4 Wheel Drive (4WD) System

Specifications
Tightening Torques
Items N.m Kgf.m lb-ft
Transfer assembly mounting
60.8 ~ 65.7 6.2 ~ 6.7 44.8 ~ 48.5
bolts
4WD ECM mounting nuts 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Coupling assembly
56.9 ~ 64.7 5.8 ~ 6.6 42.0 ~ 47.7
mounting bolts
Propeller shaft mounting
49.0 ~ 68.6 5.0 ~ 7.0 36.2 ~ 50.6
bolts
Transfer oil drain plug 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Transfer oil filler plug 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Lubricants

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Engine Items Specification Capacity
0.68 L
Gasoline
(0.18 U.S.gal, 0.72 U.S.qt, 0.60
3.3 Hypoid gear oil, MS 517-I5 GT lmp,qt)
Transfer oil (SAE 75W/90, API GL-5, SHELL SPIRAX X or
equivalent) 0.6 L
Gasoline
(0.16 U.S.gal., 0.63 U.S.qt, 0.53
2.4
Imp.qt.)
Transfer
All techlube megamax - alpha or equivalent As required
spline
0.485 L
All Coupling oil shell tf0870 (0.13 U.S.gal., 0.51U.S.qt,
0.43Imp.qt.)

4 Wheel Drive (4WD) System

Special Service Tools

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 Tools
(Number and Illustration Use
name)
09431-45100 Installation of transfer case oil seal.
Oil seal installer (Right side)

09473-3B100 Installation of transfer case oil seal.

Oil seal installer (Both side)

In case of right side oil seal of gasoline 3.3, use it after installing
the coupling (A).

4 Wheel Drive (4WD) System

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Inspection

• Transfer oil should be inspected and refilled every 60000 km (40000 mile) / 4 year.
1. Remove the under cover.
(Refer to Engine Mechanical System - "Engine Room Under Cover")
2. Remove the oil filler plug (A).
[Gasoline 2.4]

[Gasoline 3.3]

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3. Check the oil level.

Oil level must be up to fill the hole, if not, add oil until it runs
over.

4. Install the oil filler plug with new gasket.

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Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

5. Install the under cover.

(Refer to Engine Mechanical System - "Engine Room Under Cover")
Replacement

Change
Normal Use Severe Use
120,000 km
No service required
(80,000 miles)

Severe driving conditions

1. Driving in dusty, rough roads
2. Drivng in mountains areas
3. Driving for patrol car, taxi, commercial car or vehicle towing
4. Driving over 170Km/h
* Transfer oil should be replaced if the transfer assembly is fall into the water.
1. Remove the under cover.
(Refer to Engine Mechanical System - "Engine Room Under Cover")

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2. Drain the transfer oil after loosening the drain plug (A).

3. Install the drain plug with new gasket.

Tightening torque :
58.9 ~ 78.5 N.m (6.0 ~ 8.0 kgf.m, 43.4 ~ 57.9 lb-ft)

4. Remove the oil filler plug (A).

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[Gasoline 2.4]

[Gasoline 3.3]

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5. Add new oil through the filler plug hole.

Standard oil :
Hypoid gear oil, MS 517-I5 GT
(SAE 75W/90, API GL-5, SHELL SPIRAX X or equivalent)
Oil capacity :
Gasoline 2.4: About 0.6 L (0.16 U.S.gal., 0.63 U.S.qt, 0.53 Imp.qt.)
Gasoline 3.3: About 0.68 L(0.18 U.S.gal, 0.72 U.S.qt, 0.60 lmp,qt)

• Filled up to lower filler plug thread level.

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6. Install the oil filler plug with new gasket.

Tightening torque :
39.2 ~ 58.8 N.m (4.0 ~ 6.0 kgf.m, 28.9 ~ 43.4 lb-ft)

7. Install the under cover.

(Refer to Engine Mechanical System - "Engine Room Under Cover")
4 Wheel Drive (4WD) System

Components Location

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1. Under cover 4. Propeller shaft
2. Transaxle 5. Coupling assembly
Assembly
3. Transfer assembly

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1. Under cover 4. Propeller shaft
2. Transaxle 5. Coupling assembly
Assembly
3. Transfer assembly

4 Wheel Drive (4WD) System

Removal

It is not recommended to overhaul the transfer assembly because a special three-dimensional measuring instrument is
required to determine the sizes of the transfer assembly spacers when disassembling and reassembling the transfer
assembly. If putting wrong sized spacers in the transfer assembly, it may cause noise and vibration.So, if inner parts of the
transfer assembly need to be replaced, the transfer assembly should be replaced with new one.

