Item Standard
Drive gear to drive pinion gear 0.12 - 0.20 (0.0050 - 0.0079)

Unit: mm (in)
Item Runout limit

SELECTIVE PARTS
Unit: mm (in)

0.076 (0.030)
0.079 (0.031)
0.081 (0.032) 38151 8S101
0.084 (0.033)
0.086 (0.034)
0.089 (0.035)
0.091 (0.036)
0.094 (0.037) 38151 8S102
0.097 (0.038)
0.099 (0.039)

< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR FINAL DRIVE: M226 (ELD) ]
A
0.102 (0.040)
0.104 (0.041)
0.107 (0.042) 38151 8S103
0.109 (0.043) B
0.112 (0.044)
0.114 (0.045)
0.117 (0.046)
0.119 (0.047) 38151 8S104
C
0.122 (0.048)
0.124 (0.049)
0.127 (0.050) DLN
0.130 (0.051)
0.132 (0.052) 38151 8S105
0.135 (0.053)
0.137 (0.054) E

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TRANSMISSION & DRIVELINE

Revision: October 2008 DLN-1 2009 Xterra

SYMPTOM DIAGNOSIS ............................. 69 TRANSFER CONTROL UNIT ........................... 91

PROPELLER SHAFT ....................................... 129 PREPARATION ......................................... 145

DISASSEMBLY AND ASSEMBLY ............ 132 NOISE, VIBRATION AND HARSHNESS G

Revision: October 2008 DLN-3 2009 Xterra

ON-VEHICLE REPAIR ............................... 186 REMOVAL AND INSTALLATION ............. 222

CARRIER COVER ........................................... 188 DISASSEMBLY AND ASSEMBLY ........... 223

REAR FINAL DRIVE ........................................ 189 SERVICE DATA AND SPECIFICATIONS

Revision: October 2008 DLN-4 2009 Xterra

P1848 SOLENOID DISCONNECT ................... 261 ON-VEHICLE MAINTENANCE .................. 285

FRONT OIL SEAL ........................................... 291 SERVICE DATA AND SPECIFICATIONS

Revision: October 2008 DLN-6 2009 Xterra

Revision: October 2008 DLN-8 2009 Xterra

Revision: October 2008 DLN-9 2009 Xterra

System Description INFOID:0000000004095516

TRANSFER CONTROL DEVICE

Revision: October 2008 DLN-10 2009 Xterra

4WD Shift Switch

Condition 4WD warning lamp

ATP WARNING LAMP (A/T MODELS)

Revision: October 2008 DLN-11 2009 Xterra

Revision: October 2008 DLN-12 2009 Xterra

Refer to LAN-52, "DTC Index".

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

Revision: October 2008 DLN-13 2009 Xterra

POWER TRANSFER DIAGRAM

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

POWER TRANSFER FLOW

Revision: October 2008 DLN-14 2009 Xterra

Revision: October 2008 DLN-15 2009 Xterra

ALL MODE AWD/4WD diagnostic mode Description

SELF-DIAG RESULT MODE

Revision: October 2008 DLN-16 2009 Xterra

Monitor item selection O

Revision: October 2008 DLN-17 2009 Xterra

Revision: October 2008 DLN-18 2009 Xterra

TRANSFER FLUID (Level too high)

SHIFT FORK (Worn or damaged)

BEARING (Worn or damaged)

O-RING (Worn or damaged)

GEAR (Worn or damaged)

Revision: October 2008 DLN-19 2009 Xterra

DTC DETECTION LOGIC

DTC CONSULT-III Diagnostic item is detected when... Reference

Power supply voltage for transfer control

DTC CONFIRMATION PROCEDURE

1.CHECK POWER SUPPLY

Connector Terminal Voltage (Approx.)

Revision: October 2008 DLN-20 2009 Xterra

Connector Terminal Voltage (Approx.) B

1. Turn ignition switch “OFF”.

Continuity should exist. N

3.CHECK TRANSFER CONTROL UNIT

Revision: October 2008 DLN-21 2009 Xterra

1. Turn ignition switch “OFF”. (Stay for at least 5 seconds.)

Revision: October 2008 DLN-22 2009 Xterra

DTC DETECTION LOGIC

DTC CONFIRMATION PROCEDURE