Driveline: Section

TRANSMISSION & DRIVELINE
SECTION DLN DRIVELINE

B
DLN
E
CONTENTS
TRANSFER: TY21C 4WD SYSTEM : Protection Function .......................22 F
HOW TO USE THIS MANUAL ...................... 7 INFORMATION DISPLAY (COMBINATION

METER) ......................................................................22
G
HOW TO USE THIS SECTION ............................ 7 INFORMATION DISPLAY (COMBINATION
Information ................................................................ 7 METER) : 4WD Warning .........................................22
INFORMATION DISPLAY (COMBINATION
PRECAUTION ............................................... 8 METER) : 4WD Torque Distribution Indicator ..........23 H
PRECAUTIONS ................................................... 8 WARNING/INDICATOR/CHIME LIST ........................23

Precaution for Supplemental Restraint System WARNING/INDICATOR/CHIME LIST : Warning
I
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Lamp/Indicator Lamp ...............................................23
SIONER" ................................................................... 8 WARNING/INDICATOR/CHIME LIST : Warning/
Precautions for Removing Battery Terminal ............. 8 Indicator (On Information Display) ...........................24
Service Notice or Precautions for Transfer ............... 9 J
DIAGNOSIS SYSTEM (4WD CONTROL
PREPARATION ........................................... 11 UNIT) ................................................................. 25
CONSULT Function .................................................25 K
PREPARATION ..................................................11
Special Service Tool ............................................... 11 ECU DIAGNOSIS INFORMATION .............. 27
Commercial Service Tool ........................................ 11
Lubricant or/and Sealant ......................................... 13 4WD CONTROL UNIT ....................................... 27 L
Reference Value ......................................................27
SYSTEM DESCRIPTION ............................. 14 Fail-Safe ..................................................................29
Protection Function ..................................................30 M
COMPONENT PARTS .......................................14 DTC Inspection Priority Chart ..................................30
Component Parts Location ...................................... 14 DTC Index ...............................................................30
4WD Control Unit .................................................... 15
Electric Controlled Coupling .................................... 15 WIRING DIAGRAM ...................................... 32 N
4WD Solenoid ......................................................... 15
4WD Mode Switch ................................................... 16 4WD SYSTEM ................................................... 32
Wiring Diagram ........................................................32 O
STRUCTURE AND OPERATION .......................17
Sectional View ......................................................... 17 BASIC INSPECTION ................................... 37
Operation Description ............................................. 17
DIAGNOSIS AND REPAIR WORK FLOW ....... 37 P
SYSTEM .............................................................19 Work Flow ................................................................37
Diagnostic Work Sheet ............................................38
4WD SYSTEM ........................................................... 19
4WD SYSTEM : System Description ...................... 19 ADDITIONAL SERVICE WHEN REPLACING
4WD SYSTEM : Control in Each Mode ................... 20 4WD CONTROL UNIT ....................................... 40
4WD SYSTEM : Circuit Diagram ............................. 21 Description ...............................................................40
4WD SYSTEM : Fail-Safe ....................................... 21 Work Procedure .......................................................40
DLN-1
UNIT CHARACTERISTICS WRITING ............... 41 DTC Description ...................................................... 63
Description .............................................................. 41 Diagnosis Procedure ............................................... 63
Work Procedure ...................................................... 41
POWER SUPPLY AND GROUND CIRCUIT ..... 64
DTC/CIRCUIT DIAGNOSIS ......................... 42 Diagnosis Procedure ............................................... 64
C1201 4WD CONTROL UNIT ............................ 42 4WD INDICATOR LAMP ................................... 67

DTC Description ..................................................... 42 Component Function Check ................................... 67
Diagnosis Procedure .............................................. 42 Diagnosis Procedure ............................................... 67
C1203 ABS ACTUATOR AND ELECTRIC LOCK INDICATOR LAMP ................................. 68

UNIT (CONTROL UNIT) .................................... 43 Component Function Check ................................... 68
DTC Description ..................................................... 43 Diagnosis Procedure ............................................... 68
Diagnosis Procedure .............................................. 43
SYMPTOM DIAGNOSIS ............................ 69
C1204 4WD SOLENOID .................................... 44
DTC Description ..................................................... 44
HEAVY TIGHT-CORNER BRAKING SYMP-
Diagnosis Procedure .............................................. 44 TOM OCCURS ................................................... 69
Component Inspection ............................................ 46 Description .............................................................. 69
Diagnosis Procedure ............................................... 69
C1209 MODE SW .............................................. 47
DTC Description ..................................................... 47 VEHICLE DOES NOT ENTER 4WD MODE ...... 70
Diagnosis Procedure .............................................. 47 Description .............................................................. 70
Component Inspection ............................................ 49 Diagnosis Procedure ............................................... 70
C1210 ECM ........................................................ 50 4WD HIGH TEMP IS DISPLAYED ON INFOR-

DTC Description ..................................................... 50 MATION DISPLAY ............................................ 71
P1804 4WD CONTROL UNIT ............................ 51 TIRE SIZE INCORRECT IS DISPLAYED ON

DTC Description ..................................................... 51 INFORMATION DISPLAY ................................. 72
Diagnosis Procedure ............................................... 72
P1808 WHEEL SPEED SENSOR ...................... 52
DTC Description ..................................................... 52 NOISE, VIBRATION AND HARSHNESS
Diagnosis Procedure .............................................. 52 (NVH) TROUBLESHOOTING ............................ 73
NVH Troubleshooting Chart .................................... 73
P1809 4WD CONTROL UNIT ............................ 53
DTC Description ..................................................... 53 PERIODIC MAINTENANCE ....................... 74
TRANSFER OIL ................................................. 74
P1811 BATTERY VOLTAGE ............................. 54
DTC Description ..................................................... 54 MR20DD .................................................................... 74
Diagnosis Procedure .............................................. 54 MR20DD : Inspection .............................................. 74
MR20DD : Draining ................................................. 74
P181B INCOMPLETE SELFSHUT .................... 57 MR20DD : Refilling ................................................. 74
DTC Description ..................................................... 57
QR25DE ..................................................................... 74
QR25DE : Inspection .............................................. 75
P181D ENGINE TORQUE SIGNAL ................... 60 QR25DE : Draining ................................................. 75
DTC Description ..................................................... 60 QR25DE : Refilling .................................................. 75
REMOVAL AND INSTALLATION .............. 76
P181F INCOMPLETE CALIBRATION .............. 61
DTC Description ..................................................... 61 4WD CONTROL UNIT ....................................... 76
Diagnosis Procedure .............................................. 61 Exploded View ........................................................ 76
Removal and Installation ......................................... 76
U1000 CAN COMM CIRCUIT ............................ 62 Adjustment .............................................................. 76
DTC Description ..................................................... 62
Diagnosis Procedure .............................................. 62 4WD MODE SWITCH ........................................ 77
Exploded View ........................................................ 77
U1010 CONTROL UNIT (CAN) ......................... 63 Removal and Installation ......................................... 77
DLN-2
TRANSFER COVER OIL SEAL .........................78 PRECAUTION ............................................ 110
A
MR20DD .................................................................... 78 PRECAUTIONS ............................................... 110
MR20DD : Exploded View ....................................... 78 Precaution for Supplemental Restraint System
MR20DD : Removal and Installation ....................... 78 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
MR20DD : Inspection .............................................. 79 B
SIONER" ............................................................... 110
Precautions for Removing Battery Terminal .......... 110
QR25DE ..................................................................... 79
Precaution for Stop/Start System Service ............. 111
QR25DE : Removal and Installation ....................... 79 C
Service Notice or Precautions for Transfer ............ 111
UNIT REMOVAL AND INSTALLATION ...... 80 PREPARATION ......................................... 113
TRANSFER ASSEMBLY ...................................80 DLN
PREPARATION ............................................... 113
MR20DD .................................................................... 80 Special Service Tool .............................................. 113
MR20DD : Exploded View ....................................... 80 Commercial Service Tool ...................................... 115
MR20DD : Removal and Installation ....................... 80 Lubricant or/and Sealant ....................................... 116 E
MR20DD : Inspection .............................................. 81
SYSTEM DESCRIPTION ........................... 117
QR25DE ..................................................................... 81 F
QR25DE : Exploded View ....................................... 81 COMPONENT PARTS .................................... 117
QR25DE : Removal and Installation ....................... 81 Component Parts Location .................................... 117
QR25DE : Inspection .............................................. 82 4WD Control Unit ................................................... 119
Electric Controlled Coupling .................................. 119 G
UNIT DISASSEMBLY AND ASSEMBLY ... 83 4WD Solenoid ........................................................ 119
4WD Mode Switch ................................................. 120
TRANSFER COVER ...........................................83 H
Exploded View ........................................................ 83 STRUCTURE AND OPERATION ................... 121
Disassembly and Assembly .................................... 85 Sectional View ....................................................... 121
Inspection ................................................................ 87 Operation Description ............................................ 121
I
RING GEAR SHAFT ...........................................88 SYSTEM .......................................................... 123
Exploded View ........................................................ 88
4WD SYSTEM .......................................................... 123
Disassembly and Assembly .................................... 90 J
4WD SYSTEM : System Description ..................... 123
Inspection ................................................................ 92
4WD SYSTEM : Control in Each Mode ................. 124
DRIVE PINION ....................................................94 4WD SYSTEM : Circuit Diagram ........................... 125
Exploded View ........................................................ 94 4WD SYSTEM : Fail-Safe ..................................... 125 K
Disassembly and Assembly .................................... 96 4WD SYSTEM : Protection Function ..................... 126
Adjustment .............................................................. 98
INFORMATION DISPLAY (COMBINATION
Inspection .............................................................. 102 L
METER) .................................................................... 126
TRANSFER CASE ........................................... 103 INFORMATION DISPLAY (COMBINATION
Exploded View ...................................................... 103 METER) : 4WD Warning ....................................... 126
Disassembly and Assembly .................................. 105 INFORMATION DISPLAY (COMBINATION M
Inspection .............................................................. 107 METER) : 4WD Torque Distribution Indicator ........ 127
SERVICE DATA AND SPECIFICATIONS WARNING/INDICATOR/CHIME LIST ...................... 127

N
WARNING/INDICATOR/CHIME LIST : Warning
(SDS) .......................................................... 108 Lamp/Indicator Lamp ............................................. 127
SERVICE DATA AND SPECIFICATIONS WARNING/INDICATOR/CHIME LIST : Warning/
Indicator (On Information Display) ......................... 128 O
(SDS) ................................................................ 108
General Specifications .......................................... 108 DIAGNOSIS SYSTEM (4WD CONTROL
Preload Torque ..................................................... 108 UNIT) ............................................................... 129
Backlash ................................................................ 108 P
CONSULT Function ............................................... 129
Companion Flange Runout ................................... 108
TRANSFER: TY30A ECU DIAGNOSIS INFORMATION ............ 131
HOW TO USE THIS MANUAL ................... 109 4WD CONTROL UNIT ..................................... 131
Reference Value .................................................... 131
HOW TO USE THIS SECTION ......................... 109 Fail-Safe ................................................................ 133
Information ............................................................ 109 Protection Function ................................................ 134
DLN-3
DTC Inspection Priority Chart ................................134 Diagnosis Procedure ............................................. 158
DTC Index .............................................................134
P181B INCOMPLETE SELFSHUT ................... 161
WIRING DIAGRAM .................................... 136 DTC Description .................................................... 161
Diagnosis Procedure ............................................. 161
4WD SYSTEM .................................................. 136
Wiring Diagram ......................................................136 P181D ENGINE TORQUE SIGNAL ................. 164
DTC Description .................................................... 164
BASIC INSPECTION .................................. 141 Diagnosis Procedure ............................................. 164
DIAGNOSIS AND REPAIR WORK FLOW ...... 141 P181F INCOMPLETE CALIBRATION ............. 165
Work Flow ..............................................................141 DTC Description .................................................... 165
Diagnostic Work Sheet ..........................................142 Diagnosis Procedure ............................................. 165
ADDITIONAL SERVICE WHEN REPLACING U1000 CAN COMM CIRCUIT ........................... 166
4WD CONTROL UNIT ..................................... 144 DTC Description .................................................... 166
Description .............................................................144 Diagnosis Procedure ............................................. 166
Work Procedure .....................................................144
U1010 CONTROL UNIT (CAN) ........................ 167
UNIT CHARACTERISTICS WRITING ............. 145 DTC Description .................................................... 167
Description .............................................................145 Diagnosis Procedure ............................................. 167
Work Procedure .....................................................145
POWER SUPPLY AND GROUND CIRCUIT .... 168
DTC/CIRCUIT DIAGNOSIS ........................ 146 Diagnosis Procedure ............................................. 168
C1201 4WD CONTROL UNIT .......................... 146 4WD INDICATOR LAMP .................................. 171
DTC Description ....................................................146 Component Function Check ................................. 171
Diagnosis Procedure .............................................146 Diagnosis Procedure ............................................. 171
C1203 ABS ACTUATOR AND ELECTRIC LOCK INDICATOR LAMP ................................ 172
UNIT (CONTROL UNIT) .................................. 147 Component Function Check ................................. 172
DTC Description ....................................................147 Diagnosis Procedure ............................................. 172
Diagnosis Procedure .............................................147
SYMPTOM DIAGNOSIS ........................... 173
C1204 4WD SOLENOID .................................. 148
DTC Description ....................................................148 HEAVY TIGHT-CORNER BRAKING SYMP-
Diagnosis Procedure .............................................148 TOM OCCURS .................................................. 173
Component Inspection ...........................................150 Description ............................................................ 173
C1209 MODE SW ............................................ 151
DTC Description ....................................................151 VEHICLE DOES NOT ENTER 4WD MODE ..... 174
Diagnosis Procedure .............................................151 Description ............................................................ 174
Component Inspection ...........................................153 Diagnosis Procedure ............................................. 174
C1210 ECM ...................................................... 154 4WD HIGH TEMP IS DISPLAYED ON INFOR-

DTC Description ....................................................154 MATION DISPLAY ........................................... 175
P1804 4WD CONTROL UNIT .......................... 155 TIRE SIZE INCORRECT IS DISPLAYED ON
DTC Description ....................................................155 INFORMATION DISPLAY ................................ 176
P1808 WHEEL SPEED SENSOR .................... 156
DTC Description ....................................................156 NOISE, VIBRATION AND HARSHNESS
Diagnosis Procedure .............................................156 (NVH) TROUBLESHOOTING ........................... 177
NVH Troubleshooting Chart .................................. 177
P1809 4WD CONTROL UNIT .......................... 157
DTC Description ....................................................157 PERIODIC MAINTENANCE ...................... 178
Diagnosis Procedure .............................................157
TRANSFER OIL ................................................ 178
P1811 BATTERY VOLTAGE ........................... 158 Inspection .............................................................. 178
DTC Description ....................................................158 Draining ................................................................. 178
DLN-4
Refilling ................................................................. 178 STRUCTURE AND OPERATION ................... 211
Sectional View ....................................................... 211 A
REMOVAL AND INSTALLATION ............. 179
SYMPTOM DIAGNOSIS ............................ 212
4WD CONTROL UNIT ...................................... 179
Exploded View ...................................................... 179 NOISE, VIBRATION AND HARSHNESS B
Removal and Installation ....................................... 179 (NVH) TROUBLESHOOTING ......................... 212
Adjustment ............................................................ 179 NVH Troubleshooting Chart .................................. 212
C
4WD MODE SWITCH ....................................... 180 PERIODIC MAINTENANCE ...................... 213
Exploded View ...................................................... 180
Removal and Installation ....................................... 180 REAR PROPELLER SHAFT ........................... 213
Inspection .............................................................. 213 DLN
UNIT REMOVAL AND INSTALLATION .... 181
REMOVAL AND INSTALLATION ............. 214
TRANSFER ASSEMBLY ................................. 181 E
Exploded View ...................................................... 181 REAR PROPELLER SHAFT ........................... 214
Removal and Installation ....................................... 181 Exploded View ....................................................... 214
Inspection .............................................................. 183 Removal and Installation ....................................... 214
Inspection .............................................................. 217 F
UNIT DISASSEMBLY AND ASSEMBLY . 184
SERVICE DATA AND SPECIFICATIONS
ADAPTER CASE .............................................. 184 (SDS) .......................................................... 219 G
Exploded View ...................................................... 184
Disassembly and Assembly .................................. 185 SERVICE DATA AND SPECIFICATIONS
Inspection .............................................................. 186 (SDS) ............................................................... 219
H
General Specifications ........................................... 219
RING GEAR SHAFT ......................................... 187
Propeller Shaft Runout .......................................... 219
Exploded View ...................................................... 187
Journal Axial Play .................................................. 219
Disassembly and Assembly .................................. 188 I
Inspection .............................................................. 190 REAR FINAL DRIVE: R145
DRIVE PINION .................................................. 192 PRECAUTION ............................................ 220

Exploded View ...................................................... 192 J
PRECAUTIONS ............................................... 220
Disassembly and Assembly .................................. 193
Precautions for Removing Battery Terminal .......... 220
Adjustment ............................................................ 195
Service Notice or Precautions for Rear Final Drive.. 221
Inspection .............................................................. 204 K
TRANSFER CASE ........................................... 205 PREPARATION ......................................... 222
Exploded View ...................................................... 205 PREPARATION ............................................... 222
Disassembly and Assembly .................................. 206 L
Special Service Tools ............................................ 222
Inspection .............................................................. 207 Commercial Service Tools ..................................... 224
Lubricant or/and Sealant ....................................... 224
SERVICE DATA AND SPECIFICATIONS M
(SDS) .......................................................... 208 SYSTEM DESCRIPTION ........................... 225
SERVICE DATA AND SPECIFICATIONS STRUCTURE AND OPERATION ................... 225 N
(SDS) ................................................................ 208 Sectional View ....................................................... 225
General Specifications .......................................... 208 Electric Controlled Coupling .................................. 225
Preload Torque ..................................................... 208
Backlash ................................................................ 208 SYMPTOM DIAGNOSIS ............................ 226 O
Companion Flange Runout ................................... 208
NOISE, VIBRATION AND HARSHNESS
REAR PROPELLER SHAFT: C-CVJ-C
(NVH) TROUBLESHOOTING ......................... 226 P
PRECAUTION ............................................ 209 NVH Troubleshooting Chart .................................. 226
PRECAUTIONS ................................................ 209 PERIODIC MAINTENANCE ...................... 227

Precautions for Removing Battery Terminal ......... 209
Service Notice or Precautions for Propeller Shaft.. 210
REAR DIFFERENTIAL GEAR OIL ................. 227
Inspection .............................................................. 227
SYSTEM DESCRIPTION ........................... 211 Draining ................................................................. 227
Refilling .................................................................. 227
DLN-5
REMOVAL AND INSTALLATION .............. 228 UNIT DISASSEMBLY AND ASSEMBLY .. 242
DRIVE PINION OIL SEAL ............................... 228 ELECTRIC CONTROLLED COUPLING .......... 242
Exploded View .......................................................228 Exploded View ...................................................... 242
Removal and Installation .......................................228 Disassembly and Assembly .................................. 243
Inspection ..............................................................228
DIFFERENTIAL ASSEMBLY ........................... 246
SIDE OIL SEAL ............................................... 229 Exploded View ...................................................... 246
Exploded View .......................................................229 Disassembly and Assembly .................................. 247
Removal and Installation .......................................229 Adjustment ............................................................ 252
Inspection ..............................................................230 Inspection .............................................................. 255
ELECTRIC CONTROLLED COUPLING ......... 231 DRIVE PINION .................................................. 257

Exploded View .......................................................231 Exploded View ...................................................... 257
Removal and Installation .......................................231 Disassembly and Assembly .................................. 258
Inspection and Adjustment ....................................235 Inspection .............................................................. 262
AIR BREATHER .............................................. 236 SERVICE DATA AND SPECIFICATIONS

Exploded View .......................................................236 (SDS) ......................................................... 263
Removal and Installation .......................................236
SERVICE DATA AND SPECIFICATIONS
UNIT REMOVAL AND INSTALLATION .... 239 (SDS) ................................................................ 263
General Specifications .......................................... 263
REAR FINAL DRIVE ASSEMBLY ................... 239
Preload Torque ..................................................... 263
Exploded View .......................................................239
Drive Gear Runout ................................................ 263
Removal and Installation .......................................239
Backlash ............................................................... 263
Inspection and Adjustment ....................................241
Differential Side Gear Clearance .......................... 263
DLN-6
HOW TO USE THIS SECTION
< HOW TO USE THIS MANUAL > [TRANSFER: TY21C]
HOW TO USE THIS MANUAL A

Information INFOID:0000000011058854
B
Both “VDC” and “ESP” are used in this manual. These indicate the same system.
C
DLN
DLN-7
PRECAUTIONS
< PRECAUTION > [TRANSFER: TY21C]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000010992652
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING:
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precautions for Removing Battery Terminal INFOID:0000000010992653
• With the adoption of Auto ACC function, ACC power is automatically supplied by operating the intelligent key
or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.
• When disconnecting the 12V battery terminal, turn off the ACC
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below.
NOTE:
Some ECUs operate for a certain fixed time even after ignition
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC
detection or ECU data damage may occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE:
SEF289H
If the ignition switch is turned ON with any one of the terminals of
main battery and sub battery disconnected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
HOW TO DISCONNECT 12V BATTERY TERMINAL
Disconnect 12V battery terminal according to Instruction 1 or Instruction 2 described below.
For vehicles parked by ignition switch OFF, refer to Instruction 2.
INSTRUCTION 1
1. Open the hood.
DLN-8
PRECAUTIONS
2. Turn key switch to the OFF position with the driver side door opened.
3. Get out of the vehicle and close the driver side door. A
4. Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.
B
D4D engine : 20 minutes
HRA2DDT : 12 minutes
K9K engine : 4 minutes C
M9R engine : 4 minutes
R9M engine : 4 minutes
V9X engine : 4 minutes DLN
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of
this caution results in the activation of ACC power supply according to the Auto ACC function. E
5. Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC. F
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
1. Unlock the door with intelligent key or remote keyless entry.
NOTE: G
At this moment, ACC power is supplied.
2. Open the driver side door.
3. Open the hood. H
4. Close the driver side door.
5. Wait at least 3 minutes.
CAUTION: I
this caution results in the activation of ACC power supply according to the Auto ACC function.
6. Remove 12V battery terminal. J
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
Service Notice or Precautions for Transfer INFOID:0000000010991949
K
• Use recommended transfer oil only, refer to MA-23, "Fluids and Lubricants".
• Never reuse transfer oil, once it has been drained. L
• Check the oil level or replace the oil only with the vehicle parked on level ground.
• During removal or installation, keep inside of transfer clear of dust or dirt.
• Replace all tires at the same time. Always use tires of the proper size and the same brand and pattern. Fit-
ting improper size and unusually worn tires applies excessive force to vehicle mechanism and can cause M
longitudinal vibration.
• Disassembly should be done in a clean work area, it is preferable to work in dustproof area.
• Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal N
parts from becoming contaminated by dirt or other foreign matter.
• All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
O
• Check for the correct installation status prior to removal or disassembly. If matching marks are required, be
certain they do not interfere with the function of the parts when applied.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary. P
• Gaskets, seals and O-rings should be replaced any time the transfer is disassembled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tight-
ening sequence is specified, use it.
• Observe the specified torque when assembling.
• Clean and flush the parts sufficiently and blow-dry them.
• Be careful not to damage sliding surfaces and mating surfaces.
DLN-9
PRECAUTIONS
• Clean inner parts with lint-free cloth or towels. Do not use cotton work gloves and rags to prevent adhering
fibers.
DLN-10
PREPARATION
< PREPARATION > [TRANSFER: TY21C]
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000010991950
B
Tool number
Description C
Tool name
ST33061000 Removing gear ring bearing inner race (trans-
Drift fer case side)
a: 38 mm (1.50 in) dia. DLN
b: 28.5 mm (1.122 in) dia.
E
ZZA0810D
KV381054S0 Removing ring gear shaft oil seal

Puller F
ZZA0601D
H
ST3127S000 Measuring preload torque
Preload gauge
J
ZZA0503D
Commercial Service Tool INFOID:0000000010991951

K
Tool name Description

Oil seal remover Removing transfer cover oil seal (outer/inner)
L
JSDIA4998ZZ
N
Drift Removing ring gear bearing inner race (trans-
a: 52 mm (2.05 in) dia. fer cover side)
b: 44 mm (1.73 in) dia. O
P
ZZA1002D
DLN-11
PREPARATION
Drift Installing side oil seal (installing transfer case
a: 56.5 mm (2.224 in) dia. oil seal)
b: 48 mm (1.89 in) dia.
NT115
Drift Installing ring gear shaft oil seal

a: 44 mm (1.73 in) dia.
b: 33 mm (1.3 in) dia.
NT115
Puller Removing ring gear bearing (left) inner race

(transfer case side)
NT077
Drift Installing oil seal (installing pinion bearing

a: 70 mm (2.76 in) dia. seal)
b: 60 mm (2.36 in) dia.
NT115
Drift Installing side oil seal [installing transfer cover

a: 78 mm (3.07 in) dia. oil seal (outer inner)]
b: 68 mm (2.68 in) dia.
NT115
Replacer • Removing drive pinion

• Removing ring gear bearing (left) inner race
(transfer cover side)
ZZA0700D
Drift Installing ring gear bearing (left) inner race

a: 58 mm (2.28 in) dia. (transfer case side)
b: 55 mm (2.17 in) dia.
NT115
DLN-12
PREPARATION
A
Drift Installing ring gear bearing (right) inner race
a: 62 mm (2.44 in) dia. (transfer cover side)
b: 58 mm (2.28 in) dia.
B
C
NT115
Drift Installing ring gear bearing (left) outer race

a: 73.5 mm (2.894 in) dia. (transfer case side)
DLN
SCIA5338E
Drift Installing ring gear bearing (right) outer race F

a: 87 mm (3.43 in) dia. (transfer cover side)
SCIA5338E
H
Drift Installing and removing drive pinion
a: 20 mm (0.79 in) dia.
J
SCIA5338E
Drift Installing companion flange

a: 40 mm (1.57 in) dia. K
b: 25 mm (0.98 in) dia.
NT115
M
Lubricant or/and Sealant INFOID:0000000010991952
Item Use N
Red lead or equivalent Checking tooth contact
DLN-13
COMPONENT PARTS
< SYSTEM DESCRIPTION > [TRANSFER: TY21C]
SYSTEM DESCRIPTION
COMPONENT PARTS
Component Parts Location INFOID:0000000010991953
JSDIA6380ZZ
Console switch panel Rear wheel house outer panel in lug- Rear final drive
gage room of left side
No. Component Function

Mainly transmits the following signals to 4WD control unit via CAN communication.
• Accelerator pedal position signal
• Engine speed signal
ECM
• Engine status signal
For detailed installation location, refer to EC-28, "ENGINE CONTROL SYSTEM : Com-
ponent Parts Location" (MR20DD), EC-440, "Component Parts Location" (QR25DE).
• Input shaft revolutional signal
TCM • CVT ratio signal
For detailed installation location, refer to TM-235, "CVT CONTROL SYSTEM : Com-
ponent Parts Location".
Steering angle sensor • Steering angle sensor signal
For detailed installation location, refer to BRC-14, "Component Parts Location".
DLN-14
COMPONENT PARTS
A
• Parking brake switch signal
Mainly receives the following signals from 4WD control unit via CAN communication.
• 4WD warning lamp signal B
Combination meter
• 4WD mode indicator lamp signal
• Torque distribution indicator signal
For detailed installation location, refer to MWI-7, "METER SYSTEM : Component Parts
Location". C
• Each wheel speed signal
ABS actuator and electric unit (con- • Decel G sensor signal DLN
trol unit) • Side G sensor signal
• Yaw rate sensor signal
E
4WD mode switch Refer to DLN-16, "4WD Mode Switch".
4WD control unit
Refer to DLN-15, "4WD Control Unit".
• 4WD actuator relay
F
Electric controlled coupling Refer to DLN-15, "Electric Controlled Coupling".
4WD solenoid Refer to DLN-15, "4WD Solenoid".

