Manual Transmission: Click On The Applicable Bookmark To Selected The Required Model Year
Manual Transmission: Click On The Applicable Bookmark To Selected The Required Model Year
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MANUAL
TRANSMISSION
Click on the applicable bookmark to selected the required model year.
MANUAL
TRANSMISSION
CONTENTS
GENERAL INFORMATION
Items Specifications
4th 1.000
LUBRICANTS
Items Specified lubricants Quantity L
Transmission oil Hypoid gear oil SAE 75W-90 or 75W-85W conforming to 3.2
API GL-4
Transfer oil Hypoid gear oil SAE 75W-90 or 75W-85W conforming to 2.5
API GL-4
SEALANTS
Items Specified sealant Remarks
Oil filler plug 3M ATD Part No. 8660 or equivalent Semi-drying sealant
Oil drain plug 3M ATD Part No. 8660 or equivalent Semi-drying sealant
SPECIAL TOOL
Tool Number Name Use
MD998464 Test harness Inspection of lever position sensor
(4P, square)
OK Intermittent malfunction
MUT-II Data list
D No.1 LPS (Refer to GROUP 00 - Points to
OK: Refer to P.23-5, DATA LIST Note for Transient Malfunctions.)
REFERENCE TABLE.
OK
ON-VEHICLE SERVICE
TRANSMISSION OIL CHECK
Filler plug hole
Transmission oil 1. Remove the oil filler plug.
2. Oil level should be at the lower portion of the filler plug
hole.
3. Check that the transmission oil is not noticeably dirty,
and that it has a suitable viscosity.
4. Tighten the filler plug to the specified torque.
Tightening torque: 32 ± 2 N×m
Transfer
<V5M31>
OilOil filler
filler plug
plug
OilOil
drain plug
drain plug
1 2
2H
4H
1 2
4H
4L
4H-4L
5
1
3
2
3
1
3 7
4
11 ± 2 N×m
4HLc 4H
INSPECTION
4LLc 2H TRANSFER SELECT SWITCH CONTINUITY CHECK
Switch posi- Terminal number
tion 1 2 3 5 6
2H
4H
4HLc
4LLc
TRANSMISSION ASSEMBLY
REMOVAL AND INSTALLATION
Caution
The rear propeller shaft is made of fiber-reinforced plastic tube, so always refer to GROUP 25
prior to its removal.
11
10
6
48 ± 6 N×m
35 ± 6 N×m
53 ± 5 N×m
24 ± 5 N×m
23 ± 3 N×m
35 ± 6 N×m
44 ± 10 N×m
48 ± 6 N×m
8
4
3 35 ± 6 N×m
44 ± 10 N×m
2
35 ± 6 N×mm
1 7
44 ± 10 N×m
26 ± 4 N×m
35 ± 6 N×m
9.0 ± 2.0 N×m
44 ± 10 N×m
24 ± 5 N×m
9 35 ± 6 N×m 5
11
10
6
35 ± 6 N×m
53 ± 5 N×m
48 ± 6 N×m
24 ± 5 N×m
23 ± 3 N×m
44 ± 10 N×m
8
35 ± 6 N×m
48 ± 6 N×m
44 ± 10 N×m
4
3
35 ± 6 N×m
2 35 ± 6 N×m
1 7
44 ± 10 N×m
26 ± 4 N×m
35 ± 6 N×m 44 ± 10 N×m
9.0 ± 2.0 N×m
Removal steps
1. Clutch release cylinder 7. Transmission mount center member
2. Space rubber assembly
3. Bell housing cover 8. Transmission mount insulator assem-
4. Starter motor bly
5. Dynamic damper assembly AA" 9. Transmission wiring harness connec-
6. Tension wire bracket tor connection
D Support the transmission with a "AA 10. Transmission assembly
transmission jack 11. Tension wire
24 ± 5 N×m 35 ± 6 N×m 9
13
15
10
7 14 35 ± 6 N×m
53 ± 5 N×m
24 ± 5 N×m
48 ± 6 N×m
8
44 ± 10 N×m
11 ± 1 N×m
48 ± 6 N×m
12
44 ± 10 N×m
6
1
3
5 11
44 ± 10 N×m
26 ± 4 N×m
48 ± 6 N×m
4 2
44 ± 10 N×m
Removal steps
1. Clutch release cylinder 4. Battery cable connection
(Refer to GROUP15) 5. Spacing rubber
2. Clutch dumper assembly 6. Dust cover
(Refer to GROUP15) 7. Heater hose connection
3. Exhaust support bracket 8. Starter motor
12
24 ± 5 N×m
35 ± 6 N×m 8
14
9
13
35 ± 6 N×m
53 ± 5 N×m
7
74 ± 10 N×m
24 ± 5 N×m
30 ± 3 N×m
5
4
44 ± 10 N×m
11
1
44 ± 10 N×m
89 ± 9 N×m
44 ± 10 N×m
<6G7> A A C 10 x 50
A
<6G7>
A
Starter
motor Bolt Diameter (D) x Length (L) mm
B
B
A 12 x 40
B 12 x 55
4WD indicator-ECU
Bracket
Transfer-ECU
INSPECTION
4WD INDICATOR-ECU
1. Measure the voltage with the control unit and harness
View A still connected.
2. Earth terminal (8) and then measure terminal voltage.
Terminal No. Inspection item Inspection condition Inspection condition Terminal voltage
1: Ignition switch 2: Transfer lever position
ON - System voltage
2H, 4H, 4L 0V
NOTE
*1: When vehicle has been moved once.
*2: Shift the lever from 4H to 2H, and then turn the ignition switch to OFF and then back to ON.
TRANSFER-ECU
Measure the terminal voltage (Refer to P.22-3).
OK Transient malfunction
MUT-II Data List
D No. 1 APS (Refer to GROUP 00 - Points to
OK: Refer to P.22-2 (Data List Note for Transient Malfunctions.)
Reference Table).
NG
NG
APS check Replace
OK
OK
NG NG
Measure at transfer-ECU connector Check the following connectors: Repair
E-105 E-105, E-113
D Measure at ECU terminals.
D Ignition switch: ON OK
D Voltage between terminal 5 and Check the harness between the APS
earth and the transfer-ECU, and repair if
OK: Fully close the accelerator necessary.
985 - 1,085 mV
fully open the accelerator OK
4,000 mV or more NG
Checkthefollowingconnector:E-105 Repair
OK