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1. Remove the following items;
A. Sub frame assembly (Only gasoline 3.3)
(Refer to Suspension System - "Sub Frame")
B. Front muffler. (Only gasoline 3.3)
(Refer to Engine Mechanical System - "Front Muffler ")
C. Drive shaft assembly.
(Refer to Driveshaft and axle - "Front Driveshaft ")
2. Remove the propeller shaft (A).

Tightening torque :
49.0 ~ 68.6 N.m (5.0 ~ 7.0 kgf.m, 36.2 ~ 50.6 lb-ft)

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3. Loosen the transfer upper & lower mounting bolts. (transfer side → transaxle side)

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4. Loosen the transfer lower mounting blot. (transaxle side → transfer side)

Installation
1. Install in the reverse order of removal.

1. Be careful not to damage the O-ring (A). If the O-ring is damaged, replace with a new one.
2. Smear and cover splines (B) with molybdenum type high pressure grease.

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TECHLUBE MEGAMAX - ALPHA or equivalent

3. Install the propeller shaft to be near runout marking (Transfer assembly 1ea, propeller shaft 1ea) each
other.

4 Wheel Drive (4WD) System

Replacement
[Right side]

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1. Remove the front muffler. (Only gasoline 3.3)
(Refer to Engine Mechanical System - "Front Muffler ")
2. Remove the driveshaft assembly. (RH side)
(Refer to Driveshaft and axle - "Front Driveshaft ")
3. Remove the dust cover (A).

4. Remove the oil seal (A, B).

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5. Install the oil seal with special service tools.

• Apply lithium type grease between seal lips.

• Use the oil seal installer (09473-3B100) after removing the coupling
(A).

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6. Install the new dust cover (A).

7. Add to transfer fluid.

(Refer to 4 Wheel Drive System - "Transfer Fluid")
8. Install the drive shaft assembly. (RH side)
(Refer to Driveshaft and axle - "Front Driveshaft ")
9. Install the front muffler. (Only gasoline 3.3)
(Refer to Engine Mechanical System - "Front Muffler ")
[Left side]
1. Remove the transfer assembly from the transaxle assembly.
(Refer to Transfer Assembyl - "Front Wheel Transfer Assembly")

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2. Remove the oil seal (A).
[Gasoline 2.4]

[Gasoline 3.3]

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3. Install the oil seal with special service tools.

• Apply lithium type grease between seal lips.

• Use the oil seal installer (09473-3B100) after removing the coupling
(A).
(Gasoline 2.4)
• Use the oil seal installer (09473-3B100) after installing the coupling
(A).
(Gasoline 3.3)

[Gasoline 2.4]

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 [Gasoline 3.3]

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4. Add to transfer fluid.
(Refer to 4 Wheel Drive System - "Transfer Fluid")
5. Install the transfer assembly.
(Refer to 4 Wheel Drive System - "Front Wheel Transfer Assembly")
4 Wheel Drive (4WD) System

Adjustment
Description
The friction material inside the coupling will degrade over time. Therefore, corresponding compensation values must be
referenced and entered after replacing the controller or the coupling.
Compensation Requirement and Procedure
1. Simultaneous replacement of 4WD ECU (Controller) and coupling
A. Does not require compensation.

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2. Replacement of coupling only
A. Reset the 4WD ECU's (Controller) clutch learning.

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3. Replacement of 4WD ECU (Controller) only

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 A. Before replacement: Check the ECU's clutch learning.

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 B. After replacement: Enter the original ECU's clutch learning into the replacement ECU.

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4 Wheel Drive (4WD) System

Components Location

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1. 4WD ECU

4 Wheel Drive (4WD) System

Description
4WD ECU processes signals from various sensors and determines the current road and driving conditions. The ECU then
utilizes this information to implement precision control over the 4WD coupling's multi-plate clutch and variably adjust the
amount of torque delivered tothe rear wheels.