G
4WD Control Unit INFOID:0000000010991954
• Controls driving force distribution by signals from each sensor from

H
front wheel driving mode (100:0) to 4-wheel driving mode (50:50).
• Fail-safe mode is available if malfunction is detected in 4WD sys-
tem. For fail-safe, refer to DLN-21, "4WD SYSTEM : Fail-Safe".
I
JSDIA6388ZZ
K
4WD ACTUATOR RELAY
4WD actuator relay is integrated with 4WD control unit, and supplies 4WD solenoid with voltage.
L
Electric Controlled Coupling INFOID:0000000010991955
Electric controlled coupling is integrated with rear final drive and transmits driving force to rear final drive. For
operation, refer to DLN-17, "Operation Description". M
4WD Solenoid INFOID:0000000010991956
• 4WD solenoid is integrated with electric controlled coupling. N

• Controls electric controlled coupling by command current from 4WD control unit.
DLN-15
COMPONENT PARTS
4WD Mode Switch INFOID:0000000010991957
4WD mode is selectable among 2WD mode, AUTO mode, and

LOCK mode by operating the 4WD mode switch while the engine is
running.
JSDIA6389ZZ
DLN-16
STRUCTURE AND OPERATION
A
Sectional View INFOID:0000000010991958
DLN
L
JSDIA3966ZZ
Transfer cover Transfer case Ring gear bearing (transfer case M

side)
Ring gear shaft Pinion bearing Drive pinion
Companion flange Ring gear Ring gear bearing (transfer cover N
side)
Operation Description INFOID:0000000010991959
O
POWER TRANSFER DIAGRAM
DLN-17
JSDIA0961ZZ
Engine Transaxle Transfer

Propeller shaft Electric controlled coupling Rear final drive
ELECTRIC CONTROLLED COUPLING

1. The 4WD control unit supplies command current to electric con-
trolled coupling (4WD solenoid).
2. The control clutch is engaged by electromagnet and torque is
detected in control clutch.
3. The cam operates in response to control clutch torque and
applies pressure to main clutch.
4. The main clutch transmits torque to front wheels according to
pressing power.
JSDIA0972GB
• Transmission torque to the rear wheels is determined accord-

ing to command current.
SDIA1844E
DLN-18
SYSTEM
SYSTEM
A
4WD SYSTEM
4WD SYSTEM : System Description INFOID:0000000010991960
B
• Pressing force of multiple disc clutch is controlled by electric control. Driving torque distribution of front and
rear wheels changes automatically between approximately 100 : 0 (2WD) and 50 : 50 (4WD) to have an opti-
mized torque distribution adapted to road condition change. C
• Driving mode is selectable among 2WD mode, AUTO mode, and LOCK mode by operating the 4WD mode
switch.
• In accordance with fail-safe function, when system is malfunctioning, 4WD control stops, and the system
becomes 2WD or slight 4WD (rear-wheels still have some driving torque). Refer to DLN-21, "4WD SYSTEM DLN
: Fail-Safe".
• When a high load status continues for electric controlled coupling, 4WD control temporarily becomes front
wheel drive, according to protection function. Refer to DLN-22, "4WD SYSTEM : Protection Function". E
SYSTEM DIAGRAM
JSDIA6026GB N
Signal with Communication Line
Major signal transmission between each unit via CAN communication lines are shown in the following table.
O
Component parts Signal item
• Parking brake switch signal P
Combination meter
• 4WD warning lamp signal
Steering angle sensor
• Steering angle sensor signal
DLN-19
SYSTEM
ABS actuator and electric unit (control unit) • Decel G sensor signal
• Side G sensor signal
ECM
TCM • Input shaft revolutional signal
• CVT ratio signal
4WD SYSTEM : Control in Each Mode INFOID:0000000010991961
2WD MODE
• Vehicle is in front-wheel drive.
CAUTION:
If front wheels are slipping in 2WD mode, never switch to AUTO or LOCK. This can cause difficulties
for the system.
NOTE:
The 4WD control unit may distribute the minimum necessary driving torque to rear wheels even when the
2WD mode is selected, depending on the driving condition. (However AUTO or LOCK indicator lamp does not
illuminate.)
AUTO MODE
• Electronic control allows optimal distribution of torque to front/rear wheels to match road conditions.
mized torque distribution adapted to road condition change.
• Sensor inputs determine the vehicle's turning condition, and tight cornering/braking are controlled by distrib-
uting optimum torque to rear wheels.
Vehicle Starts Control
• At the start, torque distribution for front and rear wheels is fixed by electric control and stable start is
achieved.
• Makes possible stable driving, with no wheel spin, on snowy roads or other slippery surfaces.
Normal Control
• On roads which do not require 4WD, it contributes to improved fuel economy by driving in conditions close to
front-wheel drive and it results in better fuel efficiency.
• When spin occurs on front wheel, distribute optimum torque to rear wheel and keep stable driving.
• The vehicle cornering status is judged according to information from each sensor, and the optimum torque is
distributed to rear wheels for preventing tight cornering/braking symptom.
LOCK MODE
• Front/rear wheel torque distribution is fixed, ensuring stable driving when climbing slopes.
• In LOCK mode, the pressing force to the multiple disc clutches is maximized by the electronic control and
the driving torque distribution of front and rear wheels is fixed to obtain the 4WD status of approximately 50 :
50.
NOTE:
Only torque distribution may be switched to the control same as the one in AUTO mode, depending on the
driving condition.
• LOCK mode will change to AUTO mode automatically, when the vehicle has been driven at a high speed.
Then LOCK mode control is canceled and the LOCK indicator lamp turns off.
• When vehicle speed exceeds the specified speed, the mode cannot be switched from AUTO mode to LOCK
mode.
• LOCK mode will change to AUTO mode automatically, when the ignition switch is turned OFF in LOCK
mode.
NOTE:
DLN-20
SYSTEM
If there is a significant difference in pressure or wear between tires, full vehicle performance is not available.
Tire conditions are detected, and LOCK mode may be prohibited, or else speeds at which LOCK mode is A
enabled may be restricted.
4WD SYSTEM : Circuit Diagram INFOID:0000000010991962
B
DLN
JSDIA6384GB
N
4WD SYSTEM : Fail-Safe INFOID:0000000010991963
If any malfunction occurs in 4WD electrical system, and control unit detects the malfunction, 4WD warning on
O
information display (combination meter) is displayed to indicate system malfunction. And then 4WD control
unit controls becomes the fail-safe mode depending on DTC.
DLN-21
SYSTEM
DTC Vehicle condition

•C1201
•C1204
•C1209
4WD control changes to front-wheel drive immediately, then 4WD control stops, and the vehicle
•P1804
becomes front-wheel drive.
•P1809
•P1811
•P181F
•C1203
•C1210
•P1808 4WD control changes to front-wheel drive gradually (rear-wheels still have some driving torque),
•P181D then 4WD control stops, and the vehicle becomes front-wheel drive.
•U1000
•U1010
•P181B No impact to vehicle behavior.
4WD SYSTEM : Protection Function INFOID:0000000010991964
4WD system activates its protection function (shuts down 4WD system temporarily) if 4WD system detects
high load continuously or the front wheel tire size differs from the rear tire size. (4WD system is automatically
restored if 4WD system no longer detects any overload or the tire size difference is eliminated.)
4WD warning (on infor- Contents of protection

DTC Error area and root cause
mation display) function
Refer to DLN-22, "IN- Rear final drive assembly in protection mode. It is not malfunction.
—
FORMATION DISPLAY (Internal temperature rise of electronic controlled coupling) Shuts down 4WD sys-
(COMBINATION tem temporarily
— METER) : 4WD Warn- Malfunction in each tire or different tire diameter (Front wheel drive)
ing".
NOTE:
• If the 4WD warning displays during driving but remains not displayed after the engine is restarted, the sys-
tem is normal. If it again displays after driving for some time, vehicle must be inspected.
• When there is a difference of revolution speed between the front and rear wheel the shift occasionally
changes to direct 4-wheel driving conditions automatically. This is not a malfunction.
INFORMATION DISPLAY (COMBINATION METER)
INFORMATION DISPLAY (COMBINATION METER) : 4WD Warning INFOID:0000000010991965
DESIGN/PURPOSE
4WD warning is displayed when the 4WD system has a malfunction. 4WD warning indicates that the vehicle is
in fail-safe mode or protection function mode.
Symbol Message Condition

4WD Error
4WD system malfunction.
See Owner’s Manual
Protection function is activated due to heavy load to
4WD High Temp. electric controlled coupling. (4WD system is not
Stop vehicle malfunctioning and 4WD system changes to front
wheel drive.)
Tire Size Incorrect

Large difference in diameter of front/rear tires.
JPNIA1896ZZ
SYNCHRONIZATION WITH MASTER WARNING LAMP

Applicable
For master warning lamp, refer to MWI-47, "WARNING LAMPS/INDICATOR LAMPS : Master Warning Lamp".
DLN-22
SYSTEM
SYSTEM DIAGRAM
A
DLN
E
JSDIA6028GB
SIGNAL PATH
F
• The 4WD control unit judges and decides a mode from among normal mode, fail-safe mode, and protection
function mode, according to signals received from each switch, sensor, and control unit.
• The 4WD control unit transmits 4WD warning signal to the combination meter via CAN communication when
judging fail-safe mode or protection function mode. G
• The combination meter displays 4WD warning on the information display when receiving 4WD warning sig-
nal transmitted from the 4WD control unit.
WARNING CONDITION H
4WD warning is displayed when the 4WD system goes into fail-safe mode or protection function mode.
WARNING CANCEL CONDITION
I
When any of the conditions listed below is satisfied:
• Ignition switch is in a position other than ON.
• 4WD warning becomes invisible when the 4WD system returns to normal.
J
INFORMATION DISPLAY (COMBINATION METER) : 4WD Torque Distribution Indica-
tor INFOID:0000000010991966
K
DESIGN/PURPOSE
Design Purpose L
Displays the drive torque distribution to the front and rear wheels while driving and informs M
the driver of this.
NOTE:
The driving force distribution may not match actual one. This is not a system malfunction.
N
JSNIA6722ZZ
WARNING/INDICATOR/CHIME LIST
O
WARNING/INDICATOR/CHIME LIST : Warning Lamp/Indicator Lamp INFOID:0000000010991967
P
Name Design Layout/Function
For layout: Refer to MWI-10, "METER SYSTEM : Design".
4WD indicator lamp For function: Refer to MWI-23, "WARNING LAMPS/INDICATOR LAMPS : 4WD Indica-
tor Lamp and LOCK Indicator Lamp".
DLN-23
SYSTEM
LOCK indicator lamp For function: Refer to MWI-23, "WARNING LAMPS/INDICATOR LAMPS : 4WD Indica-
WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display)

INFOID:0000000010991968
Name Function
Refer to DLN-22, "INFORMATION DISPLAY (COMBINATION METER) : 4WD Warn-
4WD warning
ing".
Refer to DLN-23, "INFORMATION DISPLAY (COMBINATION METER) : 4WD Torque
4WD torque distribution indicator
Distribution Indicator".
DLN-24
DIAGNOSIS SYSTEM (4WD CONTROL UNIT)
A
CONSULT Function INFOID:0000000010991969
APPLICATION ITEMS B
CONSULT can display each diagnostic item using the diagnostic test modes as follows.
Diagnostic test mode Function C

ECU Identification 4WD control unit part number can be read.
Self Diagnostic Result Self-diagnostic results and freeze frame data can be read and erased quickly.*
Data Monitor Input/Output data in the 4WD control unit can be read. DLN
Diagnostic Test Mode in which CONSULT drives some actuators apart from the 4WD control unit
Active Test
and also shifts some parameters in a specified range.
E
This mode enable a technician to adjust some devices faster and more accurately by following the
Work support
indication on the CONSULT.
*: The following diagnosis information is erased by erasing.
• DTC F
• Freeze frame data (FFD)
ECU IDENTIFICATION G
4WD control unit part number can be read.
SELF DIAGNOSTIC RESULT
Refer to DLN-30, "DTC Index". H
When “PRSNT” is displayed on self-diagnosis result.
• The system is presently malfunctioning.
I
When “PAST” is displayed on self-diagnosis result.
• System malfunction in the past is detected, but the system is presently normal.
FREEZE FRAME DATA (FFD) J
The following vehicle status is recorded when DTC is detected and is displayed.
Monitor item (Unit) Remarks

K
ODO/TRIP METER (km/h or mph) Odometer value via CAN communication line is displayed.
ABS OPERATION SIG (On/Off) ABS operation status via CAN communication line is displayed.
VDC OPERATION SIG (On/Off) VDC operation status via CAN communication line is displayed. L
TCS OPERATION SIG (On/Off) TCS operation status via CAN communication line is displayed.
HI COEF FRIC FLG 1 (LOW/HIGH) Measured friction of load is displayed when vehicle starts.
M
HI COEF FRIC FLG 2 (LOW/HIGH) Measured friction of load is displayed when vehicle during deceleration.
IGN VOLT (V) Ignition voltage supplied to 4WD control unit is displayed.
TARGET SOL CRNT (A) 4WD solenoid target current is displayed. N
SOLENOID CRNT (A) 4WD solenoid control current is displayed.
QUASI VEHICLE SPEED (km/h or mph) Vehicle speed calculated by 4WD control unit is displayed.
O
FRONT WHEEL SPEED (km/h or mph) Front wheel speed average calculated by 4WD control unit is displayed.
REAR WHEEL SPEED (km/h or mph) Rear wheel speed average calculated by 4WD control unit is displayed.
SLCT LVR POSI Current transmission gear via CAN communication line is displayed. P
OPERATION MODE Control status of 4WD mode is displayed.
FRONT RH WHEEL SPEED (km/h or mph) Wheel speed calculated by front RH wheel sensor signal is displayed.
FRONT LH WHEEL SPEED (km/h or mph) Wheel speed calculated by front LH wheel sensor signal is displayed.
REAR RH WHEEL SPEED (km/h or mph) Wheel speed calculated by rear RH wheel sensor signal is displayed.
REAR LH WHEEL SPEED (km/h or mph) Wheel speed calculated by rear LH wheel sensor signal is displayed.
DLN-25
DATA MONITOR
NOTE:
The following table includes information (items) inapplicable to this vehicle. For information (items) applicable
to this vehicle, refer to CONSULT display items.

STOP LAMP SW (On/Off) Stop lamp switch signal status via CAN communication line is displayed.
ENG SPEED SIG (Run/Stop) Engine status is displayed.
ETS ACTUATOR (On/Off) Operating condition of 4WD actuator relay (integrated in 4WD control unit) is displayed.
4WD WARN LAMP (On/Off) Control status of 4WD warning (on information display) is displayed.
4WD MODE SW (AUTO/LOCK/2WD) 4WD mode switch status is displayed.
4WD MODE MON (AUTO/LOCK/2WD) Control status of 4WD is displayed.
DIS-TIRE MONI (mm) Improper size tire installed condition is displayed.
PARKING BRAKE SW SIG (On/Off) Parking switch signal status via CAN communication line is displayed.
4WD MODE SW (2WD) (On/Off) 4WD mode switch (2WD position) signal is displayed.
4WD MODE SW (AUTO) (On/Off) 4WD mode switch (AUTO position) signal is displayed.
4WD MODE SW (LOCK) (On/Off) 4WD mode switch (LOCK position) signal is displayed.
READY (Off/Running) This item is not equipped, but displayed.
BATTERY VOLT (V) Power supply voltage value of 4WD control unit is displayed.
THRTL POS SEN (%) Throttle opening status is displayed.
ETS SOLENOID (A) Monitored value of current at 4WD solenoid is displayed.
FR RH SENSOR (km/h or mph) Wheel speed calculated by front RH wheel sensor signal is displayed.
FR LH SENSOR (km/h or mph) Wheel speed calculated by front LH wheel sensor signal is displayed.
RR RH SENSOR (km/h or mph) Wheel speed calculated by rear RH wheel sensor signal is displayed.
RR LH SENSOR (km/h or mph) Wheel speed calculated by rear LH wheel sensor signal is displayed.
ACTIVE TEST
Use this mode to determine and identify the details of a malfunction based on self-diagnostic results or data
monitor. 4WD control unit gives drive signal to actuator with receiving command from CONSULT to check
operation of actuator.
Test item Condition Description

Change command current value to 4WD solenoid, and then change driving
mode. (Monitor value is normal if it is within approx. ±10% of command value.)
• Vehicle stopped
SOLENOID • Qu: Increase current value in increments of 0.2 A
• Engine running
(Detects 4WD solenoid) • Qd: Decrease current value in increments of 0.2 A
• No DTC detected
• UP: Increase current value in increments of 0.02 A
• DOWN: Decrease current value in increments of 0.02 A
CAUTION:
Never energize continuously for a long time.
WORK SUPPORT
Item Usage
UNIT CHARACTERISTICS DATA Display the unit characteristics of electric controlled coupling written to 4WD control unit.
UNIT CHARACTERISTICS WRITE Writes the unit characteristics of electric controlled coupling to 4WD control unit.
DLN-26
4WD CONTROL UNIT
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY21C]
ECU DIAGNOSIS INFORMATION A

4WD CONTROL UNIT
Reference Value INFOID:0000000010991970
B
VALUES ON THE DIAGNOSIS TOOL

NOTE: C
Monitor item Condition Value/Status DLN

Brake pedal: Depressed On
STOP LAMP SW
Brake pedal: Released Off
E
Engine stopped
Stop
(Engine speed: Less than 400 rpm)
ENG SPEED SIG
Engine running F
Run
(Engine speed: 400 rpm or more)
Engine stopped (Ignition switch: ON) Off
ETS ACTUATOR
Engine running On G
4WD warning (on information display): Displayed On
4WD WARN LAMP
4WD warning (on information display): Not displayed Off
H
4WD mode switch: 2WD 2WD
4WD mode switch: AUTO AUTO
4WD MODE SW
4WD mode switch: LOCK I
LOCK
(State of hold of LOCK position)
4WD mode switch: AUTO AUTO J
4WD mode switch: AUTO ⇒ LOCK Vehicle speed below 10 km/h (6 mph) AUTO ⇒ LOCK
4WD MODE MON
(When switching to LOCK mode) Vehicle speed above 10 km/h (6 mph) AUTO
4WD mode switch: LOCK ⇒ AUTO
K
Vehicle speed below 10 km/h (6 mph) LOCK ⇒ AUTO
(When switching to AUTO mode)
Vehicle running with normal size tire installed 0 – 4 mm
DIS-TIRE MONI
L
Vehicle running with improper size tire installed (Front/rear tire size differ-
4 – 8 mm, 8 – mm
ence, wear condition)
PARKING BRAKE SW Parking brake operated On

M
SIG Parking brake not operated Off
4WD mode switch: 2WD On
4WD MODE SW (2WD)
4WD mode switch: Except 2WD Off N
4WD mode switch: AUTO On
4WD MODE SW (AUTO)
4WD mode switch: Except AUTO Off
O
4WD mode switch: LOCK
On
4WD MODE SW (LOCK) (State of hold of LOCK position)
4WD mode switch: Except LOCK Off
P
READY Always Off
BATTERY VOLT Always Battery voltage
When depressing accelerator pedal
THRTL POS SEN 0 – 100%
(Value rises gradually in response to throttle position.)
DLN-27
4WD CONTROL UNIT
Monitor item Condition Value/Status
2WD mode Approx. 0.000 A
Engine running
AUTO mode Approx. 0.000 A
• At idle speed
LOCK mode Approx. 0.000 A
ETS SOLENOID
Engine running
AUTO mode Approx. 0.000 – 2.490 A*
• 3,000 rpm or more constant
Vehicle stopped 0.00 km/h (0.00 mph)
FR RH SENSOR Vehicle running Nearly matches the speed

CAUTION: meter display (±10% or
Check air pressure of tire under standard condition. less)
FR LH SENSOR Vehicle running Nearly matches the speed

RR RH SENSOR Vehicle running Nearly matches the speed

RR LH SENSOR Vehicle running

Nearly matches the speed
CAUTION:
meter display (±10%)
Check air pressure of tire under standard condition.
*: The values are changed by throttle opening and engine speed.
TERMINAL LAYOUT
JSDIA0057ZZ
PHYSICAL VALUES
Terminal No.
Description
(Wire color)
Condition Value (Approx.)
Input/
+ - Signal name
Output
2WD mode 0V
Engine speed: At idle AUTO mode 0V
1 4WD solenoid power LOCK mode 0V

Ground Output
(SB) supply 2WD mode 0V
Engine speed: 3,000
AUTO mode 2.5 V*
rpm or more constant
LOCK mode 8V
2 Engine speed: At idle 0V

Ground 4WD solenoid ground Input
(Y) Engine speed: 3,000 rpm or more constant 0V
DLN-28
4WD CONTROL UNIT
Terminal No.
Description
(Wire color) A
Input/
+ - Signal name
Output
4WD mode switch: 2WD Battery voltage B
5 4WD mode switch (AU- 4WD mode switch: AUTO 0V
Ground Input Ignition switch: ON
(V) TO)
0V C
7 Ignition switch: ON Battery voltage

Ground Ignition switch Input
(LA/R) Ignition switch: OFF 0V
DLN
8 Input/
— CAN-H — —
(L) Output
9 Power supply (4WD so- E
Ground Input Always Battery voltage
(LA/G) lenoid)
10
Ground Ground — Always 0V
(B)
F
11
(B)
4WD mode switch: 2WD 0V
G
12 4WD mode switch 4WD mode switch: AUTO Battery voltage
(GR) (2WD)
Battery voltage
(State of hold of LOCK position) H
4WD mode switch: 2WD Battery voltage
(Y) (LOCK) I
0V
15 Power supply (4WD
Ground Input Always Battery voltage J
(LA/L) control unit)
16 Input/
— CAN-L — —
(P) Output
*: The values are changed by depressed accelerator pedal opening and engine speed. K
CAUTION:
When using circuit tester to measure voltage for inspection, be sure not to extend forcibly any con-
nector terminals. L
Fail-Safe INFOID:0000000010991971
If any malfunction occurs in 4WD electrical system, and control unit detects the malfunction, 4WD warning on M
N
•C1201
•C1204
•C1209
O
•P1804
•P1809
•P1811 P
•P181F
DLN-29
4WD CONTROL UNIT
•C1203
•C1210
•U1000
•U1010
Protection Function INFOID:0000000010991972

—
ing".
NOTE:
DTC Inspection Priority Chart INFOID:0000000010991973
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
Priority Detected items (DTC)

1 • C1201 CONTROLLER FAILURE
• U1000 CAN COMM CIRCUIT
2
• U1010 CONTROL UNIT (CAN)
• C1203 ABS SYSTEM
• C1210 ENGINE SIGNAL 1
3
• P1808 VHCL SPEED SEN-ABS
• P181D ENGINE SYSTEM
4 • P1809 CONTROL UNIT
• C1204 4WD SOLENOID
5
• P1811 BATTERY VOLTAGE
6 • C1209 MODE SW
• P181B INCOMP SELFSHUT
8
• P181F INCOMP CALIBRATION
DTC Index INFOID:0000000010991974
DTC Display Item Reference

C1201 CONTROLLER FAILURE DLN-42, "DTC Description"
C1203 ABS SYSTEM DLN-43, "DTC Description"
C1204 4WD SOLENOID DLN-44, "DTC Description"
DLN-30
4WD CONTROL UNIT
A
C1209 MODE SW DLN-47, "DTC Description"
C1210 ENGINE SIGNAL 1 DLN-50, "DTC Description"
P1804 CONTROL UNIT DLN-51, "DTC Description" B
P1808 VHCL SPEED SEN-ABS DLN-52, "DTC Description"
P1809 CONTROL UNIT DLN-53, "DTC Description"
P1811 BATTERY VOLTAGE DLN-54, "DTC Description" C
P181B INCOMP SELF SHUT DLN-57, "DTC Description"
P181D ENGINE SYSTEM DLN-60, "DTC Description"
DLN
P181F INCOMP CALIBRATION DLN-61, "DTC Description"
U1000 CAN COMM CIRCUIT DLN-62, "DTC Description"
U1010 CONTROL UNIT (CAN) DLN-63, "DTC Description" E
NOTE:
If some DTCs are displayed at the same time, refer to DLN-30, "DTC Inspection Priority Chart".
F
DLN-31
4WD SYSTEM
< WIRING DIAGRAM > [TRANSFER: TY21C]
WIRING DIAGRAM
4WD SYSTEM
Wiring Diagram INFOID:0000000010991975
JRDWC2858GB
DLN-32
4WD SYSTEM
DLN
JRDWC2859GB
DLN-33
4WD SYSTEM
JRDWC2860GB
DLN-34
4WD SYSTEM
DLN
JRDWC2861GB
DLN-35
4WD SYSTEM
JRDWC2862GB
DLN-36
DIAGNOSIS AND REPAIR WORK FLOW
< BASIC INSPECTION > [TRANSFER: TY21C]
BASIC INSPECTION A
Work Flow INFOID:0000000010991976
B
DETAILED FLOW
1.INTERVIEW FROM THE CUSTOMER C
Clarify customer complaints before inspection. First of all, perform an interview utilizing DLN-38, "Diagnostic
Work Sheet" and reproduce symptoms as well as fully understand it. Ask customer about his/her complaints
carefully. Check symptoms by driving vehicle with customer, if necessary. DLN
CAUTION:
Customers are not professional. Never guess easily like “maybe the customer means that...,” or
“maybe the customer mentions this symptom”. E
>> GO TO 2.
2.CHECK SYMPTOM F
Reproduce the symptom that is indicated by the customer, based on the information from the customer
obtained by interview. Also check that the symptom is not caused by protection function. Refer to DLN-30,
"Protection Function". G
CAUTION:
When the symptom is caused by normal operation, fully inspect each portion and obtain the under-
standing of customer that the symptom is not caused by a malfunction. H
>> GO TO 3.
3.PERFORM SELF-DIAGNOSIS I
With CONSULT
Perform self-diagnosis for “ALL MODE AWD/4WD”. J
Is any DTC detected?
YES >> Record or print self-diagnosis results. GO TO 4.
NO >> GO TO 6. K
4.RECHECK SYMPTOM
With CONSULT
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”. L
2. Perform DTC confirmation procedures for the error detected system.
NOTE:
If some DTCs are detected at the same time, determine the order for performing the diagnosis based on DLN- M
30, "DTC Inspection Priority Chart".
YES >> GO TO 5. N
NO >> Check harness and connectors based on the information obtained by interview. Refer to GI-44,
"Intermittent Incident".
5.REPAIR OR REPLACE ERROR-DETECTED PARTS O
• Repair or replace error-detected parts.
• Reconnect part or connector after repairing or replacing.
• When DTC is detected, erase self-diagnostic results for “ALL MODE AWD/4WD”. P
>> GO TO 7.
6.IDENTIFY ERROR-DETECTED SYSTEM BY SYMPTOM DIAGNOSIS
Estimate error-detected system based on symptom diagnosis and perform inspection.
Can the error-detected system be identified?
DLN-37
YES >> GO TO 7.
7.FINAL CHECK
With CONSULT
1. Check the reference value for 4WD control unit.
2. Recheck the symptom and check that symptom is not reproduced on the same conditions.
Is the symptom reproduced?
YES >> GO TO 3.
NO >> INSPECTION END
Diagnostic Work Sheet INFOID:0000000010991977
Description
• In general, customers have their own criteria for a problem. Therefore, it is important to understand the
symptom and status well enough by asking the customer about his/her concerns carefully. To systemize all
the information for the diagnosis, prepare the interview sheet referring to the interview points.
• In some cases, multiple conditions that appear simultaneously may cause a DTC to be detected.
Interview sheet sample
Interview sheet
Registration Initial year
Customer number registration
MR/MS
name
Vehicle type VIN
Storage date Engine Mileage km (Mile)
Vehicle does not enter 4WD mode.
4WD warning (4WD Error) is displayed.
Heavy tight-corner braking symptom occurs
Symptom
Noise Vibration
Others
( )
First occurrence Recently Others ( )
Frequency of occurrence Always Under a certain conditions of Sometimes (time(s)/day)
Irrelevant
Climate con- Weather Fine Cloud Rain Snow Others ( )

ditions Temperature Hot Warm Cool Cold Temperature (Approx. °C)
Relative humidity High Moderate Low
Urban area Suburb area High way
Road conditions
Mounting road (uphill or down hill) Rough road
Irrelevant
When engine starts During idling
Operation conditions, etc.
During driving During acceleration At constant speed driving
During deceleration During cornering (right curve or left curve)
DLN-38
Interview sheet
A
MR/MS
name
Vehicle type VIN
B
Other conditions
C
Memo
DLN
DLN-39
ADDITIONAL SERVICE WHEN REPLACING 4WD CONTROL UNIT
Description INFOID:0000000010991978
When replacing 4WD control unit, unit characteristics writing is required.

Work Procedure INFOID:0000000010991979
1.PERFORM WRITING UNIT CHARACTERISTICS

Perform writing unit characteristics of electric controlled coupling.
>> Refer to DLN-41, "Work Procedure".
DLN-40
UNIT CHARACTERISTICS WRITING
A
When replacing 4WD control unit, rear final drive assembly and/or electric controlled coupling, unit character- B
istics of electric controlled coupling writing is required.
C
1.UNIT CHARACTERISTICS WRITING
With CONSULT
1. Confirm the unit characteristics of electric controlled coupling. DLN
NOTE:
Unit characteristics is 12-digit alphanumeric.
2. Turn the ignition switch OFF to ON. E
3. Select “UNIT CHARACTERISTICS WRITE” in “WORK SUP-
PORT” for “ALL MODE AWD/4WD”.
4. Input unit characteristics.
5. Select “Start”. F
6. Check that “UNIT CHARACTERISTICS WRITE COMPLETED”
is displayed.
JSDIA5446ZZ
G
>> WORK END
DLN-41
C1201 4WD CONTROL UNIT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21C]
DTC/CIRCUIT DIAGNOSIS
DTC Description INFOID:0000000010991982
DTC DETECTION LOGIC
CONSULT screen terms

DTC No. DTC detecting condition
(Trouble diagnosis content)
CONTROLLER FAILURE
C1201 Malfunction has occurred inside 4WD control unit.
(Control unit failure)
POSSIBLE CAUSE
Internal malfunction of 4WD control unit
FAIL-SAFE
4WD control changes to front-wheel drive immediately, then 4WD control stops, and the vehicle becomes
front-wheel drive.
DTC CONFIRMATION PROCEDURE
1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT
1. Turn the ignition switch OFF to ON.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “C1201” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-42, "Diagnosis Procedure".
NO-1 >> To check malfunction symptom before repair: Refer to GI-44, "Intermittent Incident".
NO-2 >> Confirmation after repair: INSPECTION END
Diagnosis Procedure INFOID:0000000010991983
1.PERFORM SELF-DIAGNOSIS
With CONSULT
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Turn the ignition switch OFF, and then wait 10 seconds or more.
YES >> Replace 4WD control unit. Refer to DLN-76, "Removal and Installation".
NO >> Check 4WD control unit pin terminals for damage or loose connection with harness connector. If
any items are damaged, repair or replace error-detected parts.
DLN-42
C1203 ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
A
DTC DETECTION LOGIC B

(Trouble diagnosis content) C
ABS SYSTEM Malfunction related to wheel sensor has been detected by
C1203
(ABS system) ABS actuator and electric unit (control unit).
POSSIBLE CAUSE DLN

ABS malfunction
• Vehicle speed signal error
E
FAIL-SAFE
4WD control changes to front-wheel drive gradually (rear-wheels still have some driving torque), then 4WD
control stops, and the vehicle becomes front-wheel drive.
F
1.PRECONDITIONING
G
H
>> GO TO 2.
With CONSULT I
1. Drive at 30 km/h (19 MPH) or more for approximately 1 minute.
Is DTC “C1203” detected? J
NO-2 >> Confirmation after repair: INSPECTION END K
1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS L
With CONSULT
Perform self-diagnosis for “ABS”.
M
YES >> Check the DTC. Refer to BRC-84, "DTC Index".
NO >> GO TO 2.
N
2.CHECK TERMINALS AND HARNESS CONNECTORS
Check 4WD control unit pin terminals for damage or loose connection with harness connector.
Is inspection result normal? O
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC “C1203”
is detected, Replace 4WD control unit. Refer to DLN-76, "Removal and Installation".
NO >> Repair or replace error-detected parts. P
DLN-43
C1204 4WD SOLENOID
C1204 4WD SOLENOID
DTC DETECTION LOGIC

4WD SOLENOID
C1204 Malfunction related to 4WD solenoid has been detected.
(4WD solenoid)
POSSIBLE CAUSE
• Internal malfunction of electronic controlled coupling
• Malfunction of 4WD solenoid power supply circuit (open or short)
• Malfunction of 4WD solenoid command current
FAIL-SAFE
front-wheel drive.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1.CHECK 4WD SOLENOID POWER SUPPLY (1)

1. Turn the ignition switch OFF.
2. Disconnect 4WD control unit harness connector.
3. Check the voltage between 4WD control unit harness connector and ground.
4WD control unit

— Voltage
Connector Terminal
B5 9 Ground Battery voltage
4. Turn the ignition switch ON.
CAUTION:
Never start the engine.
4WD control unit

— Voltage
Connector Terminal
Is the inspection result normal?
DLN-44
C1204 4WD SOLENOID
YES >> GO TO 3.
NO >> GO TO 2. A
B
2. Check the 10A fuse (#6).
3. Disconnect fuse block (J/B) harness connector.
4. Check the continuity between 4WD control unit harness connector and fuse block (J/B) harness connec-
tor. C
4WD control unit Fuse block (J/B)

Continuity DLN
Connector Terminal Connector Terminal
B5 9 M2 15B Existed
5. Check the continuity between 4WD control unit harness connector and the ground. E
4WD control unit

— Continuity
Connector Terminal F
B5 9 Ground Not existed
G
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-12, "Wiring Diagram - BAT-
TERY POWER SUPPLY -".
NO >> Repair or replace error-detected parts.
H
3.CHECK 4WD SOLENOID GROUND
Check the continuity between 4WD control unit harness connector and ground.
I
4WD control unit
— Continuity
Connector Terminal
J
10
B5 Ground Existed
11
Is the inspection result normal? K
YES >> GO TO 4.
4.CHECK 4WD SOLENOID CIRCUIT (1) L
Check the resistance between 4WD control unit harness connector.
M
4WD control unit
Resistance (Approx.)
Connector Terminal
B5 1 2 2.5 Ω N
YES >> GO TO 7.
NO >> GO TO 5. O
5.CHECK 4WD SOLENOID CIRCUIT (2)
1. Remove 4WD solenoid harness connector. P
2. Check the continuity between 4WD control unit harness connector and 4WD solenoid harness connector.
4WD control unit 4WD solenoid

Continuity
1 2
B5 C1 Existed
2 1
DLN-45
C1204 4WD SOLENOID
3. Check the continuity between 4WD control unit harness connector and the ground.
4WD control unit

— Continuity
Connector Terminal
1
B5 Ground Not existed
2
YES >> GO TO 6.
6.CHECK 4WD SOLENOID
Check 4WD solenoid. Refer to DLN-46, "Component Inspection".
YES >> GO TO 7.
NO >> 4WD solenoid is malfunctioning. Replace electric controlled coupling. Refer to DLN-231,
"Removal and Installation".
• Check 4WD control unit pin terminals for damage or loose connection with harness connector.
• Check 4WD solenoid pin terminals for damage or loose connection with harness connector.
Component Inspection INFOID:0000000010991988

2. Disconnect 4WD solenoid harness connector.
3. Check the resistance between 4WD solenoid harness connector terminals.
4WD solenoid
Terminal
1 2 2.5 Ω
YES >> INSPECTION END
DLN-46
C1209 MODE SW
C1209 MODE SW
A

MODE SW More than two switch inputs are simultaneously detected
C1209
(Mode switch) due to short circuit of 4WD mode switch.
POSSIBLE CAUSE DLN

• Malfunction of 4WD mode switch
• Malfunction of 4WD mode switch circuit
• Internal malfunction of 4WD control unit E
FAIL-SAFE
front-wheel drive. F

1.PRECONDITIONING G
H
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE I
With CONSULT
1. Start the engine.
CAUTION: J
Stop the vehicle.
2. Operate 4WD mode switch to each position.
K
L
M
1.CHECK 4WD MODE SWITCH
Check 4WD mode switch. Refer to DLN-49, "Component Inspection".
Is the inspection result normal? N
YES >> GO TO 2.
NO >> Replace 4WD mode switch. Refer to DLN-77, "Removal and Installation".
2.CHECK 4WD MODE SWITCH SIGNAL CIRCUIT O

2. Check the continuity between 4WD control unit harness connector and 4WD mode switch harness con-
P
nector.
DLN-47
C1209 MODE SW
4WD control unit 4WD mode switch

Continuity
3 Not existed
5 6 Existed
8 Not existed
3 Existed
B5 12 M8 6 Not existed
8 Not existed
3 Not existed
14 6 Not existed
8 Existed
3. Check the continuity between 4WD control unit harness connector and ground.
4WD control unit

— Continuity
Connector Terminal
5
14
YES >> GO TO 3.
NO >> Repair or replace damaged parts.
3.CHECK 4WD CONTROL SWITCH GROUND CIRCUIT
Check the continuity between 4WD mode switch harness connector and ground.
4WD mode switch

— Continuity
Connector Terminal
M8 2 Ground Existed
YES >> GO TO 4.
4.CHECK 4WD CONTROL UNIT OUTPUT SIGNAL
1. Connect 4WD control unit harness connector.
CAUTION:
3. Check the voltage between 4WD mode switch harness connector and ground.
4WD mode switch

— Voltage
Connector Terminal
3
M8 6 Ground Battery voltage
8
YES >> GO TO 5.
DLN-48
C1209 MODE SW
• Check 4WD mode switch pin terminals for damage or loose connection with harness connector. A
NO >> Repair or replace damaged parts. B
1.CHECK 4WD MODE SWITCH C

2. Remove 4WD mode switch.
DLN
3. Check the continuity between 4WD mode switch connector terminals.
4WD mode switch

Condition Continuity E
Terminal
4WD mode switch: 2WD Existed
4WD mode switch: AUTO F
3 2
4WD mode switch: LOCK Not existed
4WD mode switch: 2WD Not existed G
4WD mode switch: AUTO
6 2
4WD mode switch: LOCK Existed
H
4WD mode switch: 2WD

Not existed
8 2 I
Existed
Is the inspection result normal? J
K
DLN-49
C1210 ECM
C1210 ECM
DTC DETECTION LOGIC

ENGINE SIGNAL 1
C1210 Malfunction related to engine signal has been detected.
(Engine signal 1)
POSSIBLE CAUSE
Malfunction of engine control system
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1. Drive the vehicle for a while.
1.PERFORM ECM SELF-DIAGNOSIS

With CONSULT
Perform self-diagnosis for “ENGINE”.
YES >> Check the DTC. Refer to EC-109, "DTC Index" (MR20DD), EC-517, "DTC Index" (QR25DE).
NO >> GO TO 2.
Is inspection result normal?
DLN-50
P1804 4WD CONTROL UNIT
A

CONTROL UNIT Malfunction is detected in the memory (EEPROM) system of
P1804
(Control unit) 4WD control unit.
POSSIBLE CAUSE DLN

Internal malfunction of 4WD control unit.
FAIL-SAFE E
front-wheel drive.
DTC CONFIRMATION PROCEDURE F
1.PRECONDITIONING
G
>> GO TO 2. H
With CONSULT
1. Turn the ignition switch ON. I
Is DTC “P1804” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-51, "Diagnosis Procedure". J
K
1.REPLACE 4WD CONTROL UNIT L

CAUTION:
Replace 4WD control unit when DTC “P1804” is detected simultaneously with other items.
M
>> Replace 4WD control unit. Refer DLN-76, "Removal and Installation".
DLN-51
P1808 WHEEL SPEED SENSOR
DTC DETECTION LOGIC

• Malfunction is detected in vehicle speed signal that is out-
VHCL SPEED SEN-ABS put from ABS actuator and electric unit (control unit)
P1808
(Vehicle speed sensor-ABS) through CAN communication.
• Improper signal is input while driving.
POSSIBLE CAUSE
• ABS malfunction
• Internal malfunction of 4WD control unit
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS

With CONSULT
NO >> GO TO 2.
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC “P1808”
DLN-52
A

CONTROL UNIT
P1809 AD converter system of 4WD control unit is malfunctioning.
(Control unit)
POSSIBLE CAUSE DLN

FAIL-SAFE E
front-wheel drive.
1.PRECONDITIONING
G
>> GO TO 2. H
With CONSULT
K

CAUTION:
M
DLN-53
P1811 BATTERY VOLTAGE
DTC DETECTION LOGIC

BATTERY VOLTAGE When engine is running and 4WD control unit power supply
P1811
(Battery voltage) is less than 9 V or higher than 16 V.
POSSIBLE CAUSE
• Malfunction of 4WD control unit power supply circuit (open or short)
• Battery power supply
• Ignition power supply
FAIL-SAFE
front-wheel drive.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1.CHECK 4WD CONTROL UNIT POWER SUPPLY (1)

4WD control unit

— Voltage (Approx.)
Connector Terminal
B5 7 Ground 0V
CAUTION:
4WD control unit

— Voltage
Connector Terminal
DLN-54
YES >> GO TO 3. A
NO >> GO TO 2.
B
4. Check the continuity between 4WD control unit harness connector and fuse block (J/B) harness connec- C
tor.
4WD control unit Fuse block (J/B) DLN

Continuity
B5 7 M3 7C Existed
E
4WD control unit F

— Continuity
Connector Terminal
G
YES >> Perform the trouble diagnosis for ignition power supply circuit. Refer to PG-52, "Wiring Diagram -
IGNITION POWER SUPPLY -".
H
1. Turn the ignition switch OFF. I
4WD control unit J

Connector Terminal
K
CAUTION:
4. Check the voltage between 4WD control unit harness connector and ground. L
4WD control unit

— Voltage M
Connector Terminal
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK 4WD CONTROL UNIT POWER SUPPLY (4) O
3. Disconnect fuse block (J/B) harness connector. P
tor.

Continuity
B5 15 B107 6H Existed
DLN-55
4WD control unit

— Continuity
Connector Terminal
5.CHECK 4WD CONTROL UNIT GROUND
4WD control unit

— Continuity
Connector Terminal
10
B5 Ground Existed
11
YES >> GO TO 6.
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P1811” is detected, Replace 4WD control unit. Refer to DLN-76, "Removal and Installation".
DLN-56
P181B INCOMPLETE SELFSHUT
A

INCOMP SELF SHUT When ignition switch is ON, self-shut of 4WD control unit
P181B
(Incomplete self shut) was incomplete.
POSSIBLE CAUSE DLN

• Ignition power supply E
FAIL-SAFE
No impact to vehicle behavior. F

1.PRECONDITIONING G
H
>> GO TO 2.
With CONSULT
2. Perform self-diagnosis for “ALL MODE AWD/4WD”. J
Is DTC “P181B” detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-44, "Intermittent Incident". K
L
2. Disconnect 4WD control unit harness connector. M
4WD control unit N

Connector Terminal
B5 7 Ground 0V
O
CAUTION:
P
4WD control unit

— Voltage
Connector Terminal
DLN-57
YES >> GO TO 3.
NO >> GO TO 2.
tor.

Continuity
B5 7 M3 7C Existed
4WD control unit

— Continuity
Connector Terminal
4WD control unit

Connector Terminal
CAUTION:
4WD control unit

— Voltage
Connector Terminal
YES >> GO TO 5.
NO >> GO TO 4.
tor.

Continuity
DLN-58
4WD control unit A

— Continuity
Connector Terminal
B
TERY POWER SUPPLY -". C
1. Turn the ignition switch OFF. DLN
4WD control unit E

— Continuity
Connector Terminal
10
B5 Ground Existed F
11
YES >> GO TO 6. G
H
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC I
“P181B” is detected, Replace 4WD control unit. Refer to DLN-76, "Removal and Installation".
J
DLN-59
P181D ENGINE TORQUE SIGNAL
DTC DETECTION LOGIC

ENGINE SYSTEM
P181D Malfunction related to engine signal has been detected.
(Engine system)
POSSIBLE CAUSE
• Malfunction of engine control system
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Stop the vehicle.
Is DTC “P181D” detected?

With CONSULT
YES >> Check the DTC. Refer to EC-109, "DTC Index" (MR20DD), EC-517, "DTC Index" (QR25DE).
NO >> GO TO 2.
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC “P181D”
DLN-60
P181F INCOMPLETE CALIBRATION
A

INCOMP CALIBRATION When incomplete writing unit characteristics of electric con-
P181F
(Incomplete calibration) trolled coupling are detected.
POSSIBLE CAUSE DLN

Writing unit characteristics are incomplete.
FAIL-SAFE E
front-wheel drive.
1.PRECONDITIONING
G
>> GO TO 2. H
With CONSULT
1. Turn the ignition switch OFF to ON. I
Is DTC “P181F” detected?
K
1.PERFORM WRITING UNIT CHARACTERISTICS L

1. Erase self-diagnostic result for “ALL MODE AWD/4WD”.
2. Perform writing unit characteristics. Refer to DLN-41, "Work Procedure".
4. Perform self-diagnosis for “ALL MODE AWD/4WD”. M
Is any DTC except “P181F” detected?
YES >> Perform trouble diagnosis for detected DTC. Refer to DLN-30, "DTC Index".
NO >> GO TO 2. N
2.PERFORM SELF-DIAGNOSIS AGAIN

With CONSULT O
Perform “DTC CONFIRMATION PROCEDURE” (self-diagnosis) again. Refer to DLN-61, "DTC Description".
YES >> Replace 4WD control unit. Refer to DLN-76, "Removal and Installation". P
DLN-61
U1000 CAN COMM CIRCUIT
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
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring.
Each control unit communicate data but selectively reads required data only.
DTC DETECTION LOGIC

CAN COMM CIRCUIT 4WD control unit is not transmitting/receiving CAN commu-
U1000
(CAN communication circuit) nication signal for 2 seconds or more.
POSSIBLE CAUSE
• CAN communication error
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
Is DTC “U1000” detected?
Proceed to LAN-17, "Trouble Diagnosis Flow Chart".
DLN-62
U1010 CONTROL UNIT (CAN)
A
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul- B
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring. C
DTC DETECTION LOGIC
DLN
CONTROL UNIT (CAN) Detecting error during the initial diagnosis of CAN controller
E
U1010
[Control unit (CAN)] of 4WD control unit.
POSSIBLE CAUSE F
FAIL-SAFE
4WD control changes to front-wheel drive gradually (rear-wheels still have some driving torque), then 4WD G
H
1.PRECONDITIONING
wait at least 10 seconds before conducting the next test. I
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE J
With CONSULT
1. Turn the ignition switch OFF to ON. K
YES >> Proceed to diagnosis procedure. Refer to DLN-63, "Diagnosis Procedure". L
Diagnosis Procedure INFOID:0000000010992011 M
1.CHECK 4WD CONTROL UNIT

Check 4WD control unit harness connector for disconnection and deformation. N
NO >> Repair or replace error-detected parts. O
DLN-63
POWER SUPPLY AND GROUND CIRCUIT

4WD control unit

Connector Terminal
B5 7 Ground 0V
CAUTION:
4WD control unit

— Voltage
Connector Terminal
YES >> GO TO 3.
NO >> GO TO 2.
tor.

Continuity
B5 7 M3 7C Existed
4WD control unit

— Continuity
Connector Terminal
4WD control unit

Connector Terminal
DLN-64
CAUTION:
Never start the engine. A
4WD control unit B

— Voltage
Connector Terminal
C
YES >> GO TO 5.
NO >> GO TO 4.
DLN
2. Check the 5A fuse (#2). E
tor.
F

Continuity
Connector Terminal Connector Terminal G
H
4WD control unit
— Continuity
Connector Terminal
I
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-12, "Wiring Diagram - BAT- J
5.CHECK 4WD SOLENOID POWER SUPPLY (1) K
L
4WD control unit

— Voltage
Connector Terminal
M
CAUTION: N
O
4WD control unit
— Voltage
Connector Terminal
B5 9 Ground Battery voltage P
YES >> GO TO 7.
NO >> GO TO 6.
DLN-65
tor.

Continuity
B5 9 M2 15B Existed
4WD control unit

— Continuity
Connector Terminal
4WD control unit

— Continuity
Connector Terminal
10
B5 Ground Existed
11
DLN-66
4WD INDICATOR LAMP
4WD INDICATOR LAMP
A
Component Function Check INFOID:0000000010992013
1.4WD INDICATOR LAMP OPERATION CHECK B

Check that 4WD indicator lamp turns ON for several seconds after the ignition switch is turned ON.
C
NO >> Proceed to DLN-67, "Diagnosis Procedure".
DLN
With CONSULT E
Perform self-diagnosis for “ALL MODE AWD/4WD”.
YES >> Perform trouble diagnosis for detected DTC. Refer to DLN-30, "DTC Index". F
NO >> GO TO 2.
G
Perform the trouble diagnosis for 4WD mode switch. Refer to DLN-47, "Diagnosis Procedure".
Is the inspection results normal?
YES >> GO TO 3. H
NO >> Repair or replace the error-detected parts.
3.CHECK 4WD INDICATOR LAMP SIGNAL
I
With CONSULT
CAUTION:
Stop the vehicle. J
2. Change 4WD mode switch from "2WD” to “AUTO”.
3. Check “4WD MODE MON” in “DATA MONITOR” for “ALL MODE AWD/4WD”.
Does the item on “DATA MONITOR” indicate “AUTO”? K
YES >> Perform the trouble diagnosis for combination meter. Refer to MWI-84, "On Board Diagnosis
Function".
NO >> Replace 4WD control unit. Refer to DLN-76, "Removal and Installation". L
DLN-67
LOCK INDICATOR LAMP
LOCK INDICATOR LAMP
1.LOCK INDICATR LMAP OPERATION CHECK

Check that LOCK indicator lamp turns ON for several seconds after the ignition switch is turned ON.
With CONSULT
NO >> GO TO 2.
YES >> GO TO 3.
3.CHECK LOCK INDICATOR LAMP SIGNAL
With CONSULT
CAUTION:
Stop the vehicle.
2. Change 4WD mode switch from "AUTO” to “LOCK”.
Does the item on “DATA MONITOR” indicate “LOCK”?
Function".
NO >> Replace 4WD control unit. Refer to DLN-76, "Removal and Installation".
DLN-68
HEAVY TIGHT-CORNER BRAKING SYMPTOM OCCURS
< SYMPTOM DIAGNOSIS > [TRANSFER: TY21C]
SYMPTOM DIAGNOSIS A
B
Heavy tight-corner braking symptom occurs when the vehicle is driven and the steering wheel is turned fully to
either side after the engine is started.
NOTE: C
Light tight-corner braking symptom may occur depending on driving conditions. This is not malfunction.
DLN
With CONSULT E
YES >> Check the DTC. Refer to EC-109, "DTC Index" (MR20DD), EC-517, "DTC Index" (QR25DE). F
NO >> GO TO 2.
G
With CONSULT
H
YES >> Proceed to DLN-62, "Diagnosis Procedure".
NO >> GO TO 3.
3.CHECK 4WD SOLENOID I
Perform the trouble diagnosis of the 4WD solenoid. Refer to DLN-44, "Diagnosis Procedure".
YES >> GO TO 4. J
4.CHECK ELECTRIC CONTROLLED COUPLING K
2. Set the transaxle to neutral. Release the parking brake.
3. Lift up the vehicle.
4. Rotate the propeller shaft by hand. L
5. Hold rear wheel of right and left lightly.
Does rear wheel rotate?
YES >> Replace electric controlled coupling for mechanical malfunction (clutch sticking etc.). Refer to M
DLN-231, "Removal and Installation".
NO >> Check each harness connector pin terminal for disconnection.
N
DLN-69
VEHICLE DOES NOT ENTER 4WD MODE
Vehicle does not enter 4-wheel drive mode even though 4WD warning is not displayed.
1.CHECK INFORMATION DISPLAY (COMBINATION METER)

Perform the trouble diagnosis of combination meter. Refer to MWI-84, "On Board Diagnosis Function".
YES >> GO TO 2.
2.CHECK PARKING BRAKE SWITCH SIGNAL
With CONSULT
Check “PARKING BRAKE SW SIG” of CONSULT “DATA MONITOR” for “ALL MODE AWD/4WD”.
Monitor Item Condition Status

When the parking brake is operation. On
PARKING BRAKE SW SIG
When the parking brake is not operation. Off
YES >> GO TO 3.
NO >> Proceed to BRC-107, "Diagnosis Procedure".
3.CRUISE TEST
Drive the vehicle for a period of time.
Does any symptom occur?
YES >> Replace electric controlled coupling for mechanical malfunction (mechanical engagement of
clutch is not possible). Refer to DLN-231, "Removal and Installation".
DLN-70
4WD HIGH TEMP IS DISPLAYED ON INFORMATION DISPLAY
A
While driving, 4WD warning (4WD High Temp. Stop vehicle) is displayed on information display (combination B
meter).
• This symptom protects drivetrain parts when a heavy load is applied to the electric controlled coupling and
multiple disc clutch temperature increases. Also, optional distribution of torque sometimes becomes rigid
before 4WD warning (4WD High Temp. Stop vehicle) is displayed. Both cases are not malfunction. Refer to C
DLN-30, "Protection Function".
• When this symptom occurs, stop vehicle and allow it to idle for some times. Displays will stop and system
will be restored. DLN
DLN-71
TIRE SIZE INCORRECT IS DISPLAYED ON INFORMATION DISPLAY
While driving, 4WD warning (Tire Size Incorrect: See Owner’s Manual) is displayed on information display
(combination meter).
1.CHECK TIRE
Check the following.
• Tire pressure
• Wear condition
• Front and rear tire size (There is no difference between front and rear tires.)
YES >> GO TO 2.
NO >> Repair or replace error-detected parts. And then, drive the vehicle at speed of 20 km/h (12 MPH)
or more for 5 seconds or more. Improper size information is initialized accordingly.
2.CHECK INPUT SIGNAL OF TIRE DIAMETER
With CONSULT
2. Drive at 20 km/h (12 MPH) or more for approximately 4 minutes continually.
3. Check “DIS-TIRE MONI” of CONSULT “DATA MONITOR” for “ALL MODE AWD/4WD”.
Does the item on “DATA MONITOR” indicate “0 - 4 mm”?
NO >> GO TO 3.
3.TERMINAL INSPECTION
Check 4WD control unit harness connector for disconnection.
DLN-72
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
A
NVH Troubleshooting Chart INFOID:0000000010992024
Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If nec- B
essary, repair or replace these parts.
DLN-92, "Inspection", DLN-102, "Inspection"

DLN-74, "MR20DD : Inspection" (MR20DD)
DLN-75, "QR25DE : Inspection" (QR25DE)
C
DLN
DLN-83, "Exploded View"

—
Reference
E
TRANSFER OIL (Level too high)
BEARING (Worn or damaged)

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

TRANSFER OIL (Level low)
GEAR (Worn or damaged)

TRANSFER OIL (Wrong)
SUSPECTED PARTS
(Possible cause)
I
Noise 1 2 3 3 3
Symptom
Transfer oil leakage 3 1 2 2 2 K
DLN-73
TRANSFER OIL
< PERIODIC MAINTENANCE > [TRANSFER: TY21C]
PERIODIC MAINTENANCE
TRANSFER OIL
MR20DD
MR20DD : Inspection INFOID:0000000011001968
OIL LEAKAGE
Check transfer surrounding area (oil seal, drain plug, and filler plug etc.) for oil leakage.
OIL LEVEL
1. Remove filler plug and gasket. Then check that oil is filled up
from mounting hole for filler plug.
CAUTION:
Turn the ignition switch OFF while checking oil level.
• Oil level should be level with bottom of filler plug mounting
hole. Add transfer oil if necessary. Refer to DLN-74, "MR20DD
: Refilling".
2. Set a new gasket on filler plug and install it on transfer assem-
bly. Refer to DLN-83, "Exploded View".
CAUTION:
Never reuse gasket. JSDIA5349ZZ
MR20DD : Draining INFOID:0000000011001969
1. Run the vehicle to warm up the transfer unit sufficiently.

3. Remove drain plug and gasket.
4. Drain transfer oil.
5. Before installing drain plug, set a new gasket. Install drain plug
to transfer assembly and tighten to the specified torque. Refer to
DLN-83, "Exploded View".
CAUTION:
Never reuse gasket.
JSDIA5350ZZ
MR20DD : Refilling INFOID:0000000011001970
1. Remove filler plug and gasket. Then fill with new transfer oil
until oil level reaches the specified level near filler plug mounting
hole.
Recommended : Refer to MA-23, "Fluids and Lubri-

oil and capacity cants".
2. Leave the vehicle for 3 minutes, and check the oil level again.
3. Before installing filler plug, set a new gasket. Install filler plug to
transfer assembly and tighten to the specified torque. Refer to
DLN-83, "Exploded View". JSDIA5349ZZ
CAUTION:
Never reuse gasket.
QR25DE
DLN-74
TRANSFER OIL
< PERIODIC MAINTENANCE > [TRANSFER: TY21C]
QR25DE : Inspection INFOID:0000000011001971
A
OIL LEAKAGE
B
OIL LEVEL
1. Remove filler plug and gasket. Then check that oil is filled up
from mounting hole for filler plug. C
: Oil level
: Vehicle front DLN
CAUTION:
• Oil level should be level with bottom of filler plug mounting E
hole. Add transfer oil if necessary. Refer to DLN-75, "QR25DE
: Refilling". ALDIA0503ZZ
2. Set a new gasket on filler plug and install it on transfer assem- F

bly. Refer to DLN-83, "Exploded View".
CAUTION:
Never reuse gasket.
G
QR25DE : Draining INFOID:0000000011001972
1. Run the vehicle to warm up the transfer unit sufficiently. H

I
: Vehicle front

J
5. Before installing drain plug, set a new gasket. Install drain plug
to transfer assembly and tighten to the specified torque. Refer to
DLN-83, "Exploded View".
CAUTION: K
Never reuse gasket.
AWDIA1153ZZ
L
QR25DE : Refilling INFOID:0000000011001973
1. Remove filler plug and gasket. Then fill with new transfer oil
until oil level reaches the specified level near filler plug mounting M
hole.
: Oil level N
: Vehicle front
O
ALDIA0503ZZ
2. Leave the vehicle for 3 minutes, and check the oil level again. P
3. Before installing filler plug, set a new gasket. Install filler plug to transfer assembly and tighten to the spec-
ified torque. Refer to DLN-83, "Exploded View".
CAUTION:
Never reuse gasket.
DLN-75
4WD CONTROL UNIT
< REMOVAL AND INSTALLATION > [TRANSFER: TY21C]
REMOVAL AND INSTALLATION

4WD CONTROL UNIT
Exploded View INFOID:0000000010992028
JSDIA5368GB
4WD control unit
: Vehicle front
: N·m (kg-m, in-lb)
Removal and Installation INFOID:0000000010992029
REMOVAL
2. Remove luggage side lower finisher LH. Refer to INT-43, "LUGGAGE SIDE LOWER FINISHER :
Removal and Installation".
4. Remove 4WD control unit mounting nuts and remove 4WD
control unit .
: Vehicle front
NOTE:
4WD control unit is located on the back side of the rear wheel
house outer panel LH.
AWDIA1154ZZ
INSTALLATION
Note the following, and install in the reverse order of removal.
• Perform adjustment after installation. Refer to DLN-76, "Adjustment".
Adjustment INFOID:0000000010992030
ADJUSTMENT AFTER INSTALLATION

When replaced 4WD control unit, perform writing unit characteristics. Refer to DLN-41, "Work Procedure".
DLN-76
4WD MODE SWITCH
4WD MODE SWITCH
A
DLN
JSDIA5457ZZ
E
4WD mode switch Console switch panel
Removal and Installation INFOID:0000000010992032 F
REMOVAL
1. Remove console switch panel from center console assembly. Refer to IP-25, "Removal and Installation" G
(LHD models), IP-52, "Removal and Installation" (RHD models).
2. Disconnect 4WD mode switch harness connector.
H
3. Remove 4WD mode switch from console switch panel.
INSTALLATION
Install in the reverse order of removal. I
DLN-77
TRANSFER COVER OIL SEAL
MR20DD
MR20DD : Exploded View INFOID:0000000010992033
JSDIA5360ZZ
Transfer assembly Transfer cover oil seal (inner) Transfer cover oil seal (outer)
Oil seal lip
: Always replace after every disassembly.

: Apply transfer oil.
: Apply multi-purpose grease.
MR20DD : Removal and Installation INFOID:0000000010992034
REMOVAL
1. Drain the transfer oil. Refer to DLN-74, "MR20DD : Draining".
2. Remove front drive shaft (right side). Refer to FAX-101, "MR20DD : Removal and Installation".
CAUTION:
Oil may leak from the opening. Use cap and/or plug to prevent leakage.
3. Remove transfer cover oil seal (outer/inner), using oil seal remover (commercial service tool).
CAUTION:
Never damage transfer cover.
INSTALLATION
1. Using drift (commercial service tool), install transfer cover oil
seal (outer/inner) with the directions below.
A : Installation dimension for transfer cover oil seal (inner)

B : Installation dimension for transfer cover oil seal (outer)
A : 10.3 +0.6/-0 mm (0.406 +0.024/-0 in)

B : 0 +0.6/-0 mm (0 +0.024/-0 in)
CAUTION:
• Never reuse oil seal. JSDIA3993ZZ
• When installing, never incline oil seal.

• Apply multi-purpose grease onto oil seal lips, and transfer oil onto the circumference of oil seal.
2. Install front drive shaft (right side). Refer to FAX-101, "MR20DD : Removal and Installation".
3. Refill the transfer oil to transfer assembly. Refer to DLN-74, "MR20DD : Refilling".
DLN-78
4. Perform inspection after installation. Refer to DLN-79, "MR20DD : Inspection".
A
INSPECTION AFTER INSTALLATION

B
Check oil level and transfer for oil leakage. Refer to DLN-74, "MR20DD : Inspection".
QR25DE
QR25DE : Removal and Installation INFOID:0000000011001966
C
NOTE:
• Replacement on vehicle may cause damage to transfer cover, and may cause a transfer oil leak. DLN
• If transfer cover oil seal requires replacement, remove transfer assembly from the vehicle before replacing
transfer cover oil seal. Refer to DLN-85, "Disassembly and Assembly".
E
DLN-79
TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: TY21C]
UNIT REMOVAL AND INSTALLATION

TRANSFER ASSEMBLY
MR20DD
MR20DD : Exploded View INFOID:0000000011002856
JSDIA5353GB
Transfer gusset Transfer assembly
: N·m (kg-m, ft-lb)

*: Apply anti-corrosion oil.
MR20DD : Removal and Installation INFOID:0000000011002857
REMOVAL
1. Remove exhaust front tube. Refer to EX-6, "Removal and Installation".
2. Remove front drive shaft (RH). Refer to FAX-101, "MR20DD : Removal and Installation".
CAUTION:
3. Remove propeller shaft from transfer assembly. Refer to DLN-214, "Removal and Installation".
CAUTION:
The joint of propeller shaft must be handled with care.
4. Remove transfer gusset .
5. Remove transfer assembly from transaxle assembly.
CAUTION:
• Never damage ring gear shaft.
• Be careful when removing transfer assembly form the
vehicle because it is heavy.
JSDIA5358ZZ
INSTALLATION
DLN-80
TRANSFER ASSEMBLY
• When installing the transfer to the transaxle, install the mounting
bolts following the standard below, tighten bolts to the specified A
torque. For each tightening torque, refer to DLN-81, "QR25DE :
Exploded View".
B
Bolt symbol
Quantity 4 2
Bolt length C
40 (1.57) 40 (1.57)
“L” mm (in)
Insertion direction Transfer to transaxle Transaxle to transfer JSDIA5355ZZ
DLN
CAUTION:
• Apply anti-corrosion oil to the thread and seat of mounting bolts.
• Never damage O-ring of transfer.
• For mounting bolts of transfer gusset, temporarily tightening the engine side bolt first. After this, tighten bolts E
to the specified torque in the order from transfer side bolt to engine side bolt. For tightening torque, refer to
DLN-81, "QR25DE : Exploded View".
• Perform inspection after installation. Refer to DLN-82, "QR25DE : Inspection". F
INSPECTION AFTER INSTALLATION G

When oil leaks while removing/installing transfer assembly, check oil level after the installation. Refer to DLN-
74, "MR20DD : Inspection".
QR25DE H
QR25DE : Exploded View INFOID:0000000011002859
JSDIA6394GB
N
Transfer assembly

O
QR25DE : Removal and Installation INFOID:0000000011002860

P
REMOVAL
1. Remove front drive shaft (RH). Refer to FAX-113, "QR25DE : Removal and Installation".
CAUTION:
2. Remove front suspension member. Refer to FSU-22, "Removal and Installation".
3. Remove exhaust front tube. Refer to EX-12, "Removal and Installation".
DLN-81
TRANSFER ASSEMBLY
4. Remove propeller shaft. Refer to DLN-214, "Removal and Installation".
5. Remove transfer assembly mounting bolts.
6. Remove transfer assembly from the vehicle.
INSTALLATION
bolts following the standard below, tighten bolts to the specified
torque. For each tightening torque, refer to DLN-81, "QR25DE :
Exploded View".
Bolt symbol
Quantity 4 2
Bolt length
40 (1.57) 40 (1.57)
“L” mm (in)
CAUTION:
• Apply anti-corrosion oil to the thread and seat of mounting bolts.
• Never damage O-ring of transfer.
• Perform inspection after installation. Refer to DLN-82, "QR25DE : Inspection".
QR25DE : Inspection INFOID:0000000011002861

75, "QR25DE : Inspection".
DLN-82
TRANSFER COVER
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21C]
UNIT DISASSEMBLY AND ASSEMBLY A

TRANSFER COVER
B
MR20DD models
C
DLN
K
JSDIA5341GB
Pinion lock nut Companion flange Dust cover

Oil seal Pinion bearing assembly O-ring L
Drive pinion adjusting shim Drive pinion O-ring
Oil seal Dowel pin Plug
M
Gasket Transfer case Baffle plate
Ring gear bearing adjusting shim Ring gear bearing (transfer case Ring gear
(transfer case side) side) N
Ring gear shaft Ring gear shaft oil seal Ring gear bearing (transfer cover
side)
Ring gear bearing adjusting shim Oil seal O-ring
O
Transfer cover Oil seal Filler plug
Drain plug
P
Oil seal lip Comply with the assembly procedure
when tightening. Refer to DLN-96,
"Disassembly and Assembly".

DLN-83
TRANSFER COVER
: Select with proper thickness.

*: Apply anti-corrosive oil.
QR25DE models
AWDIA1138ZZ
DLN-84
TRANSFER COVER
Filler plug Gasket Drain plug A

Oil seal Transfer cover Oil seal
O-ring Ring gear bearing adjusting shim Ring gear bearing (transfer cover
(transfer cover side) side) B
Ring gear shaft oil seal Ring gear shaft Ring gear bearing (transfer case
side)
Ring gear bearing adjusting shim Ring gear Baffle plate C
Transfer case Plug O-ring
Oil seal Dowel pin Drive pinion DLN
Drive pinion adjusting shim O-ring Pinion bearing assembly
Oil seal Dust cover Companion flange
E
Pinion lock nut
Oil seal lip Comply with the assembly proce-
dure when tightening. Refer to DLN-
96, "Disassembly and Assembly". F
: N·m (kg-m, ft-lb) G


H
I
Disassembly and Assembly INFOID:0000000010992040
J
DISASSEMBLY
1. Remove transfer cover mounting bolts ( ).
K
AWDIA1139ZZ
N
2. Lightly tap transfer cover with a plastic hammer to remove
transfer cover.
3. Remove O-ring from transfer cover. O
CAUTION:
• Never use a suitable tool.
• Never damage transfer cover. P
ALDIA0446ZZ
DLN-85
TRANSFER COVER
4. Lightly tap the metal part of oil seals with punch from back
side of transfer cover to remove oil seals.
CAUTION:
When removing, never damage the transfer cover by scoop-
ing it out with a suitable tool.
JSDIA3990ZZ
5. Remove the ring gear bearing adjusting shim (transfer cover

side) and ring gear bearing outer race (transfer cover side)
using suitable tool.
7. Remove filler plug and gasket.
8. Perform inspection after disassembly. Refer to DLN-87, "Inspec-
tion".
JSDIA3992ZZ
ASSEMBLY
1. Select the ring gear bearing adjusting shim (transfer cover side). Refer to DLN-98, "Adjustment".
2. Install the selected ring gear bearing adjusting shim (transfer
cover side) and ring gear bearing outer race (transfer cover
side) using suitable tool.
CAUTION:
• Never reuse ring gear bearing.
• Apply transfer oil to the ring gear bearing.
3. Install gasket onto drain plug and install them to transfer cover.
CAUTION:
Never reuse gasket.
JSDIA3992ZZ
4. Install the transfer cover to the transfer case, and apply anti-cor-
rosive oil onto thread and seats on the mounting bolts. Then
tighten mounting bolts to the specified torque.
A : M10 bolt
B : M8 bolt
NOTE:
At this timing, O-ring installing to transfer cover is not necessary.
Install O-ring after tooth contact is checked.
5. Check backlash, tooth contact, total preload and companion
AWDIA1140ZZ
flange runout. Refer to DLN-98, "Adjustment".
CAUTION:
Measure the total preload without oil seals of transfer cover and transfer case.
6. Remove transfer cover to install O-ring.
7. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the transfer cover.
CAUTION:
• Never reuse O-ring.
• When installing O-ring, never use a suitable tool.
• Never damage O-ring.
DLN-86
TRANSFER COVER
8. Install the transfer cover to the transfer case, and apply anti-cor-
rosive oil onto thread and seats on the mounting bolts. Then A
tighten mounting bolts to the specified torque.
A : M10 bolt
B
B : M8 bolt
AWDIA1140ZZ
DLN
9. Using drift (commercial service tool), install transfer cover oil
seal (outer/inner) with the directions below.
A : Installation dimension for transfer cover oil seal (inner) E

B : Installation dimension for transfer cover oil seal (outer)
A : 10.3 +0.6/-0 mm (0.406 +0.024/-0 in) F

B : 0 +0.6/-0 mm (0 +0.024/-0 in)
CAUTION: G
• When checking the total preload torque, measure it with- JSDIA3993ZZ
out the oil seal, then install the oil seal.