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 4 Wheel Drive (4WD) System

Power Flow Diagram

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4WD ECU Input&Output Diagram

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4 Wheel Drive (4WD) System

Circuit Diagram
4WD ECU Connector

Pin Function
1 MOTOR A
2 MOTOR B
3 LOCK MODE SWITCH (Input)
4 -
5 PRESSURE SENSOR SIGNAL (Input)
6 -
7 CAN communication line (Low)
8 CAN communication line (High)
9 -
10 -
11 -
12 IG. POWER (Input)

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13 GROUND
14 BATTERY (Input)
15 PRESSURE SENSOR GROUND (-)
16 PRESSURE SENSOR SUPPLY (+)
17 -
18 -

4WD ECU Circuit Diagram

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4 Wheel Drive (4WD) System

Removal
1. Prior to replacing the 4WD ECU, check the 4WD ECU's clutch learing with the GDS tool.
(Refer to 4WD Control System - "Repair procedures")
2. Disconnect the battery negative cable from the battery

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3. Disconnect the 4WD ECU connector (A).

4. Loosen the nuts (A) and then remove the 4WD ECU.

Tightening torque:
56.9 ~ 64.7 N.m (5.8 ~ 6.6 kgf.m, 42 ~ 47.7 lb-ft)

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Installation
1. Install in the reverse order of removal.
2. Prior to installing a new ECU, upload the original ECU’s clutch learing to the replacement ECU using the GDS tool.
(Refer to 4WD Control System - "Repair procedures")
4 Wheel Drive (4WD) System

Component Location

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1. Coupling 3. Transfer assembly
assembly
2. Propeller shaft

Components

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1. Coupling assembly 4. Extension wiring
2. Input shaft 5. Oil hydraulic
3. Pressure sensor Motor(Actuator)

4 Wheel Drive (4WD) System

Description
4WD ECU processes signals from various sensors and determines the current road and driving conditions. The ECU then
utilizes this information to implement precision control over the 4WD coupling's multi-plate clutch and variably adjust the
amount of torque delivered tothe rear wheels.
Four Wheel Drive (4WD) transfer mode selection
1. AUTO MODE:
A. When driving in 4WD AUTO mode, the vehicle operates similar to conventional 2WD vehicles under normal
operating conditions. However, if the system determines that there is a need for the 4WD mode, the engine’s driving
power is distributedto all four wheels automatically without driver intervention.
B. When driving on normal roads and pavement, the vehicle moves similar to conventional 2WD vehicles.

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 2. LOCK MODE:
A. This mode is used for climbing or descending sharp grades, off-road driving, driving on sandy and muddy roads, etc.,
to maximize traction.
B. This mode automatically begins to deactivate at speeds above 30 km/h (19 mph) and is shifted to 4WD AUTO
mode at speed above 40 km/h (25 mph). If the vehicle speed decelerates to below 30 km/h (19 mph), however, the
transfermode is shifted into 4WD LOCK mode again.
Electronic Coupling - 4WD Control (By Driving Condition)
1. Cruising (Auto Mode)
- Power is delivered mostly to the front wheels.

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2. Cornering (Auto Mode)
- Adjusts the amount of power to the rear wheels based on the turning radius and cornering speed.

3. Wheel Slip (Auto Mode)

- If one or both of the front wheels lose traction, the system transfers an appropriate amount of power to the rear wheels
based on the slip amount at the front wheels.

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4. Lock Mode
- Maximizes rough terrain performance (active only at speeds below 40 km/h).

Operation
Electronic Coupling
[Inactive]

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[Active]

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Operation Order
1. 4WD ECU receives CAN signals from the vehicle's sensors.
2. 4WD ECU calculates the necessary amount of rear-wheel torque and sends the corresponding driving current to the
actuator (electronic motor and hydraulic pump).
3. Hydraulic pressure generated by the actuator moves the piston.
4. Friction from the piston's movement engages the clutch.
5. Power is delivered to the rear wheels.

4 Wheel Drive (4WD) System

Inspection

All units are filled up with coupling fluid (ultra-low viscosity ATF) prior to shipping. Inspection, fill-up, and replacement of
coupling fluid is therefore not necessary (zero maintenance, lifetime fluid).
Removal

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Coupling Maintenance Precautions
Maintain the coupling at a horizontal level.
• Refer to the handling caution level (A) when servicing the coupling (removal, installation, replacement, etc.).