• Never reuse the oil seal.
• When installing, never incline oil seal. H
• Apply multi-purpose grease onto oil seal lips, and transfer oil onto the circumference of the oil
seal.
10. Install gasket onto filler plug and install them to transfer cover. I
CAUTION:
• Never reuse gasket.
• Install filler plug after oil is filled. J
Inspection INFOID:0000000010992042
INSPECTION AFTER DISASSEMBLY K

Check items below. If necessary, replace them with new ones.
Transfer cover
L
Check the bearing mounting surface for wear, cracks and damages.
DLN-87
RING GEAR SHAFT
RING GEAR SHAFT
MR20DD models
JSDIA5341GB

Oil seal Pinion bearing assembly O-ring
(transfer case side) side)
side)
Drain plug

DLN-88
RING GEAR SHAFT

A
B
QR25DE models
DLN
AWDIA1138ZZ
DLN-89
RING GEAR SHAFT
Filler plug Gasket Drain plug

(transfer cover side) side)
side)
Ring gear bearing adjusting shim Ring gear Baffle plate
Oil seal Dowel pin Drive pinion
Pinion lock nut
96, "Disassembly and Assembly".


DISASSEMBLY
1. Remove transfer cover assembly. Refer to DLN-85, "Disassembly and Assembly".
2. Remove ring gear bearing outer race (transfer cover side) and ring gear bearing adjusting shim (transfer
cover side) from the transfer cover. Refer to DLN-85, "Disassembly and Assembly".
3. Remove ring gear shaft assembly from the transfer case.
4. Remove ring gear bearing outer race (transfer case side) and ring gear bearing adjusting shim (transfer
case side) from the transfer case. Refer to DLN-105, "Disassembly and Assembly".
5. Remove ring gear bearing inner race (transfer cover side) from
ring gear shaft using suitable tool (A) and suitable tool.
JPDIE0030ZZ
DLN-90
RING GEAR SHAFT
6. Remove ring gear bearing inner race (transfer case side) from
ring gear shaft with suitable tool (A) and Tool. A
Tool number : ST33061000

7. Remove the ring gear mounting bolts. B
JPDIE0031ZZ
DLN
8. Lightly tap ring gear with a plastic hammer to remove ring gear
from the ring gear shaft.
E
G
SDIA1807J
9. Remove ring gear shaft oil seal from the ring gear shaft with the
H
Tool (A).
Tool number : KV381054S0

I
10. Perform inspection after disassembly. Refer to DLN-92, "Inspec-
tion".
J
JPDIE0032ZZ
K
ASSEMBLY
1. Using suitable tool (A), install ring gear shaft oil seal within the
dimension (L) shown as follows. L
L : 2.0 +0.6/−0 mm (0.079 +0.024/−0 in)

CAUTION: M
• Never reuse the oil seal.
• Apply multi-purpose grease onto oil seal lips, and transfer N
oil onto the circumference of the oil seal.
2. Select ring gear bearing adjusting shim (transfer case side) and
JSDIA2492ZZ
ring gear bearing adjusting shim (transfer cover side). Refer to O
DLN-98, "Adjustment".
3. Assemble the selected ring gear bearing adjusting shim (transfer case side) and ring gear bearing outer
race (transfer case side) to transfer case. Refer to DLN-105, "Disassembly and Assembly".
P
CAUTION:
4. Assemble the selected ring gear bearing adjusting shim (transfer cover side) and ring gear bearing outer
race (transfer cover side) to transfer cover. Refer to DLN-85, "Disassembly and Assembly".
CAUTION:
DLN-91
RING GEAR SHAFT
5. Install the ring gear to ring gear shaft, and tighten mounting bolts to the specified torque.
6. Install ring gear bearing inner race (transfer cover side) with drift
(A) (commercial service tool).
CAUTION:
JSDIA1056ZZ
7. Install the ring gear bearing inner race (transfer case side) to
ring gear shaft with suitable tool (A).
CAUTION:
8. Install the ring gear shaft assembly to the transfer case.
CAUTION:
Protect transfer case oil seals beforehand from being dam-
aged by the spline of ring gear shaft below method follow-
ing.
JSDIA1055ZZ
a. Apply multi-purpose grease to spline part indicated in the figure.
JSDIA4195ZZ
b. Wrap piece of vinyl to spline part only indicated in the figure.

[(A): limit line]
CAUTION:
Never wrap sliding surfaces on oil seal.
9. Install transfer cover to check and adjust each part. Refer to
DLN-85, "Disassembly and Assembly".
NOTE:
Install O-ring after backlash and tooth contact are checked.
flange runout. Refer to DLN-98, "Adjustment". JSDIA4196ZZ
CAUTION:
11. Reinstall transfer cover to install O-ring. Refer to DLN-85, "Disassembly and Assembly".
12. After installing transfer case oil seals, remove wrapped vinyl from the spline of ring gear shaft.
INSPECTION AFTER DISASSEMBLY

Gear and Shaft
DLN-92
RING GEAR SHAFT
Check gear face and shaft for wear, cracks, damage, and seizure.
CAUTION: A
If malfunction is detected on the ring gear or drive pinion, replace the ring gear and drive pinion as a
set.
Bearing B
Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.
CAUTION: C
When replacing the bearing, always replace the inner race and outer race as a pair.
Shim
Check for seizure, damage, and unusual wear. DLN
DLN-93
DRIVE PINION
DRIVE PINION
MR20DD models
JSDIA5341GB

side)
Drain plug

DLN-94
DRIVE PINION

A
B
QR25DE models
DLN
AWDIA1138ZZ
DLN-95
DRIVE PINION
Filler plug Gasket Drain plug

(transfer cover side) side)
side)
Ring gear bearing adjusting shim Ring gear Baffle plate
Oil seal Dowel pin Drive pinion
Pinion lock nut
96, "Disassembly and Assembly".


DISASSEMBLY
1. Remove pinion bearing assembly mounting bolts.
JSDIA3951ZZ
2. Lightly tap companion flange with a plastic hammer to remove

drive pinion assembly .
3. Remove the O-ring from pinion bearing.
4. Remove the pinion lock nut.
JSDIA3952ZZ
DLN-96
DRIVE PINION
5. Remove drive pinion from pinion bearing assembly using suit-
able tool (A) and suitable tool (B). A
6. Remove adjusting shim.
7. Remove companion flange.
8. Remove the dust cover. B
9. Remove the oil seal.
10. Perform inspection after disassembly. Refer to DLN-102,
"Inspection". C
JSDIA3953ZZ
DLN
ASSEMBLY
1. Select drive pinion adjusting shim. Refer to DLN-98, "Adjustment".
2. Assemble the selected drive pinion adjusting shim to drive pinion. E
3. Install the drive pinion to pinion bearing assembly using suitable tool.
CAUTION:
• Never reuse pinion bearing assembly.
F
• Apply transfer oil to pinion bearing part.
4. Install oil seal to pinion bearing assembly using suitable tool (A).
CAUTION:
• Never reuse the oil seal. G
• Apply multi-purpose grease onto oil seal lips, and transfer
oil onto the circumference of the oil seal. H
5. Install dust cover.
NOTE:
Tighten dust cover together with pinion bearing assembly. I
JSDIA3996ZZ
J
6. Install companion flange to pinion bearing using suitable tool
(A).
7. Apply anti-corrosive oil to the thread and seat of the lock nut,
and adjust the pinion lock nut tightening torque and pinion bear- K
ing preload torque, using a preload gauge.
a. Install pinion lock nut, and then tighten to the specified torque.
L
Pinion lock nut : 90±9 N·m (9.2±0.92kg-m, 66±7 ft-lb)
tightening torque
CAUTION: M
JSDIA3997ZZ
• Never reuse pinion lock nut.
• Check that pinion lock nut is seated on the companion flange.
b. After tightening pinion lock nut to the specified torque, retighten the pinion lock nut by 25 degrees. N
c. Measure the pinion bearing preload.
Pinion bearing preload : Refer to DLN-108, "Preload Torque". O
8. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the pinion bearing assembly.
CAUTION:
• Never reuse O-ring. P
• Never damage O-ring.
DLN-97
DRIVE PINION
9. Install drive pinion assembly, and apply anti-corrosive oil onto
thread and seats on the mounting bolts. Tighten to the specified
torque.
NOTE:
Tighten dust cover together with pinion bearing assembly.
CAUTION:
Measure the total preload without oil seals of transfer cover
and transfer case.
JSDIA3951ZZ
ADJUSTING SHIM SELECTION

Measurement point
JSDIA4034ZZ
Select adjusting shim of T1, T2, and T3, respectively, by using the following equation.
T1 [Ring gear bearing adjusting shim (transfer case side)]
• T1 = A −(B +X/2) +C +W −V −F −(M/100) +0.071 mm (0.0028 in)
DLN-98
DRIVE PINION
T2 [Ring gear bearing adjusting shim (transfer cover side)]
• T2 = −Y +Z +(B +X/2) −C −D −H +(M/100) +0.071 mm (0.0028 in) A
T3 (Drive pinion adjusting shim)
• T3 = −Q +(R +S/2) −K +(O/100)
• Check dimension (M) on the ring gear side face. B
NOTE:
Dimension “M” indicates the difference between the optimum
engagement and standard dimensions in increments of 0.01 mm
(0.0004 in) written on the ring gear side face. C
DLN
JSDIA2495ZZ E
• Check dimension (O) on the gear end of drive pinion.

NOTE: F
Dimension “O” indicates the difference between the optimum
engagement and the standard dimensions in increments of 0.01
mm (0.0004 in) written on the gear end of drive pinion.
G
JSDIA2496ZZ
I
PINION BEARING PRELOAD
CAUTION:
When measuring preload, the rotating speed must be set to 30 rpm.
J
1. Remove ring gear shaft assembly from the transfer case. Refer to DLN-90, "Disassembly and Assembly".
2. Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking,
and so on.
K
3. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
4. Measure the pinion bearing preload using Tool (A).
L
Pinion bearing preload : Refer to DLN-108, "Preload
Torque".
Tool number : ST3127S000
M
CAUTION:
Each rotational part should rotate smoothly with the speci-
fied transfer oil.
N
• If outside the standard, disassemble the drive pinion assembly
to check and adjust each part. JSDIA2500ZZ
TOTAL PRELOAD O
CAUTION:
When measuring preload, the rotating speed must be set to 30 rpm.
1. Measure pinion bearing preload. P
CAUTION:
Check that the pinion bearing preload is within the standard.
2. Assemble the ring gear shaft assembly to the transfer case. Refer to DLN-90, "Disassembly and Assem-
bly"
3. Install transfer cover to check and adjust each part. Refer to DLN-85, "Disassembly and Assembly".
DLN-99
DRIVE PINION
5. Measure the total preload using Tool (A).
Total preload : Refer to DLN-108, "Preload

Torque".
Tool number : ST3127S000
CAUTION:
fied transfer oil.
• If outside the standard, disassemble the transfer assembly to
check and adjust each part. Measure it with the transfer case JSDIA2500ZZ
oil seal and transfer cover oil seal removed when measuring
total preload after disassembly. Then install transfer case oil seals and transfer cover oil seal.
BACKLASH
1. Install the bolt to the companion flange.
2. Fit a dial indicator onto the bolt .
3. Measure the circumference backlash of the companion flange.
Backlash : Refer to DLN-108, "Backlash".

• If outside the standard, disassemble the transfer assembly to
check and adjust each part.
JSDIA2501ZZ
TOOTH CONTACT
1. Remove transfer cover. Refer to DLN-85, "Disassembly and Assembly".
2. Remove ring gear shaft assembly from transfer case. Refer to DLN-90, "Disassembly and Assembly".
3. Apply red lead or equivalent onto the ring gear.
CAUTION:
Apply red lead or equivalent to both faces of 3 to 4 gears at
4 locations evenly spaced on the ring gear.
4. Assemble the ring gear shaft assembly to the transfer case.
Refer to DLN-90, "Disassembly and Assembly".
NOTE:
Install O-ring after backlash and tooth contact are checked. JSDIA2188ZZ
6. Remove the plug from the transfer case.

7. Rotate the companion flange back and forth several times, and check the drive pinion gear to ring gear
tooth contact by viewing from the plug hole.
DLN-100
DRIVE PINION
Tooth Contact Judgment Guide
A
DLN
H
JSDIA4035GB
8. Follow the procedure below to adjust pinion height (dimension

X) if tooth contact is improper. For selecting adjusting shim, refer
to the latest parts information. I
CAUTION:
If no adjusting shim with the calculated value is available,
select the thicker and closest one. J
JSDIA1221ZZ
L
• Thicken the drive pinion adjusting shim to move the drive pin-
ion closer to the ring gear in case of face contact or heel con-
tact.
CAUTION: M
Only one adjusting shim can be selected.
O
PDIA0440E
DLN-101
DRIVE PINION
• Thin the drive pinion adjusting shim to move the drive pinion
farther from the ring gear in case of flank contact or toe con-
tact.
CAUTION:
PDIA0441E
COMPANION FLANGE RUNOUT

1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate the companion flange to check for runout.
Companion flange runout : Refer to DLN-108, "Com-

panion Flange Runout".
3. Fit suitable tool to the inner side of the companion flange (socket
diameter).
Companion flange runout : Refer to DLN-108, "Com-

panion Flange Runout".
5. Follow the procedure below to adjust if runout value is outside
the repair limit.
a. Check for runout while changing the phase between companion
flange and drive pinion in 90° steps. Then search for the mini-
mum point.
b. Replace companion flange if runout value is still outside the limit
after the phase has been changed.
c. Adjust assembly status of the pinion bearing and drive pinion, or JSDIA3981ZZ
replace pinion bearing assembly if runout is outside the standard
after the companion flange is replaced.

Gear and Shaft
CAUTION:
Replace ring gear and drive pinion as a set (hypoid gear set) if any malfunction is detected on the ring
gear or drive pinion.
Bearing
damage.
Shim
Check for seizure, damage, and unusual wear.
DLN-102
TRANSFER CASE
TRANSFER CASE
A
MR20DD models B
DLN
JSDIA5341GB
Pinion lock nut Companion flange Dust cover K

Drive pinion adjusting shim Drive pinion O-ring L
Ring gear bearing adjusting shim Ring gear bearing (transfer case Ring gear M
side) N
O
Drain plug
when tightening. Refer to DLN-96, P

DLN-103
TRANSFER CASE

QR25DE models
AWDIA1138ZZ
DLN-104
TRANSFER CASE
Filler plug Gasket Drain plug A

(transfer cover side) side) B
side)
Ring gear bearing adjusting shim Ring gear Baffle plate C
Oil seal Dowel pin Drive pinion DLN
E
Pinion lock nut
96, "Disassembly and Assembly". F
: N·m (kg-m, ft-lb) G


H
I
J
DISASSEMBLY
1. Remove transfer cover. Refer to DLN-85, "Disassembly and Assembly".
K
2. Remove ring gear shaft assembly. Refer to DLN-90, "Disassembly and Assembly".
3. Remove drive pinion assembly. Refer to DLN-96, "Disassembly and Assembly".
4. Remove O-ring from transfer case. L
CAUTION:
• Never use a suitable tool.
• Never damage transfer case.
M
5. Remove oil seals .
CAUTION:
Never damage transfer case.
N
P
JSDIA3983ZZ
DLN-105
TRANSFER CASE
6. Remove baffle plate .
JSDIA3982ZZ
7. Remove the ring gear bearing adjusting shim (transfer case

side) and ring gear bearing outer race (transfer case side)
by tapping from the 2 cutouts ( ) on the transfer case.
CAUTION:
8. Remove plug and gasket.
"Inspection".
JSDIA3984ZZ
ASSEMBLY
1. Select the ring gear bearing adjusting shim (transfer case side). Refer to DLN-98, "Adjustment".
2. Install the selected ring gear bearing adjusting shim (transfer
case side) and ring gear bearing outer race (transfer case side)
using suitable tool (A).
CAUTION:
JSDIA3998ZZ
3. Install baffle plate .

4. Install ring gear shaft assembly. Refer to DLN-90, "Disassembly
and Assembly".
CAUTION:
Protect transfer case oil seals beforehand from being dam-
aged by the spline of ring gear shaft.
5. Install drive pinion assembly. Refer to DLN-96, "Disassembly
and Assembly".
JSDIA3982ZZ
NOTE:
At this timing, O-ring installing to transfer cover is not necessary. Install O-ring after backlash and tooth
contact are checked.
7. Check backlash, tooth contact, total preload and companion flange runout. Refer to DLN-98, "Adjust-
ment".
CAUTION:
8. Reinstall transfer cover to install O-ring. Refer to DLN-85, "Disassembly and Assembly".
DLN-106
TRANSFER CASE
9. Install oil seals using suitable tool.
A
A : 24.8 mm (0.976 in)
B : 10.3 mm (0.406 in)
B
CAUTION:
• When checking the total preload torque, measure it with-
out the oil seal, then install the oil seal.
• Never reuse the oil seal. C
• Apply multi-purpose grease onto oil seal lips, and transfer
JSDIA4047ZZ
oil onto the circumference of the oil seal. DLN
• Never damage oil seals by spline of ring gear shaft.
10. After installing oil seals to transfer case, remove wrapped vinyl from the spline of ring gear shaft.
11. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the transfer case. E
CAUTION:
• Never damage O-ring. F
G
Case H
DLN-107
SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [TRANSFER: TY21C]

General Specifications INFOID:0000000010992056
Axle 4WD
Applied model Engine MR20DD QR25DE
Transaxle CVT
Transfer model TY21C
Gear ratio 0.404
Ring gear 42
Number of teeth
Drive pinion 17
Oil capacity Refer to MA-23, "Fluids and Lubricants".
Preload Torque INFOID:0000000010992057
Unit: N·m (kg-m, in-lb)

Item Standard
Pinion bearing preload (P1) 0.25 – 1.15 (0.03 – 0.11, 3.0 – 10.0)
With all oil seals P1 + 0.7 – 1.0 (0.08 – 0.1, 7.0 – 8.0)
Total preload Without oil seals (for transfer cover and
P1 + 0.5 – 0.8 (0.06 – 0.08, 5.0 – 7.0)
transfer case)
Backlash INFOID:0000000010992058
Unit: mm (in)
Item Standard
Ring gear to drive pinion 0.16 – 0.21 (0.0063 – 0.0083)
Companion Flange Runout INFOID:0000000010992059
Unit: mm (in)
Item Standard
Companion flange face runout 0.15 (0.0059) or less
Inner side of the companion flange runout 0.1 (0.004) or less
DLN-108
< HOW TO USE THIS MANUAL > [TRANSFER: TY30A]
HOW TO USE THIS MANUAL A

Information INFOID:0000000011058862
B
Both “VDC” and “ESP” are used in this manual. These indicate the same system.
C
DLN
DLN-109
PRECAUTIONS
< PRECAUTION > [TRANSFER: TY30A]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000011003962
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
NOTE:
NOTE:
SEF289H
NOTE:
INSTRUCTION 1
1. Open the hood.
DLN-110
PRECAUTIONS
3. Get out of the vehicle and close the driver side door. A
B
K9K engine : 4 minutes C
V9X engine : 4 minutes DLN
CAUTION:
this caution results in the activation of ACC power supply according to the Auto ACC function. E
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC. F
NOTE: G
3. Open the hood. H
CAUTION: I
6. Remove 12V battery terminal. J
CAUTION:
Precaution for Stop/Start System Service INFOID:0000000011046001
K
CAUTION:
When performing an inspection and its related work with the engine at idle, always turn the stop/start L
OFF switch ON or open the hood to release the stop/start system.
Service Notice or Precautions for Transfer INFOID:0000000011003964
M
• Use recommended transfer oil only, refer to MA-23, "Fluids and Lubricants".
• Never reuse transfer oil, once it has been drained.
• Check the oil level or replace the oil only with the vehicle parked on level ground. N
• During removal or installation, keep inside of transfer clear of dust or dirt.
• Replace all tires at the same time. Always use tires of the proper size and the same brand and pattern. Fit-
ting improper size and unusually worn tires applies excessive force to vehicle mechanism and can cause
longitudinal vibration. O
• Disassembly should be done in a clean work area, it is preferable to work in dustproof 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
• All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
certain they do not interfere with the function of the parts when applied.
• 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 be replaced any time the transfer is disassembled.
DLN-111
PRECAUTIONS
ening sequence is specified, use it.
• Observe the specified torque when assembling.
• Clean inner parts with lint-free cloth or towels. Do not use cotton work gloves and rags to prevent adhering
fibers.
DLN-112
PREPARATION
< PREPARATION > [TRANSFER: TY30A]
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000011003965
B
Tool number
Description C
Tool name
ST30720000 • Installing adapter case oil seal (inner/outer)
Drift • Installing drive pinion oil seal
a: 77 mm (3.03 in) dia. DLN
b: 55.5 mm (2.185 in) dia.
E
NT115
ST27861000 • Installing adapter case oil seal (inner/outer)

Drift • Installing drive pinion oil seal F
a: 62 mm (2.44 in) dia.
b: 52 mm (2.05 in) dia.
G
ZZA1003D
H
ST22730000 • Removing inner race of ring gear shaft bear-
Replacer ing (transfer case side)
• Removing inner race of drive pinion bearing
(front side) I
J
ZZA0700D
ST33052000 • Removing ring gear

Drift • Removing inner race of drive pinion bearing
K
a: 22 mm (0.87 in) dia. (front side)
b: 28 mm (1.10 in) dia.
NT116
ST01530000 Installing ring gear M

Drift
a: 48 mm (1.89 in) dia.
b: 41 mm (1.61 in) dia.
N
ZZA0534D O
ST35272000 • Installing ring gear
Drift • Installing outer race of drive pinion bearing
a: 72 mm (2.83 in) dia. (front side) P
b: 40 mm (1.57 in) dia.
c: 35.5 mm (1.398 in) dia.
NT107
DLN-113
PREPARATION
Tool number
Description
Tool name
KV10111400 Installing inner race of ring gear shaft bearing
Drift (transfer case side)
a: 25 mm (0.98 in) dia.
b: 20.8 mm (0.819 in) dia.
ZZA1003D
KV381054S0 Removing drive pinion oil seal

Puller
ZZA0601D
ST23860000 Installing inner race of drive pinion bearing

Drift (front side)
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
ZZA0534D
ST3127S000 Measuring preload torque

Preload gauge
ZZA0503D
ST38280000 Installing outer race of drive pinion bearing

Bushing remover (front side)
NT685
ST33230000 Installing outer race of drive pinion bearing

Drift (rear side)
a: 51 mm (2.01 in) dia.
ZZA0938D
DLN-114
PREPARATION
Commercial Service Tool INFOID:0000000011003966

Drift Installing adapter case oil seal (inner) B
a: 63 mm (2.48 in) dia.
b: 58 mm (2.28 in) dia.
ZZA1003D DLN
Drift Installing adapter case oil seal (outer)
a: 90 mm (3.54 in) dia.
b: 88 mm (3.46 in) dia. E
F
ZZA1003D
Drift Removing inner race of ring gear shaft bear-

a: 12 mm (0.47 in) dia. ing (transfer case side) G
b: 18 mm (0.71 in) dia.
ZZA1178D
I
Drift Removing inner race of ring gear shaft bear-
a: 49 mm (1.93 in) dia. ing (adapter case side)
b: 67 mm (2.64 in) dia.
J
K
NT660
Drift Installing outer race of ring gear shaft bearing

a: 80 mm (3.15 in) dia. (adapter case side)
b: 50 mm (1.97 in) dia. L
ZZA1000D
DLN-115
PREPARATION
Drift Installing inner race of ring gear shaft bearing
a: 57 mm (2.24 in) dia. (adapter case side)
b: 47 mm (1.85 in) dia.
ZZA1003D
Installing outer race of drive pinion bearing

Drift (front side)
a: 61 mm (2.40 in) dia.
b: 48 mm (1.89 in) dia.
ZZA1000D
Item Use
Genuine Liquid Gasket
Application to threads of plug
(Three Bond 1217 or equivalent)
DLN-116
COMPONENT PARTS
< SYSTEM DESCRIPTION > [TRANSFER: TY30A]
SYSTEM DESCRIPTION A
COMPONENT PARTS
Component Parts Location INFOID:0000000011003968
B
LHD MODELS
C
DLN
K
JSDIA6448ZZ
Console switch panel Rear wheel house outer panel in lug- Rear final drive L
No. Component Function M

ECM • Engine speed signal N
For detailed installation location, refer to EC-812, "Component Parts Location".
O
Combination meter
• 4WD mode indicator lamp signal P
For detailed installation location, refer to MWI-7, "METER SYSTEM : Component Parts
Location".
DLN-117
COMPONENT PARTS
ABS actuator and electric unit (con- • Decel G sensor signal
4WD control unit
RHD MODELS
JSDIA6451ZZ
Console switch panel Rear wheel house outer panel in lug- Rear final drive
DLN-118
COMPONENT PARTS
No. Component Function A

ECM • Engine speed signal
B
For detailed installation location, refer to EC-812, "Component Parts Location".
• Each wheel speed signal C
ABS actuator and electric unit (con- • Decel G sensor signal
DLN
For detailed installation location, refer to BRC-14, "Component Parts Location". E
Mainly receives the following signals from 4WD control unit via CAN communication. F
Combination meter
For detailed installation location, refer to MWI-7, "METER SYSTEM : Component Parts G
Location".
4WD control unit
H
I
4WD Control Unit INFOID:0000000011003969

J
• Controls driving force distribution by signals from each sensor from
front wheel driving mode (100:0) to 4-wheel driving mode (50:50).
• Fail-safe mode is available if malfunction is detected in 4WD sys- K
tem. For fail-safe, refer to DLN-125, "4WD SYSTEM : Fail-Safe".
M
JSDIA6388ZZ
4WD ACTUATOR RELAY N

4WD actuator relay is integrated with 4WD control unit, and supplies 4WD solenoid with voltage.
O
Electric controlled coupling is integrated with rear final drive and transmits driving force to rear final drive. For
operation, refer to DLN-121, "Operation Description".
4WD Solenoid INFOID:0000000011003971 P
• 4WD solenoid is integrated with electric controlled coupling.

• Controls electric controlled coupling by command current from 4WD control unit.
DLN-119
COMPONENT PARTS
4WD Mode Switch INFOID:0000000011003972
4WD mode is selectable among 2WD mode, AUTO mode, and

LOCK mode by operating the 4WD mode switch while the engine is
running.
JSDIA6389ZZ
DLN-120
A
DLN
I
JSDIA0206ZZ
Transfer case Adapter case Ring gear shaft J

Ring gear Companion flange Drive pinion
Operation Description INFOID:0000000011003974 K
POWER TRANSFER DIAGRAM

L
JSDIA0208ZZ
O
Engine Transaxle Transfer

Propeller shaft Electric controlled coupling Rear final drive P
DLN-121
1. The 4WD control unit supplies command current to electric con-
trolled coupling (4WD solenoid).
2. The control clutch is engaged by electromagnet and torque is
detected in control clutch.
3. The cam operates in response to control clutch torque and
applies pressure to main clutch.
4. The main clutch transmits torque to front wheels according to
pressing power.
JSDIA0972GB
• Transmission torque to the rear wheels is determined accord-

ing to command current.
SDIA1844E
DLN-122
SYSTEM
SYSTEM
A
4WD SYSTEM
4WD SYSTEM : System Description INFOID:0000000011003975
B
mized torque distribution adapted to road condition change. C
• Driving mode is selectable among 2WD mode, AUTO mode, and LOCK mode by operating the 4WD mode
switch.
• In accordance with fail-safe function, when system is malfunctioning, 4WD control stops, and the system
becomes 2WD or slight 4WD (rear-wheels still have some driving torque). Refer to DLN-125, "4WD SYS- DLN
TEM : Fail-Safe".
• When a high load status continues for electric controlled coupling, 4WD control temporarily becomes front
wheel drive, according to protection function. Refer to DLN-126, "4WD SYSTEM : Protection Function". E
SYSTEM DIAGRAM
JSDIA6449GB N
Signal with Communication Line
Major signal transmission between each unit via CAN communication lines are shown in the following table.
O
• Parking brake switch signal P
Combination meter
Steering angle sensor
• Steering angle sensor signal
DLN-123
SYSTEM
ABS actuator and electric unit (control unit) • Decel G sensor signal
• Side G sensor signal
ECM
4WD SYSTEM : Control in Each Mode INFOID:0000000011003976
2WD MODE
• Vehicle is in front-wheel drive.
CAUTION:
If front wheels are slipping in 2WD mode, never switch to AUTO or LOCK. This can cause difficulties
for the system.
NOTE:
The 4WD control unit may distribute the minimum necessary driving torque to rear wheels even when the
2WD mode is selected, depending on the driving condition. (However AUTO or LOCK indicator lamp does not
illuminate.)
AUTO MODE
• Electronic control allows optimal distribution of torque to front/rear wheels to match road conditions.
mized torque distribution adapted to road condition change.
• Sensor inputs determine the vehicle's turning condition, and tight cornering/braking are controlled by distrib-
uting optimum torque to rear wheels.
Vehicle Starts Control
• At the start, torque distribution for front and rear wheels is fixed by electric control and stable start is
achieved.
• Makes possible stable driving, with no wheel spin, on snowy roads or other slippery surfaces.
Normal Control
• On roads which do not require 4WD, it contributes to improved fuel economy by driving in conditions close to
front-wheel drive and it results in better fuel efficiency.
• When spin occurs on front wheel, distribute optimum torque to rear wheel and keep stable driving.
• The vehicle cornering status is judged according to information from each sensor, and the optimum torque is
distributed to rear wheels for preventing tight cornering/braking symptom.
LOCK MODE
• Front/rear wheel torque distribution is fixed, ensuring stable driving when climbing slopes.
• In LOCK mode, the pressing force to the multiple disc clutches is maximized by the electronic control and
the driving torque distribution of front and rear wheels is fixed to obtain the 4WD status of approximately 50 :
50.
NOTE:
Only torque distribution may be switched to the control same as the one in AUTO mode, depending on the
driving condition.
• LOCK mode will change to AUTO mode automatically, when the vehicle has been driven at a high speed.
Then LOCK mode control is canceled and the LOCK indicator lamp turns off.
• When vehicle speed exceeds the specified speed, the mode cannot be switched from AUTO mode to LOCK
mode.
• LOCK mode will change to AUTO mode automatically, when the ignition switch is turned OFF in LOCK
mode.
NOTE:
If there is a significant difference in pressure or wear between tires, full vehicle performance is not available.
Tire conditions are detected, and LOCK mode may be prohibited, or else speeds at which LOCK mode is
enabled may be restricted.
DLN-124
SYSTEM
4WD SYSTEM : Circuit Diagram INFOID:0000000011003977
DLN
JSDIA6450GB
M
4WD SYSTEM : Fail-Safe INFOID:0000000011003978
If any malfunction occurs in 4WD electrical system, and control unit detects the malfunction, 4WD warning on
information display (combination meter) is displayed to indicate system malfunction. And then 4WD control N
DLN-125
SYSTEM

•C1201
•C1204
•C1209
•P1804
•P1809
•P1811
•P181F
•C1203
•C1210
•U1000
•U1010
4WD SYSTEM : Protection Function INFOID:0000000011003979

—
ing".
NOTE:
INFORMATION DISPLAY (COMBINATION METER)
INFORMATION DISPLAY (COMBINATION METER) : 4WD Warning INFOID:0000000011003980
DESIGN/PURPOSE
4WD warning is displayed when the 4WD system has a malfunction. 4WD warning indicates that the vehicle is
in fail-safe mode or protection function mode.
Symbol Message Condition

4WD Error
4WD system malfunction.
Protection function is activated due to heavy load to
4WD High Temp. electric controlled coupling. (4WD system is not
Stop vehicle malfunctioning and 4WD system changes to front
wheel drive.)
Tire Size Incorrect

Large difference in diameter of front/rear tires.
JPNIA1896ZZ
SYNCHRONIZATION WITH MASTER WARNING LAMP

Applicable
For master warning lamp, refer to MWI-47, "WARNING LAMPS/INDICATOR LAMPS : Master Warning Lamp".
DLN-126
SYSTEM
SYSTEM DIAGRAM
A
DLN
E
JSDIA6028GB
SIGNAL PATH
F
• The 4WD control unit judges and decides a mode from among normal mode, fail-safe mode, and protection
function mode, according to signals received from each switch, sensor, and control unit.
• The 4WD control unit transmits 4WD warning signal to the combination meter via CAN communication when
judging fail-safe mode or protection function mode. G
• The combination meter displays 4WD warning on the information display when receiving 4WD warning sig-
nal transmitted from the 4WD control unit.
WARNING CONDITION H
4WD warning is displayed when the 4WD system goes into fail-safe mode or protection function mode.
WARNING CANCEL CONDITION
I
When any of the conditions listed below is satisfied:
• Ignition switch is in a position other than ON.
• 4WD warning becomes invisible when the 4WD system returns to normal.
J
INFORMATION DISPLAY (COMBINATION METER) : 4WD Torque Distribution Indica-
tor INFOID:0000000011003981
K
DESIGN/PURPOSE
Design Purpose L
Displays the drive torque distribution to the front and rear wheels while driving and informs M
the driver of this.
NOTE:
The driving force distribution may not match actual one. This is not a system malfunction.
N
JSNIA6722ZZ
WARNING/INDICATOR/CHIME LIST
O
WARNING/INDICATOR/CHIME LIST : Warning Lamp/Indicator Lamp INFOID:0000000011003982
P
4WD indicator lamp For function: Refer to MWI-23, "WARNING LAMPS/INDICATOR LAMPS : 4WD Indica-
DLN-127
SYSTEM
LOCK indicator lamp For function: Refer to MWI-23, "WARNING LAMPS/INDICATOR LAMPS : 4WD Indica-
WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display)

INFOID:0000000011003983
Name Function
Refer to DLN-126, "INFORMATION DISPLAY (COMBINATION METER) : 4WD Warn-
4WD warning
ing".
Refer to DLN-127, "INFORMATION DISPLAY (COMBINATION METER) : 4WD Torque
4WD torque distribution indicator
Distribution Indicator".
DLN-128
A
CONSULT Function INFOID:0000000011003984
APPLICATION ITEMS B
CONSULT can display each diagnostic item using the diagnostic test modes as follows.
Diagnostic test mode Function C

ECU Identification 4WD control unit part number can be read.
Self Diagnostic Result Self-diagnostic results and freeze frame data can be read and erased quickly.*
Data Monitor Input/Output data in the 4WD control unit can be read. DLN
Diagnostic Test Mode in which CONSULT drives some actuators apart from the 4WD control unit
Active Test
and also shifts some parameters in a specified range.
E
This mode enable a technician to adjust some devices faster and more accurately by following the
Work support
indication on the CONSULT.
*: The following diagnosis information is erased by erasing.
• DTC F
• Freeze frame data (FFD)
ECU IDENTIFICATION G
4WD control unit part number can be read.
SELF DIAGNOSTIC RESULT
Refer to DLN-134, "DTC Index". H
When “PRSNT” is displayed on self-diagnosis result.
• The system is presently malfunctioning.
I
When “PAST” is displayed on self-diagnosis result.
• System malfunction in the past is detected, but the system is presently normal.
FREEZE FRAME DATA (FFD) J
The following vehicle status is recorded when DTC is detected and is displayed.

K
ODO/TRIP METER (km/h or mph) Odometer value via CAN communication line is displayed.
ABS OPERATION SIG (On/Off) ABS operation status via CAN communication line is displayed.
VDC OPERATION SIG (On/Off) VDC operation status via CAN communication line is displayed. L
TCS OPERATION SIG (On/Off) TCS operation status via CAN communication line is displayed.
HI COEF FRIC FLG 1 (LOW/HIGH) Measured friction of load is displayed when vehicle starts.
M
HI COEF FRIC FLG 2 (LOW/HIGH) Measured friction of load is displayed when vehicle during deceleration.
IGN VOLT (V) Ignition voltage supplied to 4WD control unit is displayed.
TARGET SOL CRNT (A) 4WD solenoid target current is displayed. N
SOLENOID CRNT (A) 4WD solenoid control current is displayed.
QUASI VEHICLE SPEED (km/h or mph) Vehicle speed calculated by 4WD control unit is displayed.
O
FRONT WHEEL SPEED (km/h or mph) Front wheel speed average calculated by 4WD control unit is displayed.
REAR WHEEL SPEED (km/h or mph) Rear wheel speed average calculated by 4WD control unit is displayed.
SLCT LVR POSI This item is not equipped, but displayed. P
OPERATION MODE Control status of 4WD mode is displayed.
FRONT RH WHEEL SPEED (km/h or mph) Wheel speed calculated by front RH wheel sensor signal is displayed.
FRONT LH WHEEL SPEED (km/h or mph) Wheel speed calculated by front LH wheel sensor signal is displayed.
REAR RH WHEEL SPEED (km/h or mph) Wheel speed calculated by rear RH wheel sensor signal is displayed.
REAR LH WHEEL SPEED (km/h or mph) Wheel speed calculated by rear LH wheel sensor signal is displayed.
DLN-129
DATA MONITOR
NOTE:

STOP LAMP SW (On/Off) Stop lamp switch signal status via CAN communication line is displayed.
ENG SPEED SIG (Run/Stop) Engine status is displayed.
ETS ACTUATOR (On/Off) Operating condition of 4WD actuator relay (integrated in 4WD control unit) is displayed.
4WD WARN LAMP (On/Off) Control status of 4WD warning (on information display) is displayed.
4WD MODE SW (AUTO/LOCK/2WD) 4WD mode switch status is displayed.
4WD MODE MON (AUTO/LOCK/2WD) Control status of 4WD is displayed.
DIS-TIRE MONI (mm) Improper size tire installed condition is displayed.
PARKING BRAKE SW SIG (On/Off) Parking switch signal status via CAN communication line is displayed.
4WD MODE SW (2WD) (On/Off) 4WD mode switch (2WD position) signal is displayed.
4WD MODE SW (AUTO) (On/Off) 4WD mode switch (AUTO position) signal is displayed.
4WD MODE SW (LOCK) (On/Off) 4WD mode switch (LOCK position) signal is displayed.
READY (Off/Running) This item is not equipped, but displayed.
BATTERY VOLT (V) Power supply voltage value of 4WD control unit is displayed.
THRTL POS SEN (%) Throttle opening status is displayed.
ETS SOLENOID (A) Monitored value of current at 4WD solenoid is displayed.
FR RH SENSOR (km/h or mph) Wheel speed calculated by front RH wheel sensor signal is displayed.
FR LH SENSOR (km/h or mph) Wheel speed calculated by front LH wheel sensor signal is displayed.
RR RH SENSOR (km/h or mph) Wheel speed calculated by rear RH wheel sensor signal is displayed.
RR LH SENSOR (km/h or mph) Wheel speed calculated by rear LH wheel sensor signal is displayed.
ACTIVE TEST
Use this mode to determine and identify the details of a malfunction based on self-diagnostic results or data
monitor. 4WD control unit gives drive signal to actuator with receiving command from CONSULT to check
operation of actuator.
Test item Condition Description

Change command current value to 4WD solenoid, and then change driving
mode. (Monitor value is normal if it is within approx. ±10% of command value.)
• Vehicle stopped
SOLENOID • Qu: Increase current value in increments of 0.2 A
• Engine running
(Detects 4WD solenoid) • Qd: Decrease current value in increments of 0.2 A
• No DTC detected
• UP: Increase current value in increments of 0.02 A
• DOWN: Decrease current value in increments of 0.02 A
CAUTION:
Never energize continuously for a long time.
WORK SUPPORT
Item Usage
UNIT CHARACTERISTICS DATA Display the unit characteristics of electric controlled coupling written to 4WD control unit.
UNIT CHARACTERISTICS WRITE Writes the unit characteristics of electric controlled coupling to 4WD control unit.
DLN-130
4WD CONTROL UNIT
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY30A]
ECU DIAGNOSIS INFORMATION A

4WD CONTROL UNIT
Reference Value INFOID:0000000011003985
B
VALUES ON THE DIAGNOSIS TOOL

NOTE: C
Monitor item Condition Value/Status DLN

Brake pedal: Depressed On
STOP LAMP SW
Brake pedal: Released Off
E
Engine stopped
Stop
(Engine speed: Less than 400 rpm)
ENG SPEED SIG
Engine running F
Run
(Engine speed: 400 rpm or more)
Engine stopped (Ignition switch: ON) Off
ETS ACTUATOR
Engine running On G
4WD warning (on information display): Displayed On
4WD WARN LAMP
4WD warning (on information display): Not displayed Off
H
4WD mode switch: AUTO AUTO
4WD MODE SW
4WD mode switch: LOCK I
LOCK
4WD mode switch: AUTO AUTO J
4WD mode switch: AUTO ⇒ LOCK Vehicle speed below 10 km/h (6 mph) AUTO ⇒ LOCK
4WD MODE MON
(When switching to LOCK mode) Vehicle speed above 10 km/h (6 mph) AUTO
4WD mode switch: LOCK ⇒ AUTO
K
Vehicle speed below 10 km/h (6 mph) LOCK ⇒ AUTO
(When switching to AUTO mode)
Vehicle running with normal size tire installed 0 – 4 mm
DIS-TIRE MONI
L
Vehicle running with improper size tire installed (Front/rear tire size differ-
4 – 8 mm, 8 – mm
ence, wear condition)
PARKING BRAKE SW Parking brake operated On

M
SIG Parking brake not operated Off
4WD mode switch: 2WD On
4WD MODE SW (2WD)
4WD mode switch: Except 2WD Off N
4WD mode switch: AUTO On
4WD MODE SW (AUTO)
4WD mode switch: Except AUTO Off
O
On
4WD MODE SW (LOCK) (State of hold of LOCK position)
4WD mode switch: Except LOCK Off
P
READY Always Off
BATTERY VOLT Always Battery voltage
When depressing accelerator pedal
THRTL POS SEN 0 – 100%
(Value rises gradually in response to throttle position.)
DLN-131
4WD CONTROL UNIT
Monitor item Condition Value/Status
Engine running
AUTO mode Approx. 0.000 A
• At idle speed
ETS SOLENOID
Engine running
AUTO mode Approx. 0.000 – 2.490 A*
• 3,000 rpm or more constant
FR RH SENSOR Vehicle running Nearly matches the speed

FR LH SENSOR Vehicle running Nearly matches the speed

RR RH SENSOR Vehicle running Nearly matches the speed

RR LH SENSOR Vehicle running

Nearly matches the speed
CAUTION:
meter display (±10%)
Check air pressure of tire under standard condition.
*: The values are changed by throttle opening and engine speed.
TERMINAL LAYOUT
JSDIA0057ZZ
PHYSICAL VALUES
Terminal No.
Description
(Wire color)
Input/
+ - Signal name
Output
2WD mode 0V
Engine speed: At idle AUTO mode 0V
1 4WD solenoid power LOCK mode 0V

Ground Output
(SB) supply 2WD mode 0V
Engine speed: 3,000
AUTO mode 2.5 V*
rpm or more constant
LOCK mode 8V
2 Engine speed: At idle 0V

Ground 4WD solenoid ground Input
(Y) Engine speed: 3,000 rpm or more constant 0V
DLN-132
4WD CONTROL UNIT
Terminal No.
Description
(Wire color) A
Input/
+ - Signal name
Output
4WD mode switch: 2WD Battery voltage B
5 4WD mode switch (AU- 4WD mode switch: AUTO 0V
(V) TO)
0V C
7 Ignition switch: ON Battery voltage

Ground Ignition switch Input
(LA/R) Ignition switch: OFF 0V
DLN
8 Input/
— CAN-H — —
(L) Output
9 Power supply (4WD so- E
Ground Input Always Battery voltage
(LA/G) lenoid)
10
(B)
F
11
(B)
4WD mode switch: 2WD 0V
G
(GR) (2WD)
Battery voltage
(State of hold of LOCK position) H
4WD mode switch: 2WD Battery voltage
(Y) (LOCK) I
0V
15 Power supply (4WD
Ground Input Always Battery voltage J
(LA/L) control unit)
16 Input/
— CAN-L — —
(P) Output
*: The values are changed by depressed accelerator pedal opening and engine speed. K
CAUTION:
When using circuit tester to measure voltage for inspection, be sure not to extend forcibly any con-
nector terminals. L
Fail-Safe INFOID:0000000011003986
If any malfunction occurs in 4WD electrical system, and control unit detects the malfunction, 4WD warning on M
N
•C1201
•C1204
•C1209
O
•P1804
•P1809
•P1811 P
•P181F
DLN-133
4WD CONTROL UNIT
•C1203
•C1210
•U1000
•U1010
Protection Function INFOID:0000000011003987

—
ing".
NOTE:
DTC Inspection Priority Chart INFOID:0000000011003988
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
Priority Detected items (DTC)

1 • C1201 CONTROLLER FAILURE
• U1000 CAN COMM CIRCUIT
2
• U1010 CONTROL UNIT (CAN)
• C1203 ABS SYSTEM
• C1210 ENGINE SIGNAL 1
3
• P1808 VHCL SPEED SEN-ABS
• P181D ENGINE SYSTEM
• C1204 4WD SOLENOID
5
• P1811 BATTERY VOLTAGE
6 • C1209 MODE SW
• P181B INCOMP SELFSHUT
8
• P181F INCOMP CALIBRATION
DTC Index INFOID:0000000011003989

C1201 CONTROLLER FAILURE DLN-146, "DTC Description"
C1203 ABS SYSTEM DLN-147, "DTC Description"
C1204 4WD SOLENOID DLN-148, "DTC Description"
DLN-134
4WD CONTROL UNIT
A
C1209 MODE SW DLN-151, "DTC Description"
C1210 ENGINE SIGNAL 1 DLN-154, "DTC Description"
P1804 CONTROL UNIT DLN-155, "DTC Description" B
P1808 VHCL SPEED SEN-ABS DLN-156, "DTC Description"
P1809 CONTROL UNIT DLN-157, "DTC Description"
P1811 BATTERY VOLTAGE DLN-158, "DTC Description" C
P181B INCOMP SELF SHUT DLN-161, "DTC Description"
P181D ENGINE SYSTEM DLN-164, "DTC Description"
DLN
P181F INCOMP CALIBRATION DLN-165, "DTC Description"
U1000 CAN COMM CIRCUIT DLN-166, "DTC Description"
U1010 CONTROL UNIT (CAN) DLN-167, "DTC Description" E
NOTE:
If some DTCs are displayed at the same time, refer to DLN-134, "DTC Inspection Priority Chart".
F
DLN-135
4WD SYSTEM
< WIRING DIAGRAM > [TRANSFER: TY30A]
WIRING DIAGRAM
4WD SYSTEM
Wiring Diagram INFOID:0000000011003990
JRDWC2863GB
DLN-136
4WD SYSTEM
DLN
JRDWC2864GB
DLN-137
4WD SYSTEM
JRDWC2865GB
DLN-138
4WD SYSTEM
DLN
JRDWC2866GB
DLN-139
4WD SYSTEM
JRDWC2867GB
DLN-140
< BASIC INSPECTION > [TRANSFER: TY30A]
BASIC INSPECTION A
Work Flow INFOID:0000000011003991
B
DETAILED FLOW
1.INTERVIEW FROM THE CUSTOMER C
Clarify customer complaints before inspection. First of all, perform an interview utilizing DLN-142, "Diagnostic
Work Sheet" and reproduce symptoms as well as fully understand it. Ask customer about his/her complaints
carefully. Check symptoms by driving vehicle with customer, if necessary. DLN
CAUTION:
Customers are not professional. Never guess easily like “maybe the customer means that...,” or
“maybe the customer mentions this symptom”. E
>> GO TO 2.
2.CHECK SYMPTOM F
Reproduce the symptom that is indicated by the customer, based on the information from the customer
obtained by interview. Also check that the symptom is not caused by protection function. Refer to DLN-134,
"Protection Function". G
CAUTION:
When the symptom is caused by normal operation, fully inspect each portion and obtain the under-
standing of customer that the symptom is not caused by a malfunction. H
>> GO TO 3.
3.PERFORM SELF-DIAGNOSIS I
With CONSULT
Perform self-diagnosis for “ALL MODE AWD/4WD”. J
YES >> Record or print self-diagnosis results. GO TO 4.
NO >> GO TO 6. K
4.RECHECK SYMPTOM
With CONSULT
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”. L
2. Perform DTC confirmation procedures for the error detected system.
NOTE:
If some DTCs are detected at the same time, determine the order for performing the diagnosis based on DLN- M
134, "DTC Inspection Priority Chart".
YES >> GO TO 5. N
5.REPAIR OR REPLACE ERROR-DETECTED PARTS O
• Repair or replace error-detected parts.
• Reconnect part or connector after repairing or replacing.
• When DTC is detected, erase self-diagnostic results for “ALL MODE AWD/4WD”. P
>> GO TO 7.
6.IDENTIFY ERROR-DETECTED SYSTEM BY SYMPTOM DIAGNOSIS
Estimate error-detected system based on symptom diagnosis and perform inspection.
Can the error-detected system be identified?
DLN-141
YES >> GO TO 7.
7.FINAL CHECK
With CONSULT
1. Check the reference value for 4WD control unit.
2. Recheck the symptom and check that symptom is not reproduced on the same conditions.
Is the symptom reproduced?
YES >> GO TO 3.
NO >> INSPECTION END
Diagnostic Work Sheet INFOID:0000000011003992
Description
• In general, customers have their own criteria for a problem. Therefore, it is important to understand the
symptom and status well enough by asking the customer about his/her concerns carefully. To systemize all
the information for the diagnosis, prepare the interview sheet referring to the interview points.
• In some cases, multiple conditions that appear simultaneously may cause a DTC to be detected.
Interview sheet sample
Interview sheet
MR/MS
name
Vehicle type VIN
Vehicle does not enter 4WD mode.
4WD warning (4WD Error) is displayed.
Heavy tight-corner braking symptom occurs
Symptom
Noise Vibration
Others
( )
First occurrence Recently Others ( )
Frequency of occurrence Always Under a certain conditions of Sometimes (time(s)/day)
Irrelevant
Climate con- Weather Fine Cloud Rain Snow Others ( )

ditions Temperature Hot Warm Cool Cold Temperature (Approx. °C)
Relative humidity High Moderate Low
Urban area Suburb area High way
Road conditions
Mounting road (uphill or down hill) Rough road
Irrelevant
When engine starts During idling
Operation conditions, etc.
During driving During acceleration At constant speed driving
During deceleration During cornering (right curve or left curve)
DLN-142
Interview sheet
A
MR/MS
name
Vehicle type VIN
B
Other conditions
C
Memo
DLN
DLN-143
When replacing 4WD control unit, unit characteristics writing is required.

1.PERFORM WRITING UNIT CHARACTERISTICS

Perform writing unit characteristics of electric controlled coupling.
>> Refer to DLN-145, "Work Procedure".
DLN-144
A
When replacing 4WD control unit, rear final drive assembly and/or electric controlled coupling, unit character- B
istics of electric controlled coupling writing is required.
C
1.UNIT CHARACTERISTICS WRITING
With CONSULT
1. Confirm the unit characteristics of electric controlled coupling. DLN
NOTE:
Unit characteristics is 12-digit alphanumeric.
2. Turn the ignition switch OFF to ON. E
3. Select “UNIT CHARACTERISTICS WRITE” in “WORK SUP-
PORT” for “ALL MODE AWD/4WD”.
4. Input unit characteristics.
5. Select “Start”. F
6. Check that “UNIT CHARACTERISTICS WRITE COMPLETED”
is displayed.
JSDIA5446ZZ
G
>> WORK END
DLN-145
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY30A]
DTC/CIRCUIT DIAGNOSIS
DTC DETECTION LOGIC

CONTROLLER FAILURE
C1201 Malfunction has occurred inside 4WD control unit.
(Control unit failure)
POSSIBLE CAUSE
FAIL-SAFE
front-wheel drive.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
With CONSULT
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Turn the ignition switch OFF, and then wait 10 seconds or more.
DLN-146
A

ABS SYSTEM Malfunction related to wheel sensor has been detected by
C1203
(ABS system) ABS actuator and electric unit (control unit).
POSSIBLE CAUSE DLN

ABS malfunction
• Vehicle speed signal error
E
FAIL-SAFE
F
1.PRECONDITIONING
G
H
>> GO TO 2.
With CONSULT I
1. Drive at 30 km/h (19 MPH) or more for approximately 1 minute.
Is DTC “C1203” detected? J
NO-2 >> Confirmation after repair: INSPECTION END K
1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS L
With CONSULT
M
NO >> GO TO 2.
N
Is inspection result normal? O
NO >> Repair or replace error-detected parts. P
DLN-147
C1204 4WD SOLENOID
C1204 4WD SOLENOID
DTC DETECTION LOGIC

4WD SOLENOID
C1204 Malfunction related to 4WD solenoid has been detected.
(4WD solenoid)
POSSIBLE CAUSE
• Internal malfunction of electronic controlled coupling
• Malfunction of 4WD solenoid power supply circuit (open or short)
• Malfunction of 4WD solenoid command current
FAIL-SAFE
front-wheel drive.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT

4WD control unit

— Voltage
Connector Terminal
CAUTION:
4WD control unit

— Voltage
Connector Terminal
DLN-148
C1204 4WD SOLENOID
YES >> GO TO 3.
NO >> GO TO 2. A
B
tor. C

Continuity DLN
B5 9 M2 15B Existed
5. Check the continuity between 4WD control unit harness connector and the ground. E
4WD control unit

— Continuity
Connector Terminal F
G
H
3.CHECK 4WD SOLENOID GROUND
Check the continuity between 4WD control unit harness connector and ground.
I
4WD control unit
— Continuity
Connector Terminal
J
10
B5 Ground Existed
11
Is the inspection result normal? K
YES >> GO TO 4.
4.CHECK 4WD SOLENOID CIRCUIT (1) L
Check the resistance between 4WD control unit harness connector.
M
4WD control unit
Connector Terminal
B5 1 2 2.5 Ω N
YES >> GO TO 7.
NO >> GO TO 5. O
5.CHECK 4WD SOLENOID CIRCUIT (2)
1. Remove 4WD solenoid harness connector. P
2. Check the continuity between 4WD control unit harness connector and 4WD solenoid harness connector.
4WD control unit 4WD solenoid

Continuity
1 2
B5 C1 Existed
2 1
DLN-149
C1204 4WD SOLENOID
4WD control unit

— Continuity
Connector Terminal
1
B5 Ground Not existed
2
YES >> GO TO 6.
Check 4WD solenoid. Refer to DLN-150, "Component Inspection".
YES >> GO TO 7.
• Check 4WD solenoid pin terminals for damage or loose connection with harness connector.

2. Disconnect 4WD solenoid harness connector.
3. Check the resistance between 4WD solenoid harness connector terminals.
4WD solenoid
Terminal
1 2 2.5 Ω
DLN-150
C1209 MODE SW
C1209 MODE SW
A

MODE SW More than two switch inputs are simultaneously detected
C1209
(Mode switch) due to short circuit of 4WD mode switch.
POSSIBLE CAUSE DLN

• Malfunction of 4WD mode switch
• Malfunction of 4WD mode switch circuit
• Internal malfunction of 4WD control unit E
FAIL-SAFE
front-wheel drive. F

1.PRECONDITIONING G
H
>> GO TO 2.
With CONSULT
CAUTION: J
Stop the vehicle.
2. Operate 4WD mode switch to each position.
K
L
M
Check 4WD mode switch. Refer to DLN-153, "Component Inspection".
YES >> GO TO 2.
2.CHECK 4WD MODE SWITCH SIGNAL CIRCUIT O

2. Check the continuity between 4WD control unit harness connector and 4WD mode switch harness con-
P
nector.
DLN-151
C1209 MODE SW
4WD control unit 4WD mode switch

Continuity
3 Not existed
5 6 Existed
8 Not existed
3 Existed
B5 12 M8 6 Not existed
8 Not existed
3 Not existed
14 6 Not existed
8 Existed
4WD control unit

— Continuity
Connector Terminal
5
14
YES >> GO TO 3.
3.CHECK 4WD CONTROL SWITCH GROUND CIRCUIT
Check the continuity between 4WD mode switch harness connector and ground.
4WD mode switch

— Continuity
Connector Terminal
M8 2 Ground Existed
YES >> GO TO 4.
4.CHECK 4WD CONTROL UNIT OUTPUT SIGNAL
1. Connect 4WD control unit harness connector.
CAUTION:
3. Check the voltage between 4WD mode switch harness connector and ground.
4WD mode switch

— Voltage
Connector Terminal
3
M8 6 Ground Battery voltage
8
YES >> GO TO 5.
DLN-152
C1209 MODE SW
• Check 4WD mode switch pin terminals for damage or loose connection with harness connector. A
NO >> Repair or replace damaged parts. B
1.CHECK 4WD MODE SWITCH C

2. Remove 4WD mode switch.
DLN
3. Check the continuity between 4WD mode switch connector terminals.
4WD mode switch

Condition Continuity E
Terminal
4WD mode switch: 2WD Existed
4WD mode switch: AUTO F
3 2
4WD mode switch: LOCK Not existed
4WD mode switch: 2WD Not existed G
6 2
4WD mode switch: LOCK Existed
H
4WD mode switch: 2WD

Not existed
8 2 I
Existed
Is the inspection result normal? J
K
DLN-153
C1210 ECM
C1210 ECM
DTC DETECTION LOGIC

ENGINE SIGNAL 1
C1210 Malfunction related to engine signal has been detected.
(Engine signal 1)
POSSIBLE CAUSE
Malfunction of engine control system
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT

With CONSULT
YES >> Check the DTC. Refer to EC-908, "DTC Index".
NO >> GO TO 2.
DLN-154
A

CONTROL UNIT Malfunction is detected in the memory (EEPROM) system of
P1804
(Control unit) 4WD control unit.
POSSIBLE CAUSE DLN

Internal malfunction of 4WD control unit.
FAIL-SAFE E
front-wheel drive.
1.PRECONDITIONING
G
>> GO TO 2. H
With CONSULT
K

CAUTION:
M
DLN-155
DTC DETECTION LOGIC

• Malfunction is detected in vehicle speed signal that is out-
VHCL SPEED SEN-ABS put from ABS actuator and electric unit (control unit)
P1808
(Vehicle speed sensor-ABS) through CAN communication.
• Improper signal is input while driving.
POSSIBLE CAUSE
• ABS malfunction
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS

With CONSULT
NO >> GO TO 2.
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC “P1808”
DLN-156
A

CONTROL UNIT
P1809 AD converter system of 4WD control unit is malfunctioning.
(Control unit)
POSSIBLE CAUSE DLN

FAIL-SAFE E
front-wheel drive.
1.PRECONDITIONING
G
>> GO TO 2. H
With CONSULT
K

CAUTION:
M
DLN-157
DTC DETECTION LOGIC

BATTERY VOLTAGE When engine is running and 4WD control unit power supply
P1811
(Battery voltage) is less than 9 V or higher than 16 V.
POSSIBLE CAUSE
• Ignition power supply
FAIL-SAFE
front-wheel drive.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT

4WD control unit

Connector Terminal
B5 7 Ground 0V
CAUTION:
4WD control unit

— Voltage
Connector Terminal
DLN-158
YES >> GO TO 3. A
NO >> GO TO 2.
B
4. Check the continuity between 4WD control unit harness connector and fuse block (J/B) harness connec- C
tor.
4WD control unit Fuse block (J/B) DLN

Continuity
B5 7 M3 7C Existed
E
4WD control unit F

— Continuity
Connector Terminal
G
H
1. Turn the ignition switch OFF. I
4WD control unit J

Connector Terminal
K
CAUTION:
4. Check the voltage between 4WD control unit harness connector and ground. L
4WD control unit

— Voltage M
Connector Terminal
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK 4WD CONTROL UNIT POWER SUPPLY (4) O
3. Disconnect fuse block (J/B) harness connector. P
tor.

Continuity
DLN-159
4WD control unit

— Continuity
Connector Terminal
4WD control unit

— Continuity
Connector Terminal
10
B5 Ground Existed
11
YES >> GO TO 6.
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P1811” is detected, Replace 4WD control unit. Refer to DLN-179, "Removal and Installation".
DLN-160
A

INCOMP SELF SHUT When ignition switch is ON, self-shut of 4WD control unit
P181B
(Incomplete self shut) was incomplete.
POSSIBLE CAUSE DLN

• Ignition power supply E
FAIL-SAFE
No impact to vehicle behavior. F

1.PRECONDITIONING G
H
>> GO TO 2.
With CONSULT
2. Perform self-diagnosis for “ALL MODE AWD/4WD”. J
Is DTC “P181B” detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-44, "Intermittent Incident". K
L
2. Disconnect 4WD control unit harness connector. M
4WD control unit N

Connector Terminal
B5 7 Ground 0V
O
CAUTION:
P
4WD control unit

— Voltage
Connector Terminal
DLN-161
YES >> GO TO 3.
NO >> GO TO 2.
tor.

Continuity
B5 7 M3 7C Existed
4WD control unit

— Continuity
Connector Terminal
4WD control unit

Connector Terminal
CAUTION:
4WD control unit

— Voltage
Connector Terminal
YES >> GO TO 5.
NO >> GO TO 4.
tor.

Continuity
DLN-162
4WD control unit A

— Continuity
Connector Terminal
B
TERY POWER SUPPLY -". C
1. Turn the ignition switch OFF. DLN
4WD control unit E

— Continuity
Connector Terminal
10
B5 Ground Existed F
11
YES >> GO TO 6. G
H
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC I
“P181B” is detected, Replace 4WD control unit. Refer to DLN-179, "Removal and Installation".
J
DLN-163
DTC DETECTION LOGIC

ENGINE SYSTEM
P181D Malfunction related to engine signal has been detected.
(Engine system)
POSSIBLE CAUSE
• Malfunction of engine control system
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Stop the vehicle.
Is DTC “P181D” detected?

With CONSULT
YES >> Check the DTC. Refer to EC-908, "DTC Index".
NO >> GO TO 2.
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC “P181D”
DLN-164
A

INCOMP CALIBRATION When incomplete writing unit characteristics of electric con-
P181F
(Incomplete calibration) trolled coupling are detected.
POSSIBLE CAUSE DLN

Writing unit characteristics are incomplete.
FAIL-SAFE E
front-wheel drive.
1.PRECONDITIONING
G
>> GO TO 2. H
With CONSULT
1. Turn the ignition switch OFF to ON. I
K
1.PERFORM WRITING UNIT CHARACTERISTICS L

1. Erase self-diagnostic result for “ALL MODE AWD/4WD”.
2. Perform writing unit characteristics. Refer to DLN-145, "Work Procedure".
4. Perform self-diagnosis for “ALL MODE AWD/4WD”. M
Is any DTC except “P181F” detected?
NO >> GO TO 2. N
2.PERFORM SELF-DIAGNOSIS AGAIN

With CONSULT O
Perform “DTC CONFIRMATION PROCEDURE” (self-diagnosis) again. Refer to DLN-165, "DTC Description".
YES >> Replace 4WD control unit. Refer to DLN-179, "Removal and Installation". P
DLN-165
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring.
DTC DETECTION LOGIC

CAN COMM CIRCUIT 4WD control unit is not transmitting/receiving CAN commu-
U1000
(CAN communication circuit) nication signal for 2 seconds or more.
POSSIBLE CAUSE
• CAN communication error
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
Proceed to LAN-17, "Trouble Diagnosis Flow Chart".
DLN-166
A
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul- B
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring. C
DTC DETECTION LOGIC
DLN
CONTROL UNIT (CAN) Detecting error during the initial diagnosis of CAN controller
E
U1010
[Control unit (CAN)] of 4WD control unit.
POSSIBLE CAUSE F
FAIL-SAFE
4WD control changes to front-wheel drive gradually (rear-wheels still have some driving torque), then 4WD G
H
1.PRECONDITIONING
wait at least 10 seconds before conducting the next test. I
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE J
With CONSULT
1. Turn the ignition switch OFF to ON. K
YES >> Proceed to diagnosis procedure. Refer to DLN-167, "Diagnosis Procedure". L
Diagnosis Procedure INFOID:0000000011004026 M
1.CHECK 4WD CONTROL UNIT

Check 4WD control unit harness connector for disconnection and deformation. N
NO >> Repair or replace error-detected parts. O
DLN-167

4WD control unit

Connector Terminal
B5 7 Ground 0V
CAUTION:
4WD control unit

— Voltage
Connector Terminal
YES >> GO TO 3.
NO >> GO TO 2.
tor.