1. Remove the 4WD coupling assembly bolts (A-3ea) mounted to the rear propeller shaft (B).

Tightening torque :
49.0 ~ 68.6 N.m (5.0 ~ 7.0 kgf.m, 36.2 ~ 50.6 lb-ft)

2. Using a flat tool, separate the propellar shaft from 4WD coupling assembly.

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3. Disconnect the pressure sensor connector (A) and Oil hydraulic Motor connector (B).

4. Loosen the coupling assembly mounting bolts (A-4ea).

Tightening torque :
58.8 ~ 63.7 N.m (6.0 ~ 6.5 kgf.m, 43.4 ~ 47.0 lb-ft)

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5. Using a flat tool, separate the 4WD coupling assembly from the rear differential carrier assembly.
Installation
1. Install in the reverse order of removal.

• Smear the splines (A) with molybdenum type high pressure

grease.
• When install the coupling, be careful not to damage the oil seal
(B).

2. After replacing the coupling, reset the 4WD ECU's clutch learing using the GDS tool.
(Refer to 4WD Control System - "Repair procedures")
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 4 Wheel Drive (4WD) System

Description
The 4WD ECM controls the Pump Motor Pump (Actuator) to generating an oil pressure. The pressure engages a multiple
disk clutch to transfer torque to the rear wheels. The torque to the rear wheels varies according to the pressure on the clutch.

4 Wheel Drive (4WD) System

Circuit Diagram

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4 Wheel Drive (4WD) System

Inspection

If you have trouble code related to the oil hydraulic motor (actuator), check oil hydraulic motor (actuator) according to the
inspection process.

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Oil Hydraulic Motor (Actuator) Inspection Procedure

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Removal
1. Remove the coupling assembly.
(Refer to Coupling Assembly - "Direct Electro Hydraulic Actuator Coupling")
2. Keep going perpendicular state after remove the coupling assembly.

• Keep going perpendicular state during remove (install) the hydraulic motor
(actuators).

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3. Remove the hydraulic motor (A) after loosening bolts with hex wrench.

• Remove the hydraulic motor (actuators) after dropping residual oil as much as possible inside the coupling.
(about 5~10 sec)

Installation
1. Before installation, wipe the surface with a clean cloth.

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2. Check the O-rings (A) of the new hydraulic motor (actuators).

• You have to prevent any dust from entering inside hydraulic motors (actuators) and
housing.

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3. Tighten the bolts after install the hydraulic motor (actuators).

• When installing, motor connector has to toward in the direction of outside of the Coupling.

Tightening torque:
8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 8.0 lb-ft)

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• When installing, oil can be reflux by the pressure in air breather hole.

• Change direction in the direction of the arrow and lay on the floor as shown in the
illustration.
The reflux oil will flow to the bottom.
• You have to prevent additional backflow in according to order as shown in the illustration.

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4. Wipe the flowed oil to around the surface with a clean cloth.

5. Install the coupling assembly.

(Refer to Coupling Assembly - "Direct Electro Hydraulic Actuator Coupling")
4 Wheel Drive (4WD) System

Description
The 4WD ECU makes a Motor Pump(Actuator) turn round for generating an oil pressure. And then it presses a multiple
disk clutch and transfers the generated torque into rear wheels. Its torque value varies according to a pressure status.

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4 Wheel Drive (4WD) System

Circuit Diagram

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4 Wheel Drive (4WD) System

Inspection

If you have trouble code related to the pressure sensor check pressure sensor according to the inspection process.
Pressure Sensor Inspection Procedure

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Measure the resistance of pressure sensor
1. Turn ignition switch OFF.
2. Disconnect the pressure sensor connector.
3. Measure resistance between sensor terminal and terminal.
4. Check the measured resistance. (Refer to table)
Terminal Resistance
PIN 2 – PIN 3 2.755 ~ 4.133 kΩ
PIN 1 – PIN 3 1.892 ~ 2.838 kΩ
PIN 1 – PIN 2 1.714 ~ 2.838 kΩ

Removal
1. Remove the coupling assembly.
(Refer to Coupling Assembly - "Direct Electro Hydraulic Actuator Coupling")

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2. Remove the extensioncable (A).

3. Remove the pressure sensor (A) with 24mm socket.

• Keep going horizontal state to prevent leaks during remove the pressure sensor.

Tightening torque:
7.8 ~ 9.8 N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2 lb-ft)

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Installation

• Check the cleanliness of the pressure sensor before installation.

• Check the pressure sensor O-ring (A).

1. Install in the reverse order of removal.

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