Continuity
B5 7 M3 7C Existed
4WD control unit

— Continuity
Connector Terminal
4WD control unit

Connector Terminal
DLN-168
CAUTION:
Never start the engine. A
4WD control unit B

— Voltage
Connector Terminal
C
YES >> GO TO 5.
NO >> GO TO 4.
DLN
2. Check the 5A fuse (#2). E
tor.
F

Continuity
Connector Terminal Connector Terminal G
H
4WD control unit
— Continuity
Connector Terminal
I
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-12, "Wiring Diagram - BAT- J
5.CHECK 4WD SOLENOID POWER SUPPLY (1) K
L
4WD control unit

— Voltage
Connector Terminal
M
CAUTION: N
O
4WD control unit
— Voltage
Connector Terminal
B5 9 Ground Battery voltage P
YES >> GO TO 7.
NO >> GO TO 6.
DLN-169
tor.

Continuity
B5 9 M2 15B Existed
4WD control unit

— Continuity
Connector Terminal
4WD control unit

— Continuity
Connector Terminal
10
B5 Ground Existed
11
DLN-170
4WD INDICATOR LAMP
4WD INDICATOR LAMP
A
1.4WD INDICATOR LAMP OPERATION CHECK B

Check that 4WD indicator lamp turns ON for several seconds after the ignition switch is turned ON.
C
DLN
With CONSULT E
YES >> Perform trouble diagnosis for detected DTC. Refer to DLN-134, "DTC Index". F
NO >> GO TO 2.
G
YES >> GO TO 3. H
3.CHECK 4WD INDICATOR LAMP SIGNAL
I
With CONSULT
CAUTION:
Stop the vehicle. J
2. Change 4WD mode switch from "2WD” to “AUTO”.
Does the item on “DATA MONITOR” indicate “AUTO”? K
Function".
NO >> Replace 4WD control unit. Refer to DLN-179, "Removal and Installation". L
DLN-171
LOCK INDICATOR LAMP
LOCK INDICATOR LAMP
1.LOCK INDICATR LMAP OPERATION CHECK

Check that LOCK indicator lamp turns ON for several seconds after the ignition switch is turned ON.
With CONSULT
NO >> GO TO 2.
YES >> GO TO 3.
3.CHECK LOCK INDICATOR LAMP SIGNAL
With CONSULT
CAUTION:
Stop the vehicle.
2. Change 4WD mode switch from "AUTO” to “LOCK”.
Does the item on “DATA MONITOR” indicate “LOCK”?
Function".
NO >> Replace 4WD control unit. Refer to DLN-179, "Removal and Installation".
DLN-172
< SYMPTOM DIAGNOSIS > [TRANSFER: TY30A]
SYMPTOM DIAGNOSIS A
B
Heavy tight-corner braking symptom occurs when the vehicle is driven and the steering wheel is turned fully to
either side after the engine is started.
NOTE: C
Light tight-corner braking symptom may occur depending on driving conditions. This is not malfunction.
DLN
With CONSULT E
YES >> Check the DTC. Refer to EC-908, "DTC Index". F
NO >> GO TO 2.
G
With CONSULT
H
YES >> Proceed to DLN-166, "Diagnosis Procedure".
NO >> GO TO 3.
3.CHECK 4WD SOLENOID I
Perform the trouble diagnosis of the 4WD solenoid. Refer to DLN-148, "Diagnosis Procedure".
YES >> GO TO 4. J
4.CHECK ELECTRIC CONTROLLED COUPLING K
2. Set the transaxle to neutral. Release the parking brake.
3. Lift up the vehicle.
4. Rotate the propeller shaft by hand. L
5. Hold rear wheel of right and left lightly.
Does rear wheel rotate?
YES >> Replace electric controlled coupling for mechanical malfunction (clutch sticking etc.). Refer to M
N
DLN-173
Vehicle does not enter 4-wheel drive mode even though 4WD warning is not displayed.
1.CHECK INFORMATION DISPLAY (COMBINATION METER)

Perform the trouble diagnosis of combination meter. Refer to MWI-84, "On Board Diagnosis Function".
YES >> GO TO 2.
2.CHECK PARKING BRAKE SWITCH SIGNAL
With CONSULT
Check “PARKING BRAKE SW SIG” of CONSULT “DATA MONITOR” for “ALL MODE AWD/4WD”.
Monitor Item Condition Status

When the parking brake is operation. On
PARKING BRAKE SW SIG
When the parking brake is not operation. Off
YES >> GO TO 3.
NO >> Proceed to BRC-107, "Diagnosis Procedure".
3.CRUISE TEST
Drive the vehicle for a period of time.
Does any symptom occur?
YES >> Replace electric controlled coupling for mechanical malfunction (mechanical engagement of
clutch is not possible). Refer to DLN-231, "Removal and Installation".
DLN-174
A
While driving, 4WD warning (4WD High Temp. Stop vehicle) is displayed on information display (combination B
meter).
• This symptom protects drivetrain parts when a heavy load is applied to the electric controlled coupling and
multiple disc clutch temperature increases. Also, optional distribution of torque sometimes becomes rigid
before 4WD warning (4WD High Temp. Stop vehicle) is displayed. Both cases are not malfunction. Refer to C
DLN-134, "Protection Function".
• When this symptom occurs, stop vehicle and allow it to idle for some times. Displays will stop and system
will be restored. DLN
DLN-175
While driving, 4WD warning (Tire Size Incorrect: See Owner’s Manual) is displayed on information display
(combination meter).
1.CHECK TIRE
Check the following.
• Tire pressure
• Wear condition
• Front and rear tire size (There is no difference between front and rear tires.)
YES >> GO TO 2.
NO >> Repair or replace error-detected parts. And then, drive the vehicle at speed of 20 km/h (12 MPH)
or more for 5 seconds or more. Improper size information is initialized accordingly.
2.CHECK INPUT SIGNAL OF TIRE DIAMETER
With CONSULT
2. Drive at 20 km/h (12 MPH) or more for approximately 4 minutes continually.
3. Check “DIS-TIRE MONI” of CONSULT “DATA MONITOR” for “ALL MODE AWD/4WD”.
Does the item on “DATA MONITOR” indicate “0 - 4 mm”?
NO >> GO TO 3.
3.TERMINAL INSPECTION
Check 4WD control unit harness connector for disconnection.
DLN-176
A
NVH Troubleshooting Chart INFOID:0000000011004039
Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If nec- B
essary, repair or replace these parts.

C
DLN

Reference
E
DLN-178, "Inspection"
F
TRANSFER OIL (Level too high)
BEARING (Worn or damaged)

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

TRANSFER OIL (Level low)
GEAR (Worn or damaged)

H
TRANSFER OIL (Wrong)
SUSPECTED PARTS
(Possible cause) I
Noise 1 2 3 3 3
Symptom
Transfer oil leakage 3 1 2 2 2 K
DLN-177
TRANSFER OIL
< PERIODIC MAINTENANCE > [TRANSFER: TY30A]
PERIODIC MAINTENANCE
TRANSFER OIL
OIL LEAKAGE
OIL LEVEL
1. Check oil level from filler plug mounting hole as shown in the fig-
ure, after removing filler plug and gasket from transfer assem-
bly.
CAUTION:
hole. Add transfer oil if necessary. Refer to DLN-178, "Refill-
ing".
2. Set a gasket on filler plug and install it on transfer assembly.
CAUTION:
3. Tighten filler plug to the specified torque. Refer to DLN-205,

"Exploded View".
Draining INFOID:0000000011004041
1. Run the vehicle to warm up the transfer unit sufficiently.

2. Stop the vehicle and turn the ignition switch OFF.
CAUTION:
Never remove plug for tooth contact test.
5. Set a gasket on drain plug and install it to transfer assembly.
CAUTION:
Never reuse gasket.
6. Tighten drain plug to the specified torque. Refer to DLN-205,
"Exploded View".
JSDIA6403ZZ
Refilling INFOID:0000000011004042
1. Fill with new transfer oil until oil level reaches the specified level
near filler plug mounting hole, after removing filler plug and
gasket from transfer assembly.

2. Leave the vehicle for 3 minutes, and check the oil level again.
3. Set a gasket on filler plug, and install it to transfer assembly.
CAUTION:
4. Tighten filler plug to the specified torque. Refer to DLN-205,

"Exploded View".
DLN-178
4WD CONTROL UNIT
< REMOVAL AND INSTALLATION > [TRANSFER: TY30A]
REMOVAL AND INSTALLATION A

4WD CONTROL UNIT
B
DLN
JSDIA5368GB
G
4WD control unit

H
: Vehicle front

I
REMOVAL
J
2. Remove luggage side lower finisher LH. Refer to INT-43, "LUGGAGE SIDE LOWER FINISHER :
Removal and Installation". K
4. Remove 4WD control unit mounting nuts and remove 4WD
control unit . L
: Vehicle front
NOTE: M
4WD control unit is located on the back side of the rear wheel
house outer panel LH.
N
AWDIA1154ZZ
INSTALLATION O
• Perform adjustment after installation. Refer to DLN-179, "Adjustment".
P

When replaced 4WD control unit, perform writing unit characteristics. Refer to DLN-145, "Work Procedure".
DLN-179
4WD MODE SWITCH
< REMOVAL AND INSTALLATION > [TRANSFER: TY30A]
4WD MODE SWITCH
JSDIA5457ZZ
4WD mode switch Console switch panel
REMOVAL
1. Remove console switch panel from center console assembly. Refer to IP-25, "Removal and Installation"
(LHD models), IP-52, "Removal and Installation" (RHD models).
2. Disconnect 4WD mode switch harness connector.
3. Remove 4WD mode switch from console switch panel.
INSTALLATION
Install in the reverse order of removal.
DLN-180
TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: TY30A]
UNIT REMOVAL AND INSTALLATION A

TRANSFER ASSEMBLY
B
DLN
JSDIA6409GB
H
Transfer gusset Transfer assembly O-ring

I
:Apply multi purpose grease. J
K
REMOVAL
1. Remove engine assembly together with transaxle assembly and transfer assembly from vehicle. Refer to
EM-366, "Removal and Installation". L
2. Remove transfer gusset .
3. Remove transaxle assembly together with transfer assembly
from engine assembly. Refer to TM-122, "Removal and Installa- M
tion".
O
JSDIA6418ZZ
DLN-181
TRANSFER ASSEMBLY
4. Remove transfer assembly from transaxle assembly.
CAUTION:
• Be careful not to remove wrong fixing bolts ( ). Never
remove the mounting bolts of adapter case.
• Never damage air breather hose.
• Never damage oil seal.
SDIA3225J
5. Remove O-ring from transfer assembly.

CAUTION:
• Never use a tool.
• Never damage adapter case.
JSDIA6419ZZ
INSTALLATION
• Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to transfer assembly.
CAUTION:
• When installing O-ring, never use a tool.
• Never damage adapter case and O-ring.
bolts following the standard below, tighten bolts to the specified
torque. For each tightening torque, refer to DLN-181, "Exploded
View".
Bolt symbol
Quantity 4 1
Bolt length
55 (2.17) 55 (2.17)
“L” mm (in)
CAUTION:
Apply anti-corrosion oil to the thread and seat of mounting bolts.
• For mounting bolts of transfer gusset , temporarily tightening
them first. After this, tighten bolts to the specified torque in the
order from engine side bolts to transfer side bolts . For tight-
ening torque, refer to DLN-181, "Exploded View".
Bolt symbol
Quantity 2 2
Bolt length
35 (1.38) 45 (1.77)
“L” mm (in)
JSDIA6411ZZ
Mounting position Engine cylinder block side Transfer side
• Perform inspection after installation. Refer to DLN-183, "Inspection".
DLN-182
TRANSFER ASSEMBLY
A
178, "Inspection". B
DLN
DLN-183
ADAPTER CASE
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY30A]
UNIT DISASSEMBLY AND ASSEMBLY

ADAPTER CASE
JSDIA0319GB
Adapter case oil seal (outer) O-ring (outer) Adapter case oil seal (inner)
Adapter case O-ring (inner) Ring gear shaft
Ring gear adjusting shim Ring gear shaft bearing Ring gear
(adapter case side) (adapter case side)
Ring gear nut Ring gear shaft bearing Ring gear adjusting shim
(transfer case side) (transfer case side)
Transfer case Air breather hose Air breather tube
Gasket Filler plug Drain plug
Plug Drive pinion Drive pinion adjusting shim
Drive pinion bearing (front side) Collapsible spacer Drive pinion bearing (rear side)
Drive pinion oil seal Companion flange Lock nut
Oil seal lip
DLN-184
ADAPTER CASE

A
*
: Apply anti-corrosive oil.
B
: Apply Genuine Liquid Gasket, Three Bond 1217 or equivalent. C
DLN
DISASSEMBLY
1. Remove O-ring (outer) from adapter case.
CAUTION: E
• Never use a tool.
F
JSDIA6419ZZ
H
2. Remove adapter case mounting bolts ( ).
K
SDIA3076J
3. Lightly tap adapter case with a plastic hammer to remove L

adapter case.
4. Remove O-ring (inner) from adapter case.
CAUTION:
• Never use a tool. M
5. Lightly tap the metal part of adapter case oil seal with punch
from back side of adapter case to remove adapter case oil seal. N
CAUTION:
When removing oil seal, never damage adapter case by
scooping it out with a tool. JSDIA0252ZZ
O
ASSEMBLY
1. Install O-ring (inner) to adapter case.
CAUTION: P
• Never reuse O-ring (inner).
• When installing O-ring (inner), never use a tool.
• Apply multi-purpose grease to O-ring (inner).
2. Install adapter case to the transfer case.
DLN-185
ADAPTER CASE
3. Apply anti-corrosive oil onto threads and seats of bolts ( ), and
tighten with the specified torque.
CAUTION:
Measure the total preload without the adapter case oil seal
(outer/inner).
SDIA3076J
5. Install adapter case oil seal (inner) to the adapter case with
drifts.
A : Drift (SST: ST30720000)

B : Drift (SST: ST27861000)
C : Drift (commercial service tool)
Dimension “D” : 0 – 1.0 mm

CAUTION:
• Never reuse oil seal. JSDIA0259ZZ
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference.
• Install adapter case oil seal (inner) in the direction shown in the figure.
6. Install adapter case oil seal (outer) to the adapter case with
drifts so that it becomes flush with adapter case end surface.

C : Drift (commercial service tool)
CAUTION:
• Never reuse oil seal.
JSDIA0214ZZ
• Install adapter case oil seal (outer) in the direction shown
in the figure.
7. Install O-ring (outer) to the adapter case.
CAUTION:
• Never reuse O-ring (outer).
• When installing O-ring (outer), never use a tool.
• Apply multi-purpose grease to O-ring (outer).

Case
DLN-186
RING GEAR SHAFT
RING GEAR SHAFT
A
DLN
L
JSDIA0319GB
Adapter case oil seal (outer) O-ring (outer) Adapter case oil seal (inner) M
(adapter case side) (adapter case side) N
O
Drive pinion bearing (front side) Collapsible spacer Drive pinion bearing (rear side) P
Oil seal lip

DLN-187
RING GEAR SHAFT

: Apply Genuine Liquid Gasket, Three Bond 1217 or equivalent.
DISASSEMBLY
1. Remove adapter case. Refer to DLN-185, "Disassembly and Assembly".
2. Remove adapter case oil seal (outer/inner) from the adapter case. Refer to DLN-185, "Disassembly and
Assembly".
3. Tap the ring gear adjusting shim from the cutout on the adapter
case with a brass rod to remove ring gear shaft bearing outer
race (adapter case side) and ring gear adjusting shim (adapter
case side).
CAUTION:
Be careful not to damage adapter case.
5. Remove outer race of ring gear shaft bearing (transfer case
side) and ring gear adjusting shim (transfer case side) from the
transfer case.
SDIA3079J
6. Remove inner race of ring gear shaft bearing (transfer case

side) from ring gear shaft with drift (A) (commercial service tool)
and replacer (B) (SST: ST22730000).
SDIA3080J
7. Remove ring gear nut .

CAUTION:
Never damage ring gear shaft.
SDIA3081J
DLN-188
RING GEAR SHAFT
8. Remove ring gear from ring gear shaft with a drift (A) (SST:
ST33052000). A
SDIA3082J
DLN
9. Remove inner race of ring gear shaft bearing (adapter case
side) from ring gear with a drift (A) (commercial service tool) and
separator.
E
G
SDIA3083J
ASSEMBLY
H
1. Select ring gear adjusting shim (transfer case side). Refer to DLN-195, "Adjustment".
2. Assemble the selected ring gear adjusting shim (transfer case side) and outer races of ring gear shaft
bearing (transfer case side) to the transfer case.
CAUTION: I
• Never reuse ring gear shaft bearing (transfer case side).
• Apply gear oil to the ring gear shaft bearing (transfer case side).
3. Select ring gear adjusting shim (adapter case side). Refer to DLN-195, "Adjustment". J
4. Install the selected ring gear adjusting shim (adapter case side) to the adapter case.
5. Install outer race of ring gear shaft bearing (adapter case side)
to the adapter case with a drift (A) (commercial service tool). K
CAUTION:
• Never reuse ring gear shaft bearing (adapter case side).
• Apply gear oil to the ring gear shaft bearing (adapter case L
side).
SDIA3102J
N
6. Install inner race of ring gear shaft bearing (adapter case side)
to the ring gear with drifts.
O
A : Press adapter (If necessary)
B : Drift (commercial service tool)
CAUTION: P
• Never reuse ring gear shaft bearing (adapter case side).
• Apply gear oil to the ring gear shaft bearing (adapter case
side).
SDIA3097J
DLN-189
RING GEAR SHAFT
7. Apply anti-corrosive oil to the spline of ring gear shaft. Install the
ring gear to ring gear shaft with drifts.

JSDIA0253ZZ
8. Apply anti-corrosive oil to threads and seats of ring gear nut.

Tighten the ring gear nut with the specified torque by using a
torque wrench.
CAUTION:
• Never reuse ring gear nut.
SDIA3100J
9. Install inner race of ring gear shaft bearing (transfer case side)
to the ring gear shaft with a drift (A) (SST: KV10111400).
CAUTION:
• Never reuse ring gear shaft bearing (transfer case side).
• Apply gear oil to the ring gear shaft bearing (transfer race
side).
11. Install adapter case. Refer to DLN-185, "Disassembly and
Assembly".
flange runout. Refer to DLN-195, "Adjustment". JSDIA0254ZZ
CAUTION:
Measure the total preload without the adapter case oil seal.
13. Install adapter case oil seal (outer/inner) to the adapter case. Refer to DLN-185, "Disassembly and
Assembly".

Gear and Shaft
CAUTION:
Bearing
damage.
CAUTION:
Always replace inner race and outer race as a pair when replacing the bearing.
Shim
Case
DLN-190
RING GEAR SHAFT
A
DLN
DLN-191
DRIVE PINION
DRIVE PINION
JSDIA0319GB
Adapter case oil seal (outer) O-ring (outer) Adapter case oil seal (inner)
(adapter case side) (adapter case side)
Drive pinion bearing (front side) Collapsible spacer Drive pinion bearing (rear side)
Oil seal lip

DLN-192
DRIVE PINION

A
B

C
DISASSEMBLY DLN
3. Remove lock nut from the drive pinion. E
4. Put matching marks (A) on screw ends of companion flange
and drive pinion.
CAUTION: F
Use paint to avoid scratching the surface.
H
SDIA3084J
5. Remove companion flange from drive pinion with a puller. I
SDIA3085J L
6. Remove drive pinion oil seal from the transfer case with a puller
(A) (SST: KV381054S0).
M
CAUTION:
SDIA3089J
DLN-193
DRIVE PINION
7. Remove drive pinion assembly from transfer case while tapping
the drive pinion lightly with a plastic hammer.
CAUTION:
Never drop the drive pinion assembly.
8. Remove collapsible spacer from the drive pinion.
9. Remove inner race of drive pinion bearing (rear side) from trans-
fer case.
SDIA3086J
10. Remove inner race of drive pinion bearing (front side) from drive
pinion with a drift (A) (SST: ST33052000) and replacer (B) (SST:
ST22730000).
11. Remove drive pinion adjusting shim from the drive pinion.
SDIA3087J
ASSEMBLY
1. Select drive pinion adjusting shim. Refer to DLN-195, "Adjustment".
2. Install selected drive pinion adjusting shim to drive pinion.
3. Install inner race of drive pinion bearing (front side) to drive pin-
ion with a drift (A) (SST: ST23860000).
CAUTION:
• Never reuse drive pinion bearing (front side).
• Apply gear oil to the drive pinion bearing (front side).
4. Assemble the inner race of drive pinion bearing (rear side) into
the transfer case.
CAUTION:
• Never reuse drive pinion bearing (rear side).
• Apply gear oil to the drive pinion bearing (rear side).
SDIA3094J
5. Install drive pinion oil seal to transfer case with drifts so that it
becomes flush with case end surface.

CAUTION:
6. Assemble a collapsible spacer onto the drive pinion.
SDIA3093J
CAUTION:
Never reuse the collapsible spacer.
DLN-194
DRIVE PINION
7. Assemble drive pinion assembly into the transfer case, and then
install companion flange to drive pinion. A
NOTE:
Align matching marks on the thread edge of companion
flange and drive pinion and install companion flange if drive pin- B
ion is reused.
SDIA3084J
DLN
8. Tap the companion flange with a plastic hammer as far as the
lock nut can be tightened.
CAUTION:
E
Never damage drive pinion oil seal.
9. Apply anti-corrosive oil to the thread and seat of the lock nut,
and temporarily tighten lock nut to the drive pinion.
CAUTION: F
Never reuse lock nut.
G
SDIA3095J
10. Tighten lock nut within the specified torque range with a preload H
gauge (A) (SST: ST3127S000) so that the drive pinion bearing
preload is within standard.
Drive pinion bearing preload : Refer to DLN-208, "Pre- I

load Torque".
CAUTION:
• Start the tightening of lock nut from lower limit of the J
specified torque. Check the preload every 5° to 10° while
tightening the lock nut.
• Replace the collapsible spacer and tighten it again to SDIA3072J
K
adjust if preload exceeds the specified value. Never
loosen lock nut to adjust preload.
• After adjustment, rotate the drive pinion back and forth from 2 to 3 times to check for unusual
L
noise, sticking, binding, and so on.
11. Install ring gear shaft assembly. Refer to DLN-188, "Disassembly and Assembly".
12. Install adapter case. Refer to DLN-185, "Disassembly and Assembly".
M
13. Check backlash, tooth contact, total preload and companion flange runout. Refer to DLN-195, "Adjust-
ment".
CAUTION:
Measure the total preload without the adapter case oil seal. N
O
BACKLASH
1. Install the bolt to the companion flange.
P
DLN-195
DRIVE PINION
2. Fit a dial indicator onto the bolt .
3. Measure the circumference backlash of the companion flange.
Backlash : Refer to DLN-208, "Backlash".

Disassemble the transfer assembly to check and adjust each
part if outside the standard.
JSDIA0321ZZ
TOOTH CONTACT
2. Remove ring gear shaft assembly from transfer case. Then
apply red lead or equivalent onto the ring gear.
CAUTION:
Apply red lead or equivalent to both faces of 3 to 4 gears at
4 locations evenly spaced on the ring gear.
Assembly".
5. Remove plug on the lower side of the transfer case.
JSDIA0255ZZ
6. Rotate the companion flange back and forth several times. Then
check drive pinion to ring gear tooth contact by viewing from the
tooth contact test hole.
: Drive side
: Reverse side
SDIA3067J
DLN-196
DRIVE PINION
A
DLN
H
JSDIA0213GB
7. Follow the procedure below to adjust pinion height (dimension

X) if tooth contact is improper.
For selecting adjusting shims, refer to the latest parts informa- I
tion.
CAUTION:
If no adjusting shim with the calculated value is available, J
select the thicker and closest one.
SDIA3158J
L
• Thicken the drive pinion adjusting shim to move the drive pin-
ion closer to the ring gear in case of face contact or heel con-
tact.
CAUTION: M
O
PDIA0440E
DLN-197
DRIVE PINION
• Thin the drive pinion adjusting shim to move the drive pinion
farther from the ring gear in case of flank contact or toe con-
tact.
CAUTION:
8. Assemble the plug to the transfer case.
CAUTION:
• Remove old gasket on mounting surface, then remove
any moisture, oil, and foreign material on the application
and mounting surfaces.
• Apply liquid gasket to the thread, and tighten to the speci- PDIA0441E
fied torque when installing plug.
DRIVE PINION BEARING PRELOAD
3. Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking,
and so on.
5. Measure the drive pinion bearing preload with a preload gauge
(A) (SST: ST3127S000).
Drive pinion bearing preload : Refer to DLN-208, "Pre-

load Torque".
CAUTION:
fied gear oil.
• Disassemble the drive pinion assembly to check and adjust
each part if outside the standard.
SDIA3072J
TOTAL PRELOAD
1. Measure drive pinion bearing preload (P1). Refer to “DRIVE PINION BEARING PRELOAD”.
CAUTION:
Check that the drive pinion bearing preload is within the standard.
3. Install adapter case. Refer to DLN-185, "Disassembly and Assembly".
5. Measure the total preload with a preload gauge (A) (SST:
ST3127S000).
Total preload
All oil seals are installed : Refer to DLN-208,
"Preload Torque".
Without adapter case oil seals : Refer to DLN-208,
"Preload Torque".
CAUTION:
• Each rotational part should rotate smoothly with the spec- JSDIA0322ZZ
ified gear oil.

• Disassemble the transfer assembly to check and adjust each part if outside the standard. Mea-
sure it with the adapter case oil seals removed when measuring total preload after disassembly.
Then install adapter case oil seals.
COMPANION FLANGE RUNOUT
DLN-198
DRIVE PINION
1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft bolt holes). A
Companion flange face : Refer to DLN-208, "Com- B

runout panion Flange Runout".
SDIA3074J
DLN
3. Fit a test indicator to the inner side of the companion flange
(socket diameter).
E
Inner side of the companion : Refer to DLN-208,

flange runout "Companion Flange
F
Runout".
5. Follow the procedure below to adjust if runout value is outside
the repair limit. G
CAUTION: JSDIA0323ZZ
Replace collapsible spacer to check and adjust each part
when companion flange is adjusted or replaced.
H
a. Check for runout while changing the phase between companion flange and drive pinion in 90° steps. Then
search for the minimum point.
b. Replace companion flange if runout value is still outside the limit after the phase has been changed.
I
c. Adjust assembly status of the drive pinion bearings and drive pinion, or replace drive pinion bearings if
runout is outside the standard after the companion flange is replaced.
ADJUSTING SHIM SELECTION J
Measuring Point
JSDIA0256ZZ P
Adapter case Ring gear shaft bearing Ring gear shaft bearing
(Adapter case side) (Transfer case side)
Ring gear shaft Ring gear Transfer case
Ring Gear Adjusting Shim (Adapter Case Side)

1. Measure the dimensions of each measuring point with the following procedure:
DLN-199
DRIVE PINION
Dimension “A” measurement
• Measure dimension from transfer case mounting surface of
adapter case to adapter case edge surface with a pair of ver-
nier calipers and straightedge. Refer to “Measuring point”.
SDIA3105J
Dimension “B” measurement

• Measure dimension from ring gear adjusting shim mounting
surface of adapter case to adapter case edge surface with a
pair of vernier calipers and straightedge. Refer to “Measuring
point”.
JSDIA0324ZZ
Dimension “C” measurement

• Measure the diameter of drive pinion bearing (rear side)
mounting area of transfer case with a pair of vernier calipers.
Refer to “Measuring point”.
CAUTION:
SDIA3107J
Dimension “D” measurement

• Measure dimension from adapter case mounting surface of
transfer case to drive pinion bearing (rear side) mounting sur-
face with a pair of vernier calipers and straightedge. Refer to
“Measuring point”.
CAUTION:
• Consider the thickness of a straightedge.
SDIA3108J
Dimension “E” measurement
DLN-200
DRIVE PINION
• Measure dimension from outer race edge surface of ring gear
shaft bearing (adapter case side) to inner race edge surface A
with a pair of vernier calipers. Refer to “Measuring point”.
SDIA3109J
DLN
2. Calculate dimensions “M” and “N” by the formula below.
Dimension “M” = “A” – “B” E

Dimension “N” = “C” × 0.5 mm (0.020 in) + “D”
3. Convert the dimensions “E”, “M” and “N” according to the standards below.
F
“E” : Actual value regarding 20.00 mm (0.7874 in) as 0 in increments of 0.01 mm (0.0004 in).
“M” : Actual value regarding 13.90 mm (0.5472 in) as 0 in increments of 0.01 mm (0.0004 in).
G
“N” : Actual value regarding 55.00 mm (2.1654 in) as 0 in increments of 0.01 mm (0.0004 in).
4. Check dimension “Z” (machining difference) on the ring gear
back surface. H
NOTE:
Dimension “Z” indicates difference between optimum engage-
ment and the standard dimensions in increments of 0.01 mm
I
(0.0004 in) written on the ring gear back surface.
5. Calculate the thickness of the ring gear adjusting shim (adapter
case side) “T1” by the formula below.
J
“T1” = (“M” + “N” – “E” – “Z”) × 0.01 mm (0.0004 in)

+ 1.40 mm (0.0551 in) SDIA3129J
K
6. Select ring gear adjusting shim (adapter case side). For selecting adjusting shim, refer to the latest parts
information.
CAUTION:
L
• Only one adjusting shim can be selected.
• Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with
the calculated value is available.
M
Ring Gear Adjusting Shim (Transfer Case Side)
1. Measure the dimensions of each measuring point with the following procedure:
Dimension “C” measurement N
• Measure the diameter of drive pinion bearing (rear side)
mounting area of transfer case with a pair of vernier calipers.
Refer to “Measuring point”.
O
CAUTION:
SDIA3107J
Dimension “D” measurement
DLN-201
DRIVE PINION
transfer case to drive pinion bearing (rear side) mounting sur-
face with a pair of vernier calipers and straightedge. Refer to
“Measuring point”.
CAUTION:
• Consider the thickness of a straightedge.
SDIA3108J
Dimension “F” measurement

transfer case to ring gear adjusting shim mounting surface
with a depth gauge. Refer to “Measuring point”.
CAUTION:
SDIA3110J
Dimension “G” measurement

• Measure dimension from ring gear shaft bearing mounting sur-
face of ring gear to transfer case side edge surface with a
micrometer and straightedge. Refer to “Measuring point”.
CAUTION:
Consider the thickness of a straightedge.
SDIA3111J
Dimension “H” measurement

• Measure dimension from transfer case side edge surface of
ring gear to adapter case side edge surface with a pair of ver-
nier calipers. Refer to “Measuring point”.
SDIA3112J
Dimension “I” measurement
DLN-202
DRIVE PINION
• Measure dimension from ring gear mounting surface of ring
gear shaft to ring gear shaft bearing (transfer case side) A
mounting surface with a pair of vernier calipers. Refer to “Mea-
suring point”.
B
JSDIA0257ZZ
DLN
Dimension “J” measurement
• Measure dimension from outer race edge surface of ring gear
shaft bearing (transfer case side) to inner race edge surface E
with a pair of vernier calipers. Refer to “Measuring point”.
SDIA3128J
H
2. Calculate dimension “N” by the formula below.
I
Dimension “N” = “C” × 0.5 mm (0.020 in) + “D”
3. Convert the dimensions “F”, “G”, “H”, “I”, “J” and “N” according to the standards below.
J
“F” : Actual value regarding 122.60 mm (4.83 in) as 0 in increments of 0.01 mm (0.0004 in).
“G” : Actual value regarding 26.60 mm (1.0472 in) as 0 in increments of 0.01 mm (0.0004 in).
“H” : Actual value regarding 48.60 mm (1.9134 in) as 0 in increments of 0.01 mm (0.0004 in). K
“I” : Actual value regarding 119.40 mm (4.70 in) as 0 in increments of 0.01 mm (0.0004 in).
“J” : Actual value regarding 16.25 mm (0.6398 in) as 0 in increments of 0.01 mm (0.0004 in).
L
“N” : Actual value regarding 55.00 mm (2.1654 in) as 0 in increments of 0.01 mm (0.0004 in).
4. Check dimension “Z” (machining difference) on the ring gear
back surface. M
NOTE:
Dimension “Z” indicates difference between optimum engage-
ment and the standard dimensions in increments of 0.01 mm
(0.0004 in) written on the ring gear back surface. N
5. Calculate the thickness of the ring gear adjusting shim (transfer
case side) “T2” by the formula below.
O
“T2” = (“F” – “G” + “H” – “I” – “J” – “N” + “Z”) × 0.01 mm
(0.0004 in) + 1.65 mm (0.0650 in) SDIA3129J
P
6. Select ring gear adjusting shim (transfer case side). For selecting adjusting shim, refer to the latest parts
information.
CAUTION:
• Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with
the calculated value is available.
Drive Pinion Adjusting Shim
DLN-203
DRIVE PINION
1. Check the dimension “U” (machining difference) between old
and new drive pinions when hypoid gear set (drive pinion and
ring gear) has been replaced.
(Assemble new drive pinion adjusting shims with the same thick-
ness as the ones removed prior to disassembly or removed
drive pinion adjusting shims when reusing the hypoid gear set.)
NOTE:
Dimension “U” indicates the difference between optimum
engagement and the standard dimensions in increments of 0.01
mm (0.0004 in). It is written on the gear end of the drive pinion
for reference.
SDIA3131J
2. Calculate the thickness of the drive pinion adjusting shim “T” by
the formula below.
“T” = T0 + [(t1 – t2) × 0.01 mm (0.0004 in)]

“T” : Thickness of new shim
T0 : Thickness of old shim
t1 : Dimension “U” displayed on the gear end of
old drive pinion
t2 : Dimension “U” displayed on the gear end of
new drive pinion
[Example]
“T” = 3.21 + [(2 + 1) × 0.01 mm (0.0004 in)]
T0 : 3.21
t1 : +2
t2 : −1
3. Select drive pinion adjusting shim. For selecting adjusting shim, refer to the latest parts information.
CAUTION:
• Select the closest one, if no adjusting shim with the calculated value is available.

Gear and Shaft
CAUTION:
Bearing
damage.
CAUTION:
Always replace inner race and outer race as a pair when replacing the bearing.
Shim
Case
DLN-204
TRANSFER CASE
TRANSFER CASE
A
DLN
L
JSDIA0319GB
Adapter case oil seal (outer) O-ring (outer) Adapter case oil seal (inner) M
(adapter case side) (adapter case side) N
O
Drive pinion bearing (front side) Collapsible spacer Drive pinion bearing (rear side) P
Oil seal lip

DLN-205
TRANSFER CASE

DISASSEMBLY
3. Remove drive pinion assembly. Refer to DLN-193, "Disassembly and Assembly".
4. Tap the outer race of drive pinion bearing from transfer case with
a brass rod to remove outer race of drive pinion bearing (front
side and rear side).
CAUTION:
5. Remove air breather hose from transfer case.
CAUTION:
Never damage air breather hose.
6. Remove air breather tube from transfer case.
7. Remove the filler plug and drain plug from the transfer case, and
then remove each gasket. SDIA3088J
8. Remove plug from transfer case.

ASSEMBLY
1. Install outer race of drive pinion bearing (front side) to the trans-
fer case with drifts and bushing remover.
A : Drift (commercial service tool)

C : Bushing remover (SST: ST38280000)
CAUTION:
• Never reuse drive pinion bearing (front side).
• Apply gear oil to the drive pinion bearing (front side)
SDIA3091J
2. Install outer race of drive pinion bearing (rear side) to transfer

case with a drift (A) (SST: ST33230000).
CAUTION:
• Never reuse drive pinion bearing (rear side).
• Apply gear oil to the drive pinion bearing (rear side).
3. Install drive pinion assembly. Refer to DLN-193, "Disassembly
and Assembly".
4. Install ring gear shaft assembly. Refer to DLN-188, "Disassem-
bly and Assembly".
Assembly". SDIA3092J
DLN-206
TRANSFER CASE
6. Install the air breather tube to the transfer case with its opening
facing (A) rearward from transfer input shaft direction (B). A
Angle “A” : 25° – 45 °

CAUTION: B
Never reuse air breather tube.
SDIA3090J
DLN
7. Install air breather hose.
CAUTION:
• Measure hose standard insertion length (A) and put mark-
E
ing on it before installation, then install hose to the
marked position.
Insertion length (A) : 59 – 69 mm (2.32 – 2.72 in) F

- For marking, use paint.
• Never damage air breather hose.
G
JSDIA5123ZZ
CAUTION:
Measure the total preload without the adapter case oil seals. H
9. Assemble the plug to the transfer case.
CAUTION:
• Remove old gasket on mounting surface, then remove any moisture, oil, and foreign material on I
the application and mounting surfaces.
• Apply liquid gasket to the threads of plug.
10. Install gaskets onto filler plug and drain plug and install them into transfer case. J
CAUTION:
• Never reuse gaskets.
• Install filler plug after oil is filled.
K
INSPECTION AFTER DISASSEMBLY L

Case
Check the bearing mounting surface for wear, cracks and damages. M
DLN-207
< SERVICE DATA AND SPECIFICATIONS (SDS) [TRANSFER: TY30A]

Axle 4WD
Applied model Engine R9M
Transaxle M/T
Transfer model TY30A
Gear ratio 0.656
Ring gear 32
Number of teeth
Drive pinion 21
Oil capacity Refer to MA-23, "Fluids and Lubricants".
Unit: N·m (kg-m, in-lb)

Item Standard
Drive pinion bearing preload (P1) 0.52 – 1.01 (0.06 – 0.10, 5 – 8)
With all oil seals P1 + 0.76 – 0.96 (0.08 – 0.09, 7 – 8)
Total preload
Without adapter case oil seals P1 + 0.55 – 0.75 (0.06 – 0.07, 5 – 6)
Unit: mm (in)
Item Standard
Ring gear to drive pinion 0.13 – 0.19 (0.0051 – 0.0075)
Companion Flange Runout INFOID:0000000011004077
Unit: mm (in)
Item Standard
Companion flange face runout 0.1 (0.004) or less
Inner side of the companion flange runout 0.1 (0.004) or less
DLN-208
PRECAUTIONS
< PRECAUTION > [REAR PROPELLER SHAFT: C-CVJ-C]
PRECAUTION A
PRECAUTIONS
B
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time. C
“How to disconnect 12V battery terminal” described below. DLN
NOTE:
battery terminal is disconnected before ECU stops, accidental DTC E
tery and the sub battery before turning ON the ignition switch. F
NOTE:
SEF289H
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC. G
NOTE:
H
I
INSTRUCTION 1
1. Open the hood.
2. Turn key switch to the OFF position with the driver side door opened. J
3. Get out of the vehicle and close the driver side door.
of the specified time. K

HRA2DDT : 12 minutes L
K9K engine : 4 minutes
R9M engine : 4 minutes M
V9X engine : 4 minutes
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of N
CAUTION: O
1. Unlock the door with intelligent key or remote keyless entry. P
NOTE:
3. Open the hood.
DLN-209
PRECAUTIONS
< PRECAUTION > [REAR PROPELLER SHAFT: C-CVJ-C]
CAUTION:
CAUTION:
Service Notice or Precautions for Propeller Shaft INFOID:0000000010822155
• Replace the propeller shaft assembly if there is a breakage or deflection on tube.

• Never hit the tube or apply an impact on it during repair service. Never damage the tube as well.
• The joint cannot be disassembled. Never disassemble it.
• If constant velocity joint was bent during propeller shaft assembly removal, installation, or transportation, its
boot may be damaged. Wrap boot interference area to metal part with shop cloth or rubber to protect boot
from breakage.
DLN-210
< SYSTEM DESCRIPTION > [REAR PROPELLER SHAFT: C-CVJ-C]
B
PART OF JOINT
Universal Type (Shell Type) C
DLN
JSDIA4709ZZ
F
CVJ Type
G
JSDIA5322ZZ
J
DLN-211
Symptom
Reference
×: Applicable
< SYMPTOM DIAGNOSIS >
Noise
Shake
Vibration
Possible cause and SUSPECTED PARTS
NVH Troubleshooting Chart
SYMPTOM DIAGNOSIS
Uneven rotating torque DLN-213, "Inspection"
×
×
Center bearing improper installation DLN-214, "Exploded View"
×
×
×
Excessive center bearing axial end play DLN-213, "Inspection"
×
×
Center bearing mounting (insulator) cracks, damage or deterioration DLN-217, "Inspection"
×
×
DLN-212
Excessive joint angle DLN-213, "Inspection"
×
×
×
Rotation imbalance DLN-213, "Inspection"
×
×
Excessive runout DLN-213, "Inspection"
×
×
DIFFERENTIAL NVH of REAR FINAL DRIVE in this section.
×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU, and RSU section.
×
×
×
TIRE NVH in WT section.
×
×
×
ROAD WHEEL NVH in WT section.
×
×
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.
DRIVE SHAFT NVH in FAX and RAX section.
×
×
×
BRAKE NVH in BR section.
×
×
STEERING NVH in ST section.
×
×
×
[REAR PROPELLER SHAFT: C-CVJ-C]
INFOID:0000000010822157
REAR PROPELLER SHAFT
< PERIODIC MAINTENANCE > [REAR PROPELLER SHAFT: C-CVJ-C]
PERIODIC MAINTENANCE A
B
LOOSENESS OF CONNECTED PART

Check each fixing bolt and nut for looseness using torque wrench. For each tightening torque, refer to DLN- C
214, "Exploded View".
BACKLASH OF JOINT PART
Move the joint of propeller shaft up and down and from side to side DLN
(axial direction of shaft and right angle to shaft) to check that the joint
has no backlash. If the joint has a malfunction, remove propeller
shaft and perform inspection.
E
MAA0555D G
BACKLASH OF CENTER BEARING
Move the shaft near center bearing up and down and from side to
side (axial direction of shaft and right angle to shaft) to check that the H
bearing has no backlash. If the bearing has a malfunction, remove
propeller shaft and perform inspection.
I
MAA0005D
K
APPEARANCE AND NOISE
• Check the propeller shaft tube surface for dents or cracks. If malfunction is detected, replace propeller shaft
assembly. L
• If center bearing is noisy or damaged, replace propeller shaft assembly.
VIBRATION
If vibration is present at high speed, adjust the propeller shaft phase first. M
1. Check the propeller shaft for bend and damage. If damaged, replace propeller shaft assembly.
2. Perform a cruise test drive to check the propeller shaft for runout. If vibration occurs, separate propeller
shaft at final drive companion flange; then change the phase between electric controlled coupling stud bolt N
and propeller shaft by the one bolt hole at a time and install propeller shaft.
3. If vibration is still detected, measure propeller shaft runout after removing it. Refer to DLN-217, "Inspec-
tion". O
DLN-213
< REMOVAL AND INSTALLATION > [REAR PROPELLER SHAFT: C-CVJ-C]

JSDIA5323GB
Center bearing mounting bracket Clip Propeller shaft assembly

(upper)
Center bearing mounting bracket
(lower)
: Vehicle front
REMOVAL
1. Shift transaxle to the neutral position, and then release parking brake.
2. Remove mounting rubber of main muffler. Refer to EX-6,
"Removal and Installation" (MR20DD), EX-12, "Removal and
Installation" (QR25DE), EX-18, "Removal and Installation"
(R9M).
CAUTION:
Remove only near the center bearing mounting bracket of
propeller shaft.
JSDIA5464ZZ
DLN-214
3. Remove heat insulator .
A
JSDIA5324ZZ
DLN
4. Put matching marks on propeller shaft flange yoke and trans-
fer companion flange.
CAUTION: E
For matching mark, use paint. Never damage propeller shaft
flange yoke and transfer companion flange.
G
JSDIA5328ZZ
5. Put matching marks on propeller shaft flange yoke and elec- H

tric controlled coupling.
CAUTION:
• For matching mark, use paint. Never damage propeller
shaft flange yoke and electric controlled coupling. I
• If the tip of stud bolt of electric controlled coupling has a
paint mark, place a matching mark for identification of the
position of applicable stud bolt. J
JSDIA5325ZZ
K
6. Loosen mounting nuts of center bearing mounting bracket.
NOTE:
Tighten mounting nuts temporarily to prevent drop of propeller L
shaft.
N
JSDIA5326ZZ
7. Remove propeller shaft assembly fixing bolts, and separate pro- O

peller shaft assembly from transfer companion flange.
JSDIA5329ZZ
DLN-215
8. Remove propeller shaft assembly fixing nuts, and separate pro-
peller shaft assembly from electric controlled coupling of final
drive.
9. Remove center bearing mounting bracket mounting nuts.
10. Remove propeller shaft assembly.
JSDIA5330ZZ
11. Remove clips and then remove center bearing mounting bracket
(upper/lower).
12. Perform inspection after removal. Refer to DLN-217, "Inspec-
tion".
JSDIA4492ZZ
INSTALLATION
• For non-reusable parts, refer to DLN-214, "Exploded View".
• For each tightening torque, refer to DLN-214, "Exploded View".
• After removing propeller shaft, replace stud bolts on electric controlled coupling. Refer to DLN-231,
• Remove any moisture, oil, or foreign material from matching surface on transfer companion flange, electric
controlled coupling and propeller shaft flange.
• Install center bearing mounting bracket (upper) with its arrow mark
facing forward.
JSDIA4491ZZ
• Adjust position of center bearing mounting bracket (upper) , cen-

ter bearing mounting bracket (lower) sliding back and forth to
prevent play in thrust direction of center bearing insulator . Install
center bearing mounting bracket (upper/lower) to vehicle.
• Center bearing mounting bracket fixing nuts must be tightened in
the order from left to right.
JSDIA5331ZZ
DLN-216
• Align matching marks to install propeller shaft flange yoke and
electric controlled coupling of final drive. A
JSDIA5325ZZ
DLN
• Align matching marks to install propeller shaft flange yoke and
transfer companion flange.
E
G
JSDIA5328ZZ
• If propeller shaft assembly, final drive assembly or electric controlled coupling has been replaced, connect H
propeller shaft assembly and electric controlled coupling of final drive as follows:
- Install propeller shaft while aligning its matching mark of pro-
peller shaft with matching mark on stud bolt of electric controlled I
coupling as close as possible.
CAUTION:
When replaced stud bolt, use the painted matching mark in J
removal as a guide.
• Perform inspection after installation. Refer to DLN-217, "Inspec-
tion".
K
JSDIA5332ZZ
L
INSPECTION AFTER REMOVAL M

Appearance
Check propeller shaft tube surface for dents or cracks. If malfunction is detected, replace propeller shaft
assembly. N
Propeller Shaft Runout
Check propeller shaft runout at measuring points with a dial indica-
tor. If runout exceeds specifications, replace propeller shaft assem- O
bly.
Propeller shaft runout : Refer to DLN-219, "Propeller

P
Shaft Runout".
JSDIA0193ZZ
DLN-217
• Propeller shaft runout measuring point (Point “ ”).
: Front side
Dimension
MR20DD models
A : 533.5 mm (21.00 in)
B : 492.0 mm (19.37 in)
QR25DE models
A : 540.5 mm (21.28 in) JPDID0001ZZ
B : 492.0 mm (19.37 in)

R9M models
A : 474.5 mm (18.68 in)
B : 492.0 mm (19.37 in)
Journal Axial Play

As shown in the figure, while fixing yoke on one side, check axial
play of joint. If it is outside the standard, replace propeller shaft
assembly.
Journal axial play : Refer to DLN-219, "Journal Axial

Play".
CAUTION:
Never disassemble joints.
PDA0005D
Center Bearing
Check center bearing for noise and damage. If malfunction is detected, replace propeller shaft assembly.
CAUTION:
Never disassemble center bearing.
After assembly, perform a driving test to check propeller shaft vibration. If vibration occurred, separate propel-
ler shaft from final drive. Reinstall propeller shaft by changing the phase between electric controlled coupling
stud bolt and propeller shaft by the one bolt hole at a time. Then perform driving test and check propeller shaft
vibration again at each point.
DLN-218
< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR PROPELLER SHAFT: C-CVJ-C]
SERVICE DATA AND SPECIFICATIONS (SDS) A

B
Axle 4WD
C
Applied model Engine MR20DD QR25DE R9M
Transaxle CVT M/T
Propeller shaft model C-CVJ-C DLN
Number of joints 3
1st joint Universal (Shell type)
E
Joint type 2nd joint CVJ type
3rd joint Universal (Shell type)
Transfer side Flange type F
Coupling method
Rear final drive side Flange type
1st (Spider to CVJ joint center) 1181.5 mm (46.52 in) 1195.5 mm (47.07 in) 1057.5 mm (41.63 in)
Shaft length
2nd (CVJ joint center to spider) 983.4 mm (38.72 in) 983.4 mm (38.72 in) 983.4 mm (38.72 in) G
1st shaft 63.5 mm (2.500 in) 63.5 mm (2.500 in) 57.0 mm (2.244 in)
Shaft outer diameter
2nd shaft 70.0 mm (2.756 in) 70.0 mm (2.756 in) 70.0 mm (2.756 in)
H
Propeller Shaft Runout INFOID:0000000010822163
Unit: mm (in) I
Item Standard
Propeller shaft runout 0.6 (0.024) or less
J
Journal Axial Play INFOID:0000000010822164
Unit: mm (in) K
Item Standard
Journal axial play 0 (0)
L
DLN-219
PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: R145]
PRECAUTION
PRECAUTIONS
NOTE:
NOTE:
SEF289H
NOTE:
INSTRUCTION 1
1. Open the hood.
3. Get out of the vehicle and close the driver side door.

K9K engine : 4 minutes
V9X engine : 4 minutes
CAUTION:
CAUTION:
NOTE:
3. Open the hood.
DLN-220
PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: R145]
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of A
CAUTION: B
Service Notice or Precautions for Rear Final Drive INFOID:0000000011008601
C
• Use recommended gear oil only, refer to MA-23, "Fluids and Lubricants".
certain they never interfere with the function of the parts when applied.
DLN
• Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
• Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of
the unit, preventing them from entering into the unit during disassembly or assembly.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them E
with a new ones if necessary.
• Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
F
ening sequence is specified, observe it.
• When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil, G
and foreign materials from the application and mounting surfaces.
• Always use shop paper for cleaning the inside of components.
• Never use cotton gloves or shop rags to prevent entering of lint. H
• During assembly, observe the specified tightening torque, and apply new gear oil, petroleum jelly, or multi-
purpose grease as specified for each vehicle, if necessary.
DLN-221
PREPARATION
< PREPARATION > [REAR FINAL DRIVE: R145]
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000011008602
Tool number
Description
Tool name
KV40100610 • Removing and Installing rear cover (2 piec-
Drift es are used.)
a: 63 mm (2.48 in) dia. • Removing and Installing differential assem-
b: 54.3 mm (2.138 in) dia. bly (2 pieces are used.)
• Installing pinion front bearing inner race
ZZA1000D
ST33052000 Removing side bearing inner race

Adaptor
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
ZZA1023D
KV40105020 Installing side bearing inner race

Drift
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
c: 15 mm (0.59 in)
ZZA1133D
KV38100200 Installing side oil seal

Drift
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
ZZA1143D
KV38109500 • Measuring pinion bearing preload and total

Drive pinion socket preload
• Removing and installing drive pinion lock
nut
ZZA1205D
ST3127S000 Measuring pinion bearing preload and total

Preload gauge preload
ZZA0503D
DLN-222
PREPARATION
Tool number
Description
Tool name A
KV389L0010 • Checking drive gear runout
Dummy cover set • Checking tooth contact
1: Dummy cover • Checking backlash B
2: Dummy cover spacer
3: Dummy cover shim
C
SDIA2313E
KV38109400 Removing and installing drive pinion lock nut

Pinion nut wrench DLN
ZZA1206D
F
ST33200000 Installing pinion rear bearing outer race
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia. G
H
ZZA1002D
ST33230000 Installing pinion front bearing outer race

Drift
a: 51 mm (2.01 in) dia. I
b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.
J
ZZA1046D
ST23860000 • Installing pinion rear bearing inner race K

Drift • Installing pinion front bearing inner race
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
L
ZZA0534D M
ST38220000 Installing pinion front bearing inner race
Press stand
a: 75 mm (2.95 in) dia.
N
b: 63 mm (2.48 in) dia.
O
S-NT509
ST35271000 Installing drive pinion oil seal

Drift P
a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia.
ZZA0814D
DLN-223
PREPARATION
Commercial Service Tools INFOID:0000000011008603

Oil seal remover • Removing side oil seal
• Removing drive pinion oil seal
JSDIA4998ZZ
Separator • Removing side bearing inner race

• Removing pinion rear bearing inner race
ZZA0700D
Puller • Removing side bearing inner race

• Removing pinion rear bearing inner race
ZZA0119D
Pin punch Removing and installing lock pin

a: 4.5 mm (0.177 in) dia.
NT410
Item Use
Genuine Liquid Gasket • Application to mating surface of electric controlled coupling assembly
(Three Bond 1217 or equivalent) • Application to mating surface of rear cover
Genuine High Strength Thread Locking Sealant
Application into the thread hole of drive gear
(Loctite 270 or equivalent)
DLN-224
< SYSTEM DESCRIPTION > [REAR FINAL DRIVE: R145]
B
DLN
JSDIA5276ZZ J
Drive gear Side bearing Differential case

Pinion mate shaft Side gear Pinion mate gear K
Drive pinion Collapsible spacer 4WD solenoid
Stud bolt Electric controlled coupling Pinion front bearing
L
Pinion rear bearing
M
The electric controlled coupling operates as the 4WD system. For the operation, refer to DLN-17, "Operation
Description" (TY21C transfer models), DLN-121, "Operation Description" (TY30A transfer models).
N
DLN-225
Symptom
Reference
×: Applicable
< SYMPTOM DIAGNOSIS >
Noise
Possible cause and SUSPECTED PARTS
NVH Troubleshooting Chart
SYMPTOM DIAGNOSIS
Gear tooth rough DLN-255, "Inspection"
×
Gear contact improper DLN-252, "Adjustment"
DLN-226
Tooth surfaces worn DLN-255, "Inspection"
×
Backlash incorrect DLN-252, "Adjustment"
×
Companion flange excessive runout —
×
Gear oil improper DLN-227, "Inspection"
×
PROPELLER SHAFT NVH of REAR PROPELLER SHAFT in this section.
×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections.
×
TIRE NVH in WT section.
×
ROAD WHEEL NVH in WT section.
×
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.
× DRIVE SHAFT NVH in FAX and RAX section.

BRAKE NVH in BR section.

×
STEERING NVH in ST section.

×
[REAR FINAL DRIVE: R145]
INFOID:0000000011008607
REAR DIFFERENTIAL GEAR OIL
< PERIODIC MAINTENANCE > [REAR FINAL DRIVE: R145]
PERIODIC MAINTENANCE A
REAR DIFFERENTIAL GEAR OIL
B
OIL LEAKAGE
Make sure that oil is not leaking from final drive assembly or around it. C
OIL LEVEL
1. Check oil level from filler plug mounting hole as shown in the fig-
ure after removing filler plug and gasket from final drive DLN
assembly.
CAUTION:
Turn the ignition switch OFF while checking oil level. E
hole. Add gear oil if necessary. Refer to DLN-227, "Refilling".
2. Set a gasket on filler plug and install it on final drive assembly. F
CAUTION:
Never reuse gasket.
3. Tighten filler plug to the specified torque. Refer to DLN-246, JPDID0164ZZ
"Exploded View". G
Draining INFOID:0000000011008671
H
3. Drain gear oil. I
4. Set a gasket on drain plug and install it to final drive assembly.
CAUTION:
Never reuse gasket. J
5. Tighten drain plug to the specified torque. Refer to DLN-246,
"Exploded View".
K
JPDID0163ZZ
L
Refilling INFOID:0000000011008672
1. Remove filler plug and gasket. Then fill with new gear oil until
oil level reaches the specified level near filler plug mounting M
hole.
Recommended : Refer to MA-23, "Fluids and Lubri- N

2. Set a gasket on filler plug, and install it to final drive assembly.
CAUTION: O
Never reuse gasket.
3. Tighten filler plug to the specified torque. Refer to DLN-246, JPDID0164ZZ
"Exploded View". P
DLN-227
DRIVE PINION OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: R145]

DRIVE PINION OIL SEAL
JSDIA6475ZZ
Rear final drive assembly Drive pinion oil seal Electric controlled coupling assembly
Oil seal lip

: Apply gear oil.
REMOVAL
1. Drain gear oil. Refer to DLN-227, "Draining".
2. Remove electric controlled coupling assembly. Refer to DLN-231, "Removal and Installation".
3. Remove drive pinion oil seal using oil seal remover (commercial service tool).
INSTALLATION
1. Using the drift (A) (SST: ST35271000), install drive pinion oil
seal within the dimension (D) shown as follows.
D : 0.8 – 1.2 mm (0.031 – 0.047 in)

CAUTION:
onto the circumference of oil seal.
2. Install electric controlled coupling assembly. Refer to DLN-231,
JSDIA5262ZZ
3. Refill gear oil to the final drive. Refer to DLN-227, "Refilling".
4. Perform inspection after installation. Refer to DLN-228, "Inspection".

Check oil level and final drive for oil leakage. Refer to DLN-227, "Inspection".
DLN-228
SIDE OIL SEAL
SIDE OIL SEAL
A
DLN
JSDIA5269ZZ
G
Rear final drive assembly Side oil seal
Oil seal lip
: Always replace after every disassembly. H

: Apply gear oil.
I
REMOVAL J
2. Remove rear drive shafts. Refer to RAX-22, "Removal and Installation".
K
3. Remove side oil seal, using oil seal remover (commercial ser-
vice tool).
CAUTION:
Never damage gear carrier and rear cover. L
N
PDIA0431E
INSTALLATION
1. Using the drift (A) (SST: KV38100200), drive side oil seal until it O
becomes flush with the gear carrier end.
CAUTION:
• Never reuse oil seal. P
• Apply multi-purpose grease onto oil seal lip, and gear oil
2. Install rear drive shafts. Refer to RAX-22, "Removal and Installa-
tion".
3. Refill gear oil to the final drive. Refer to DLN-227, "Refilling".
JSDIA0201ZZ
DLN-229
SIDE OIL SEAL
4. Perform inspection after installation. Refer to DLN-230, "Inspection".

DLN-230
A
DLN
G
JSDIA6057GB
Rear final drive assembly Wave spring Electric controlled coupling assembly
H
Reamer bolt Connector bracket Stud bolt

I
: Apply Genuine Liquid Gasket, Three Bond 1217 or equivalent. J
K
REMOVAL
2. Remove propeller shaft from rear final drive assembly. Refer to DLN-214, "Removal and Installation". L
3. Remove stud bolts .
CAUTION:
After removing propeller shaft, replace stud bolt. M
NOTE:
When replacing electric controlled coupling assembly, stud bolts
are not required to be removed.
N
O
JSDIA5248ZZ
DLN-231
4. Disconnect 4WD solenoid harness connector .
JSDIA5249ZZ
5. Remove air breather hose from electric controlled coupling

assembly. Refer to DLN-236, "Removal and Installation".
JSDIA5235ZZ
6. Remove electric controlled coupling assembly from final drive

assembly.
7. Remove wave spring.
8. Remove drive pinion oil seal from the inside of gear carrier.
Refer to DLN-228, "Removal and Installation".
CAUTION:
When removing electric controlled coupling, replace drive
pinion oil seal.
JSDIA5250ZZ
9. Remove connector bracket from electric controlled coupling.
JSDIA5234ZZ
10. Remove band clip and connector clip to disconnect connector

bracket from 4WD solenoid harness connector.
JSDIA5241ZZ
DLN-232
INSTALLATION
1. Install connector bracket to electric controlled coupling. A
• For tightening torque, refer to DLN-231, "Exploded View".
2. Lock 4WD solenoid harness with band clip and connector clip.
3. Install drive pinion oil seal to the inside of gear carrier. Refer to B
CAUTION:
When removing electric controlled coupling, replace drive C
pinion oil seal.
DLN
JSDIA5241ZZ
E
4. Install wave spring to the inside of gear carrier.
H
JSDIA5236ZZ
5. Apply liquid gasket to mating surface of electric controlled coupling assembly. I

• For applying liquid gasket, refer to DLN-231, "Exploded View".
CAUTION:
• Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adher- J
ing to the mounting surfaces.
• The width of sealant bead is approximately 3 mm (0.12 in).
Apply sealant evenly. K
L
JSDIA5242ZZ
6. Join electric controlled coupling assembly to spline of drive

M
pinion, then install it to final drive assembly .
CAUTION:
Be careful not to damage drive pinion oil seal.
N
JSDIA5260ZZ
P
DLN-233
7. Temporarily tighten reamer bolts to the positions shown in the
figure.
8. Tighten reamer bolts and electric controlled coupling assembly
mounting bolts to the specified torque.
JSDIA5263ZZ
9. Install air breather hose to electric controlled coupling assem-

bly. Refer to DLN-236, "Removal and Installation".
JSDIA5235ZZ
10. Connect 4WD solenoid harness connector .
JSDIA5249ZZ
11. Install stud bolts .
: Electric controlled coupling side
Thread length
A : Long
B : Short
CAUTION:
• Never reuse stud bolt.
• After removing propeller shaft, replace stud bolt. JSDIA5237ZZ
• Screw long thread side of stud bolt to electric controlled

coupling.
• Screw the stud bolt until the stop by applying a torque of 15 N·m (1.5 kg-m, 11 ft-lb) ±20%.
DLN-234
• After installing stud bolt, the length of the protrusion from
electric controlled coupling must be as described below. A
Length (L) : 19.8 mm (0.780 in) ±1.4 mm (0.055 in)

NOTE: B
When replacing electric controlled coupling assembly, stud bolts
are not required to be installed.
12. Install propeller shaft. Refer to DLN-214, "Removal and Installa- C
tion".
13. Refill gear oil to the final drive. Refer to DLN-227, "Refilling". JSDIA5441ZZ
14. Perform inspection and adjustment after installation. Refer to DLN

DLN-235, "Inspection and Adjustment".
Inspection and Adjustment INFOID:0000000011008619
E
F
When replaced electric controlled coupling, perform writing unit characteristics. Refer to DLN-41, "Work Pro-
cedure" (TY21C transfer models), DLN-145, "Work Procedure" (TY30A transfer models).
G
DLN-235
AIR BREATHER
AIR BREATHER
JSDIA5437ZZ
Breather connector (resin) Trim clip Bracket

Hose clamp Air breather hose Breather connector (metal)
Breather connector (resin) Air breather hose Clip
Hose connector Air breather hose assembly Breather connector (metal)
Rear final drive assembly
REMOVAL
Final Drive Side
1. Remove hose clamp, and remove air breather hose from breather connector (metal) on rear final drive
assembly.
2. Remove breather connector (resin) together with air breather hose from bracket.
3. Remove hose clamp, and remove air breather hose from breather connector (resin).
4. Remove trim clip and remove bracket.
5. Remove breather connector (metal) from rear final drive assembly.
• When removing/installing breather connector (metal), remove rear final drive assembly from the vehicle.
Refer to DLN-239, "Removal and Installation".
Electric Controlled Coupling Side
1. Remove air breather hose assembly from breather connector (metal) on electric controlled coupling
assembly.
2. Remove air breather hose assembly from hose connector.
NOTE:
DLN-236
AIR BREATHER
The air breather hose assembly and the protective tube of elec-
trical wiring harness are integrated. A
3. Remove clip from suspension member.
4. Remove breather connector (resin) together with air breather
hose and hose connector from bracket. B
5. Remove trim clip and remove bracket.
6. Remove breather connector (metal) from electric controlled cou-
pling assembly. C
• When removing/installing breather connector (metal), remove
electric controlled coupling assembly from rear final drive JSDIA5247ZZ
assembly. Refer to DLN-231, "Removal and Installation". DLN
INSTALLATION
• For non-reusable parts, refer to DLN-236, "Exploded View". E
• When installing air breather hose, make sure there are no pinched or restricted areas on air breather hose
caused by bending or winding.
Final Drive Side F
• Set breather connector (metal) to rear final drive assembly with
the paint mark facing vehicle front.
G
: Vehicle front
I
JSDIA5212ZZ
• Observe the following instructions to install breather connector J

(resin) , air breather hose , breather connector (metal) , and
hose clamp as shown in the figure.
CAUTION:
• Be careful with insert dimension of breather connector and K
set position of hose clamp.
Insert dimension of : 20 mm (0.79 in) from breather L

breather connector connector end (air breather
(resin/metal) hose side)
Set position of hose : 5 mm (0.20 in) from breather JSDIA5439ZZ M
clamp hose end
• Be careful with orientation of hose clamp tab.
• Set bracket with the stopper facing vehicle inside. N
JSDIA5213ZZ
Electric Controlled Coupling Side
DLN-237
AIR BREATHER
• Securely install breather connector (metal) to the electric controlled
coupling assembly with the tip of tube faced in the vehicle front
direction. In addition, insert air breather hose to tube spool part
of breather connector (metal) .
: Vehicle front
JSDIA5230ZZ
• Install breather connector (resin) , air breather hose , hose

connector , and clip based on hose paint mark as shown in
the figure, complying with the directions below.
CAUTION:
• Be careful with insert dimension of breather connector
(resin) and hose connector, and set position of clip.
Insert dimension of : 20 mm (0.79 in) from breather

breather connector connector end (air breather hose
(resin) and hose side) and hose connector end (air
connector breather hose side) JSDIA5231ZZ
Set position of clip : 5 mm (0.20 in) from breather hose

end
• Cut extra band of clip.
• Set bracket with the stopper facing vehicle inside.
JSDIA5213ZZ
DLN-238
REAR FINAL DRIVE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: R145]
UNIT REMOVAL AND INSTALLATION A

B
DLN
JSDIA5275GB
G
Final drive mounting bracket Mounting stopper Rear final drive assembly
H
I
REMOVAL J
1. Remove rear drive shaft. Refer to RAX-22, "Removal and Installation".
CAUTION:
K
2. Remove propeller shaft from rear final drive assembly. Refer to DLN-214, "Removal and Installation".
CAUTION:
After removing propeller shaft, replace stud bolt .
L
NOTE:
When replacing rear final drive assembly, stud bolts are not
required to be removed.
M
JSDIA5248ZZ
O
DLN-239
3. Disconnect 4WD solenoid harness connector .
4. Remove air breather hoses from rear final drive and electric con-
trolled coupling assembly. Refer to DLN-231, "Removal and
Installation".
5. Remove fuel tank protector. Refer to FL-21, "Exploded View"
(Gasoline engine models), FL-49, "Exploded View" (Diesel
engine models).
6. Set a suitable jack to rear final drive assembly.
JSDIA5249ZZ
7. Remove rear final drive assembly mounting nut at rear suspen-

sion member.
JPDID0171ZZ
8. Remove bolts and nuts engaging final drive mounting bracket

with rear suspension member.
CAUTION:
Secure rear final drive assembly to suitable jack.
9. Remove mounting stoppers.
10. Remove rear final drive assembly.
CAUTION:
Secure rear final drive assembly to suitable jack while
removing it.
JSDIA5479ZZ
11. Remove bolts and nuts engaging final drive mounting bracket
with rear final drive assembly.
12. Remove final drive mounting bracket.
JSDIA5274ZZ
INSTALLATION
Note the following, install in the reverse order of removal.
• For non-reusable parts, refer to DLN-239, "Exploded View".
• For each tightening torque, refer to DLN-239, "Exploded View".
DLN-240
• Be careful not to install wrong stud bolt mounting direction.
A
: Electric controlled coupling side
Thread length B
A : Long
B : Short
C
CAUTION:
• After removing propeller shaft, replace stud bolt.
• Screw long thread side of stud bolt to electric controlled JSDIA5237ZZ
coupling. DLN
• Screw the stud bolt until the stop by applying a torque of 15 N·m (1.5 kg-m, 11 ft-lb) ±20%.
• After installing stud bolt, the length of the protrusion from
electric controlled coupling must be as described below. E
Length (L) : 19.8 mm (0.780 in) ±1.4 mm (0.055 in)
NOTE: F
When replacing rear final drive assembly, stud bolts are not
required to be installed.
• Perform inspection and adjustment after installation. Refer to DLN-
241, "Inspection and Adjustment". G
JSDIA5441ZZ
Inspection and Adjustment INFOID:0000000011008624

H

When oil leaks while removing/installing final drive assembly, check oil level after the installation. Refer to I
DLN-227, "Inspection".
J
When replaced rear final drive assembly or electric controlled coupling was changed, perform writing unit
characteristics. Refer to DLN-41, "Work Procedure" (TY21C transfer models), DLN-145, "Work Procedure"
(TY30A transfer models).
K
DLN-241
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: R145]
UNIT DISASSEMBLY AND ASSEMBLY

JSDIA5442GB
Stud bolt Connector bracket Reamer bolt

Electric controlled coupling assem-
Wave spring Drive pinion oil seal
bly
Drive pinion lock nut Pinion front bearing Gear carrier
Collapsible spacer Drive pinion adjusting shim Pinion rear bearing
Drive pinion Drive gear Differential case
Side bearing Side bearing adjusting shim Side oil seal
Rear cover Stud bolt Gasket
Drain plug Filler plug Pinion mate thrust washer
Pinion mate gear Side gear thrust washer Side gear
Pinion mate shaft Lock pin
Oil seal lip Screw hole

: Apply gear oil.
DLN-242

A
: Apply multi purpose grease.
: Apply Genuine High Strength Thread Locking Sealant, Loctite 270 or equivalent. B
C
DISASSEMBLY
1. Remove stud bolts .
DLN
JSDIA5282ZZ
G
2. Remove electric controlled coupling assembly from final drive
assembly.
3. Remove wave spring. H
4. Remove drive pinion oil seal from the inside of gear carrier.
Refer to DLN-258, "Disassembly and Assembly".
CAUTION: I
pinion oil seal.
J
JSDIA5250ZZ
5. Remove connector bracket from electric controlled coupling. K
JSDIA5234ZZ
N
6. Separate band clip and connector clip from connector bracket.
JSDIA5241ZZ
ASSEMBLY
DLN-243
1. Install connector bracket to electric controlled coupling.
2. Join 4WD solenoid harness with band clip and connector clip.
3. Install drive pinion oil seal to the inside of gear carrier. Refer to
CAUTION:
pinion oil seal.
JSDIA5241ZZ
4. Install wave spring to the inside of gear carrier.
JSDIA5236ZZ
5. Apply liquid gasket to mating surface of electric controlled cou-

pling assembly.
CAUTION:
Also remove any moisture, oil, or foreign material adher-
• The width of sealant bead is approximately 3 mm (0.12 in).
Apply sealant evenly.
JSDIA5242ZZ
6. Match electric controlled coupling assembly to spline of drive

pinion, then install it to final drive assembly .
CAUTION:
Be careful not to damage drive pinion oil seal.
JSDIA5260ZZ
DLN-244
7. Temporarily tighten reamer bolts to the positions shown in the
figure. A
8. Tighten reamer bolts and electric controlled coupling assembly
mounting bolts to the specified torque.
• For tightening torque, refer to DLN-242, "Exploded View". B
JSDIA5263ZZ
DLN
9. Install stud bolts .
: Electric controlled coupling side E
Thread length
A : Long F
B : Short
CAUTION:
• Never reuse stud bolt. G
• Screw long thread side of stud bolt to electric controlled JSDIA5237ZZ
coupling.
• Screw the stud bolt until the stop by applying a torque of 15 N·m (1.5 kg-m, 11 ft-lb) ±20%. H
• After installing stud bolt, the length of the protrusion from electric controlled coupling must be
19.8 mm (0.780 in) ±1.4 mm (0.055 in).
DLN-245
DIFFERENTIAL ASSEMBLY
JSDIA5442GB
Stud bolt Connector bracket Reamer bolt

bly
Drive pinion lock nut Pinion front bearing Gear carrier
Drain plug Filler plug Pinion mate thrust washer

: Apply gear oil.

DLN-246

A
: Apply Genuine High Strength Thread Locking Sealant, Loctite 270 or equivalent.

B
DISASSEMBLY
1. Remove drain plug, filler plug and gaskets.
C
2. Remove the side oil seal, using oil seal remover (commercial
service tool).
CAUTION:
Never damage gear carrier and rear cover. DLN
3. Remove rear cover mounting bolts.
F
PDG0216D
4. Set drifts (A and B) to the right and left side bearing adjusting
shims individually. Press differential assembly with side bearing G
to remove gear carrier assembly and rear cover assembly.
A : Drift (SST: KV40100610) H

B : Drift (SST: KV40100610)
CAUTION:
The pressure shall be as low as possible to remove gear I
carrier assembly and rear cover assembly. The maximum
pressure shall be 10 kN (1 ton, 1.0 Imp ton).
NOTE: JSDIA5286ZZ
J
Differential assembly, side bearings, and adjusting washers are
compressed and integrated in gear carrier and rear cover.
5. Remove stud bolt from rear cover.
K
NOTE:
It is not necessary to remove stud bolt except when it is replaced.
6. Remove side bearing adjusting shims and side bearing outer races.
CAUTION: L
Mark the side bearing adjusting shims so that the original mounting positions (right/left) can be
identified later.
7. Remove side bearing inner races, using adaptor (A), separator M
(B) and puller (C).
A : Adaptor (SST: ST33052000)

N
B : Separator (commercial service tool)
C : Puller (commercial service tool)
CAUTION: O
• To prevent damage to the side bearing and drive gear,
place copper plates between these parts and vise.
• It is not necessary to remove side bearing inner race
P
except when it is replaced. JSDIA5287ZZ
DLN-247
8. For proper reinstallation, paint matching marks on one differ-
ential assembly and drive gear.
CAUTION:
For matching marks, use paint. Never damage differential
assembly and drive gear.
9. Remove drive gear mounting bolts and then remove drive gear
from differential assembly.
JSDIA5285ZZ
10. Remove lock pin of pinion mate shaft, using the pin punch (com-
mercial service tool).
PDIA0759J
11. Remove pinion mate shaft.
SDIA0031J
12. Remove pinion mate gears, pinion mate thrust washers, side
gears, side gear thrust washers from differential case.
"Inspection".
SDIA0032J
ASSEMBLY
DLN-248
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.
2. Install side gears and side gear thrust washers into differential
case. B
SDIA0193J
DLN
3. Align 2 pinion mate gears in diagonally opposite positions, then
rotate and install them into differential case after installing thrust
washer to pinion mate gear.
E
G
SDIA0194J
4. Align the lock pin holes on differential case with pinion mate
H
shaft, and install pinion mate shaft.
SDIA0195J
K
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers.
a. Place differential assembly straight up so that side gear to be
measured comes upward. L
JPDID0205GB
O
DLN-249
b. Using feeler gauge, measure the clearance between side gear
back and differential case at 3 different points, while rotating
side gear. Average the 3 readings, and then measure the clear-
ance of the other side as well.
Side gear back clear- : Refer to DLN-263, "Differ-

ance ential Side Gear Clear-
ance".
CAUTION:
To prevent side gear from tilting, insert feeler gauges with
the same thickness from both sides.
• If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust. For selecting thrust
washer, refer to the latest parts information.
When the back clearance : Use a thicker thrust washer.

is large
When the back clearance : Use a thinner thrust washer.
is small
CAUTION:
Select a side gear thrust washer for right and left individu-
PDIA0576E
ally.
6. Drive a lock pin into pinion mate shaft, using the pin punch
(commercial service tool).
CAUTION:
Never reuse lock pin.
PDIA0759J
7. Press side bearing inner races to differential assembly, using the

drifts (A and B).
A : Drift (SST: KV40105020)

CAUTION:
• Never reuse side bearing inner race.
• Apply gear oil to side bearing.
JSDIA5288ZZ
8. Apply thread locking sealant into the thread hole of drive gear.
• For applying thread locking sealant, refer to DLN-246,
"Exploded View".
CAUTION:
Clean and degrees drive gear back and threaded holes suf-
ficiently.
9. Install the drive gear to differential assembly.
CAUTION:
Align the matching mark of differential assembly and drive
gear.
SPD554
DLN-250
10. Tighten the bolts in a crisscross fashion to the specified torque.
• For tightening torque, refer to DLN-246, "Exploded View". A
CAUTION:
Apply anti-corrosion oil to the thread and seat of mounting
bolts. B
11. Assemble side bearing outer races to inner races.
CAUTION:
• Never reuse side bearing outer race.
C
• Apply gear oil to side bearing.
12. Install new side bearing adjusting shims (2 pieces for one side)
with the same thickness as the ones installed prior to disassem- PDIA0466E
bly or re-install the old ones, on side bearing outer race of differ- DLN
ential assembly.
If side bearing adjusting shims have been already selected, use them.
13. Set the drifts (A and B) to the right and left side bearing adjusting E
shims individually. Compress differential assembly and side
bearing to gear carrier assembly to install differential assembly.
F
CAUTION: G
• The drift shall be placed on the center of the adjusting
shims.
• The pressure shall be as low as possible to install differ-
H
ential assembly into gear carrier assembly. The maximum JSDIA5289ZZ
pressure shall be 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

• If the adjusting shims are installed by tapping, the gear carrier may be damaged. Avoid tapping.
14. Install dummy cover set, check and adjust drive gear runout, tooth contact, backlash, and total preload I
torque. Refer to DLN-252, "Adjustment".
15. Remove dummy cover set.
16. Install stud bolt to rear cover. J
CAUTION:
Screw the stud bolt until the thread becomes invisible by applying a torque of 20 N·m (2.0 kg-m, 15
ft-lb) or less. K
17. Apply liquid gasket to mating surface of rear cover.
CAUTION: L
Also remove any moisture, oil, or foreign material adher-
• The width of sealant bead is approximately 3 mm (0.12 in). M
Apply sealant evenly.
N
JSDIA5290ZZ
18. Set the drifts (A and B) to the right and left side bearing adjusting O
shims individually. Compress differential assembly and side
bearing to install rear cover.
A : Drift (SST: KV40100610) P

CAUTION:
• The drift shall be placed on the center of the adjusting
shims.
JSDIA5286ZZ
DLN-251
• The pressure shall be as low as possible to install differential assembly into gear carrier assem-
bly. The maximum pressure shall be 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
• If the adjusting shims are installed by tapping, the gear carrier may be damaged. Avoid tapping.
19. Tighten rear cover mounting bolts to the specified torque.
20. Using the drift (A) (SST: KV38100200), drive side oil seals until it
becomes flush with the gear carrier end.
CAUTION:
21. Check total preload torque. Refer to DLN-252, "Adjustment".
JSDIA5291ZZ
TOTAL PRELOAD TORQUE

1. Remove electric controlled coupling assembly. Refer to DLN-243, "Disassembly and Assembly".
2. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
4. Fit drive pinion socket onto drive pinion spline. Measure the total
preload, using the preload gauge and drive pinion socket.
A : Drive pinion socket (SST: KV38109500)

B : Preload gauge (SST: ST3127S000)
Standard
Total preload torque : Refer to DLN-263, "Pre- JSDIA5303ZZ
load Torque".
NOTE:
Total preload torque = Pinion bearing torque + Side bearing torque
• If measured value is out of the specification, disassemble it to check and adjust each part. Adjust the pinion
bearing preload and side bearing preload.
Adjust the pinion bearing preload first, then adjust the side bearing preload.
When the preload torque is large

On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting shims. For selecting adjusting
shim, refer to the latest parts information.
When the preload is small

On pinion bearings: Tighten the drive pinion nut.
On side bearings: Use thicker side bearing adjusting shims. For selecting adjusting
shim, refer to the latest parts information.
DRIVE GEAR RUNOUT

1. Remove rear cover. Refer to DLN-247, "Disassembly and Assembly".
2. Following the procedure below, install the dummy cover set (SST: KV389L0010) to gear carrier.
a. Set dummy cover shims to the right and left side bearing adjusting shims.
b. Temporarily tighten dummy cover to gear carrier.
DLN-252
c. Position dummy cover spacers to dummy cover.
d. Tighten rear cover mounting bolts to the specified torque. Refer to DLN-246, "Exploded View". A
e. Tighten dummy cover spacer mounting bolts evenly to the specified torque.
B
: 5.9 N·m (0.6 kg-m, 52 in-lb)
3. Fit a dial indicator (A) to the drive gear back face.
C
B : Dummy cover set (SST: KV389L0010)
4. Rotate the drive gear to measure runout.
DLN
Limit
Drive gear back face : Refer to DLN-263, "Drive
runout Gear Runout". E
• If the runout is outside of the repair limit, check drive gear

assembly condition; foreign material may be caught between JSDIA5304ZZ
drive gear and differential case, or differential case or drive F

gear may be deformed, etc.
CAUTION:
Replace drive gear and drive pinion as a set. G
TOOTH CONTACT
H
2. Following the procedure below, install the dummy cover set (SST: KV389L0010) to gear carrier.
b. Temporarily tighten dummy cover to gear carrier. I
c. Position dummy cover spacers to dummy cover.
d. Tighten rear cover mounting bolts to the specified torque. Refer to DLN-246, "Exploded View".
e. Tighten dummy cover spacer mounting bolts evenly to the specified torque. J
: 5.9 N·m (0.6 kg-m, 52 in-lb)

K
3. Apply red lead or equivalent to drive gear.
A : Dummy cover set (SST: KV389L0010)

L
CAUTION:
Apply red lead or equivalent to both the faces of 3 to 4
gears at 4 locations evenly spaced on drive gear.
M
N
JSDIA5305ZZ
4. Rotate drive gear back and forth several times, check drive pin-
O
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.
P
SDIA0570E
DLN-253
SDIA2549E
5. If tooth contact is improperly adjusted, follow the procedure

below to adjust the pinion height (dimension X).
SDIA0517E
• If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken drive pinion gear adjusting shim to
move drive pinion closer to drive gear.
For selecting adjusting shim, refer to the latest parts informa-
tion.
PDIA0440E
DLN-254
• If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin drive pinion gear adjusting shim to move A
drive pinion farther from drive gear.
For selecting adjusting shim, refer to the latest parts informa-
tion.
B
PDIA0441E
DLN
BACKLASH
2. Following the procedure below, install the dummy cover set (SST: KV389L0010) to gear carrier. E
b. Temporarily tighten dummy cover to gear carrier.
c. Position dummy cover spacers to dummy cover. F
d. Tighten rear cover mounting bolts to the specified torque. Refer to DLN-246, "Exploded View".
e. Tighten dummy cover spacer mounting bolts evenly to the specified torque.
G
: 5.9 N·m (0.6 kg-m, 52 in-lb)
3. Fit a dial indicator (A) to the drive gear face to measure the H
backlash.
B : Dummy cover set (SST: KV389L0010)

I
Standard
Backlash : Refer to DLN-263, "Backlash". J
• If the backlash is outside of the specified value, change the
thickness of side bearing adjusting shims.
JSDIA5306ZZ K
When the backlash is large:
Make drive gear back adjusting shims thicker, and drive
gear front adjusting shims thinner. For selecting ad- L
justing shim, refer to the latest parts information.
When the backlash is small:
M
Make drive gear back adjusting shims thinner, and
drive gear front adjusting shims thicker. For selecting
adjusting shim, refer to the latest parts information.
N
INSPECTION AFTER DISASSEMBLY O
Drive Gear and Drive Pinion

• Clean up the disassembled parts.
• If the gear teeth never mesh or line-up correctly, determine the cause and adjust or replace as necessary. P
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive
gear and drive pinion as a set.
Bearing
• If any chipped (by friction), pitted, worn, rusted or scratched marks, or unusual noise from the bearing is
observed, replace as a bearing assembly (as a new set).
DLN-255
Oil Seal
• Whenever disassembled, replace.
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace them.
Differential Assembly
DIFFERENTIAL CASE
• If any wear or crack on the contact sides of the differential case is found, replace.
SIDE GEAR AND PINION MATE GEAR
• If any cracks or damage on the surface of the tooth is found, replace.
• If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
SIDE GEAR THRUST WASHER AND PINION MATE THRUST WASHER
• If it is chipped (by friction), damaged, or unusually worn, replace.
DLN-256
DRIVE PINION
DRIVE PINION
A
DLN
J
JSDIA5442GB
Stud bolt Connector bracket Reamer bolt K

bly
Drive pinion lock nut Pinion front bearing Gear carrier L
M
Drain plug Filler plug Pinion mate thrust washer N
O
: N·m (kg-m, ft-lb) P

: Apply gear oil.

DLN-257
DRIVE PINION

: Apply Genuine High Strength Thread Locking Sealant, Loctite 270 or equivalent.
DISASSEMBLY
1. Remove electric controlled coupling assembly. Refer to DLN-243, "Disassembly and Assembly".
2. Remove differential assembly. Refer to DLN-247, "Disassembly and Assembly".
3. Remove drive pinion oil seal, using oil seal remover (commercial service tool).
4. Fit drive pinion socket (A) onto drive pinion spline. Remove drive
pinion lock nut, using the pinion nut wrench (B).

B : Pinion nut wrench (SST: KV38109400)
JSDIA0265ZZ
5. Press drive pinion assembly out of gear carrier.

CAUTION:
Never drop drive pinion assembly.
6. Remove pinion front bearing inner race.
7. Remove collapsible spacer.
JSDIA5295ZZ
8. Remove pinion rear bearing inner race from drive pinion, using
the separator (A) and the puller (B).
A : Separator (commercial service tool)

B : Puller (commercial service tool)
JSDIA5296ZZ
9. Using a brass rod or equivalent (A), tap pinion front bearing

outer race evenly from the 2 cutouts on gear carrier and remove
pinion front bearing outer race.
CAUTION:
Be careful not to damage gear carrier.
JSDIA5297ZZ
DLN-258
DRIVE PINION
10. Using a brass rod or equivalent (A), tap drive pinion adjusting
shim evenly from the 2 cutouts on gear carrier and remove drive A
pinion adjusting shim and pinion rear bearing outer race.
CAUTION:
Be careful not to damage gear carrier.
B
"Inspection".
C
JSDIA5298ZZ
DLN
ASSEMBLY
1. Install a drive pinion adjusting shim of the same thickness as
was installed prior to disassembly. Press pinion rear bearing
E
outer race into gear carrier, using the drift (A) (SST:
ST33200000).
CAUTION:
• At first, using a hammer, tap bearing outer race until it F
becomes flush to gear carrier.
• Never reuse pinion rear bearing outer race.
G
JSDIA5299ZZ
H
2. Press pinion front bearing outer race into gear carrier, using the
drift (A) (SST: ST33230000).
CAUTION:
• At first, using a hammer, tap bearing outer race until it I
becomes flush to gear carrier.
• Never reuse pinion front bearing outer race.
J
K
JSDIA5300ZZ
3. Press pinion rear bearing inner race to drive pinion, using the
drift (A) (SST: ST23860000). L
CAUTION:
Never reuse pinion rear bearing inner race.
M
JSDIA5301ZZ
O
4. Check and adjust the tooth contact and back lash of drive gear and drive pinion following the procedure
below.
a. Assemble drive pinion into gear carrier. P
CAUTION:
• Never assemble collapsible spacer.
• Apply gear oil to pinion rear bearing.
b. Assemble pinion front bearing inner race to drive pinion assembly.
CAUTION:
• Never reuse pinion front bearing inner race.
• Apply gear oil to pinion front bearing.
DLN-259
DRIVE PINION
c. Using the drifts (A and C) and press stand (B), press pinion front
bearing inner race to drive pinion as far as drive pinion lock nut
can be tightened.

B : Press stand (SST: ST38220000)
C : Drift (SST: ST23860000)
d. Temporarily tighten removed drive pinion lock nut to drive pinion.
NOTE:
Use removed drive pinion lock nut only for the preload measure- JSDIA5302ZZ
ment.
e. Rotate drive pinion more than 20 times to adjust bearing.
f. Fit the drive pinion socket (A) onto the drive pinion. Using the
pinion nut wrench (B), tighten drive pinion lock nut holding drive
pinion, while adjusting pinion bearing preload torque using pre-
load gauge (C).
A : Drive pinion socket (SST: KV38109500 )

C : Preload gauge (SST: ST3127S000)

Torque".
CAUTION:
Drive pinion lock nut is tightened with no collapsible
spacer. Be careful not to overtighten it. While measuring the
preload, tighten it by 5° to 10°.
g. Install new side bearing adjusting shims (2 pieces for one side)
with the same thickness or re-install the old ones to the same
mounting position they were in prior to disassembly. Install dif-
ferential assembly to gear carrier. Refer to DLN-247, "Disassem-
bly and Assembly".
CAUTION:
Apply differential gear oil to the side bearings. JSDIA0266ZZ
h. Check and adjust tooth contact, drive gear to drive pinion back-
lash. Refer to DLN-252, "Adjustment".
i. Remove differential assembly.
j. Remove drive pinion assembly from gear carrier
k. Remove drive pinion nut and press drive pinion assembly out of gear carrier.
l. Remove pinion front bearing inner race.
5. Assemble collapsible spacer to drive pinion .

CAUTION:
• Be careful of the mounting direction of collapsible spacer.
• Never reuse collapsible spacer.
6. Assemble drive pinion into gear carrier.
CAUTION:
Apply gear oil to pinion rear bearing.
7. Assemble pinion front bearing inner race to drive pinion assem-
bly.
CAUTION:
• Never reuse pinion front bearing inner race. JSDIA0317ZZ
• Apply gear oil to pinion front bearing.
DLN-260
DRIVE PINION
8. Using the drifts (A and C) and press stand (B), press pinion front
bearing inner race to drive pinion as far as drive pinion lock nut A
can be tightened.
A : Drift (SST: KV40100610) B

B : Press stand (SST: ST38220000)
C : Drift (SST: ST23860000)
9. Apply anti-corrosion oil to the thread and seat of drive pinion C
lock nut, and temporarily tighten drive pinion lock nut to drive
pinion. JSDIA5302ZZ
CAUTION: DLN
Never reuse drive pinion lock nut.
10. Fit the drive pinion socket (A) onto the drive pinion. While hold-
ing drive pinion, tighten drive pinion lock nut within the limits of
E
specified torque so as to keep the pinion bearing preload within
a standard values, using the pinion nut wrench (B) and the pre-
load gauge (C).
F
C : Preload gauge (SST: ST3127S000) G
Drive pinion lock nut : Refer to DLN-257, "Explod-

tightening torque ed View". H
Torque".
I
CAUTION:
• Adjust the lower limit of the drive pinion lock nut tighten-
ing torque first.
• If the preload torque exceeds the specified value, replace J
collapsible spacer and tighten it again to adjust. Never
loose n drive pinion lock nut to adjust the preload torque.
• After adjustment, rotate drive pinion back and forth 2 to 3 K
times to check for unusual noise, rotation malfunction, JSDIA0266ZZ
and other malfunctions.

11. Install differential assembly. Refer to DLN-247, "Disassembly and Assembly".
CAUTION: L
Never install rear cover at this timing.
12. Check and adjust drive gear runout, tooth contact, and drive gear to drive pinion backlash. Refer to DLN-
252, "Adjustment". M
13. Remove dummy cover set, then install rear cover, and side oil seal. Refer to DLN-247, "Disassembly and
Assembly".
14. Check total preload torque. Refer to DLN-252, "Adjustment". N
15. Using the drift (A) (SST: ST35271000), install drive pinion oil
seal within the dimension (D) shown as follows.
O
D : 0.8 – 1.2 mm (0.031 – 0.047 in)
CAUTION:
• Never reuse oil seal. P
16. Install electric controlled coupling assembly. Refer to DLN-243,
JSDIA5262ZZ
DLN-261
DRIVE PINION

Drive Gear and Drive Pinion
• If the gear teeth never mesh or line-up correctly, determine the cause and adjust or replace as necessary.
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive
gear and drive pinion as a set.
Bearing
• If any chipped (by friction), pitted, worn, rusted or scratched marks, or unusual noise from the bearing is
observed, replace as a bearing assembly (as a new set).
Oil Seal
• Whenever disassembled, replace.
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace them.
DLN-262
< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR FINAL DRIVE: R145]
SERVICE DATA AND SPECIFICATIONS (SDS) A

B
Axle 4WD
C
Applied model Engine MR20DD QR25DE R9M
Transaxle CVT M/T
Final drive model R145 DLN
Gear ratio 2.466
Number of teeth (Drive gear/Drive pinion) 37/15
E
Number of pinion gears 2
Drive pinion adjustment spacer type Collapsible
Oil capacity Refer to MA-23, "Fluids and Lubricants". F
Unit: N·m (kg-m, in-lb) G

Item Standard
Pinion bearing (P1) 0.69 – 1.18 (0.07 – 0.12, 7 – 10) H
Side bearing (P2) 0.66 – 1.00 (0.07 – 0.10, 6 – 8)
Side bearing to pinion bearing (Total preload)
1.35 – 2.18 (0.14 – 0.22, 12 – 19)
(Total preload = P1 + P2) I
Drive Gear Runout INFOID:0000000011008636
Unit: mm (in) J
Item Standard
Drive gear back face runout 0.05 (0.0020) or less
K
Unit: mm (in) L
Item Standard
Drive gear to drive pinion gear 0.10 – 0.15 (0.0039 – 0.0059)
M
Differential Side Gear Clearance INFOID:0000000011008638
Unit: mm (in)
N
Item Standard
0.10 (0.004) or less
Side gear backlash (Clearance between side gear and differential
(Each gear should rotate smoothly without excessive resistance
case) O
during differential motion.)
DLN-263

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What are the main components of the 4WD system described in the document?

What are the main components of the 4WD system described in the document?

What are the main functions of the 4WD control unit?

What are the main functions of the 4WD control unit?

TRANSMISSION & DRIVELINE

SECTION DLN DRIVELINE

HOW TO USE THIS MANUAL ...................... 7 INFORMATION DISPLAY (COMBINATION

PRECAUTIONS ................................................... 8 WARNING/INDICATOR/CHIME LIST ........................23

C1201 4WD CONTROL UNIT ............................ 42 4WD INDICATOR LAMP ................................... 67

C1203 ABS ACTUATOR AND ELECTRIC LOCK INDICATOR LAMP ................................. 68

C1210 ECM ........................................................ 50 4WD HIGH TEMP IS DISPLAYED ON INFOR-

P1804 4WD CONTROL UNIT ............................ 51 TIRE SIZE INCORRECT IS DISPLAYED ON

SERVICE DATA AND SPECIFICATIONS WARNING/INDICATOR/CHIME LIST ...................... 127

C1210 ECM ...................................................... 154 4WD HIGH TEMP IS DISPLAYED ON INFOR-

DRIVE PINION .................................................. 192 PRECAUTION ............................................ 220

PRECAUTIONS ................................................ 209 PERIODIC MAINTENANCE ...................... 227

ELECTRIC CONTROLLED COUPLING ......... 231 DRIVE PINION .................................................. 257

AIR BREATHER .............................................. 236 SERVICE DATA AND SPECIFICATIONS

HOW TO USE THIS MANUAL A

KV381054S0 Removing ring gear shaft oil seal

Commercial Service Tool INFOID:0000000010991951

Tool name Description

Drift Installing ring gear shaft oil seal

Puller Removing ring gear bearing (left) inner race

Drift Installing oil seal (installing pinion bearing

Drift Installing side oil seal [installing transfer cover

Replacer • Removing drive pinion

Drift Installing ring gear bearing (left) inner race

Drift Installing ring gear bearing (left) outer race

Drift Installing ring gear bearing (right) outer race F

Drift Installing companion flange

No. Component Function

4WD solenoid Refer to DLN-15, "4WD Solenoid".

• Controls driving force distribution by signals from each sensor from

• 4WD solenoid is integrated with electric controlled coupling. N

4WD mode is selectable among 2WD mode, AUTO mode, and

Transfer cover Transfer case Ring gear bearing (transfer case M

Operation Description INFOID:0000000010991959

Engine Transaxle Transfer

ELECTRIC CONTROLLED COUPLING

• Transmission torque to the rear wheels is determined accord-

4WD SYSTEM : Control in Each Mode INFOID:0000000010991961

DTC Vehicle condition

4WD SYSTEM : Protection Function INFOID:0000000010991964

4WD warning (on infor- Contents of protection

Symbol Message Condition

Tire Size Incorrect

SYNCHRONIZATION WITH MASTER WARNING LAMP

WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display)

Diagnostic test mode Function C

Monitor item (Unit) Remarks

Monitor item (Unit) Remarks

Test item Condition Description

ECU DIAGNOSIS INFORMATION A

VALUES ON THE DIAGNOSIS TOOL

Monitor item Condition Value/Status DLN

PARKING BRAKE SW Parking brake operated On

FR RH SENSOR Vehicle running Nearly matches the speed

FR LH SENSOR Vehicle running Nearly matches the speed

Climate con- Weather Fine Cloud Rain Snow Others ( )