2.

5 Transfer Case Contents

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––
2.5 Model 163

Diagnosis
Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/1
Diagnostic Trouble Code (DTC) Memory . . . . . . . . . . . . . . . . 12/1
Complaint Related Diagnostic Chart . . . . . . . . . . . . . . . . . . . 13/1

Electrical Test Program

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21/1
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/1

b Diagnostic Manual • Chassis and Drivetrain • 06/98 2.5 C/1

2.5 Transfer Case
Diagnosis – Function Test
Notes regarding Transfer Case DTC Memory
1. If there are DTC's stored in the transfer case memory, then additional
tests can be acomplished via the HHT (such as: comparison of
Nominal/Actual Values).
2. The HHT will show in its display only defective electrical components,
or will refer directly to additional tests.
3. Should additional Actual Values be required for diagnosis, then these
can be displayed by pressing the F1 key. Pressing the "B" (return)
key, returns the display back to the current troubleshooting text
selected.
4. Information found in the Diagnostic Manual can be retrieved by pressing
the F4 key. Pressing the "B" (return) key, returns the display back to
the current troubleshooting text selected.
b Diagnostic Manual • Chassis and Drivetrain • 06/98
Model 163
5. To allow for quicker troubleshooting and to reduce the individual tests to
a minimum, all text pertaining to the transfer case have been
incroporated into the HHT test software. Which means that the entire
test sequence is shown once the DTC stored in the memory is
selected. The test sequence includes details on fault causes and their
solutions.
6. Cables and connections are included in the HHT test, however, they
should be checked again individually for open circuits, good contact
and proper connection, according to the wiring diagram.
2.5 11/1
2.5 Transfer Case Model 163

Diagnosis – Diagnostic Trouble Code (DTC) Memory

1. Connect HHT to data link connector (X11/4) as shown in connection

diagram (see section 0).

2. Ignition: ON

3. Perform Quick Test with HHT and readout DTC'S.

Note:
The HHT, via its display indicates only the defective electrical
components or refers to the corresponding Test step.

4. If no DTCs are stored in memory, then proceed with 13

b Diagnostic Manual • Chassis and Drivetrain • 06/98 2.5 12/1

2.5 Transfer Case Model 163

Diagnosis – Diagnostic Trouble Code (DTC) Memory

DTC Note Possible cause Test step/Remedy 1)

A
PI6I4 Valid for diagnostic version 1 Internal fault within transfer case control Replace N78
module (N78).

PI83I Valid for diagnostic version 1 Fault with voltage supply to transfer case range Wiring,
selection motor (A55) or position signal sensor Plug connectors,
at transfer case range selection motor is A55
unplausible.
1) Observe Preparation for Test, see 22.

b Diagnostic Manual • Chassis and Drivetrain • 06/98 2.5 12/2

2.5 Transfer Case Model 163

Diagnosis – Complaint Related Diagnostic Chart

A Complaint/Problem Possible cause

No DTC LOW RANGE indicator 1. The requirements for the function 1. Correct flow of events. See owners manual for
stored lamp (A1e53) blinks 4X within "Low range" have not been fulfilled. operational requirements for use of low range.
2 seconds and then goes out.

b Diagnostic Manual • Chassis and Drivetrain • 06/98 2.5 13/1

2.5 Transfer Case Model 163

Electrical Test Program – Component Locations

Model 163
The transfer case control module (N78) is
located forward of the transmission selector lever
under the center console

N78 Transfer case control module

P28.19-0205-06

b Diagnostic Manual • Chassis and Drivetrain • 06/98 2.5 ETC 21/1

2.5 Transfer Case Model 163

Electrical Test Program – Component Locations

Model 163
The transfer case range selection
motor (A55) is located and bolted
to the rearside of the transfer case

A55 Transfer case range selection motor

P28.19-0204-06

b Diagnostic Manual • Chassis and Drivetrain • 06/98 2.5 ETC 21/2

2.5 Transfer Case Model 163

Electrical Test Program – Component Locations

Model 163
The "low range" switch (S97/6) is located in the
upper center portion of the center console

S97/6 "Low range" switch

P28.19-0206-06

b Diagnostic Manual • Chassis and Drivetrain • 06/98 2.5 ETC 21/3

2.5 Transfer Case Model 163

Electrical Test Program – Component Locations

Model 163
The LOW RANGE indicator lamp (A1e53) is
located in the left hand portion of the instrument
cluster (A1)

A1e53 LOW RANGE indicator lamp

P28.19-0207-06

b Diagnostic Manual • Chassis and Drivetrain • 06/98 2.5 ETC 21/4

2.5 Transfer Case Model 163

Electrical Test Program – Test

Connector Layout - Transfer case control

module (N78)

P28.19-0202-04

A1 – B1 Circuit 15 voltage supply

A2 Input signal (ground) from position sensor in tranfer B2 CAN data line (Low)
case range selection motor B3 CAN data line (High)
A3 Input signal from LOW RANGE switch (S97/6) B4 Input signal from position sensor (position 4)
A4 Transfer case control module (N78) ground B5 Input signal from position sensor (position 3)
A5 – B6 Input signal from position sensor (position 2)
A6 Circuit 30 voltage supply B7 Input signal from position sensor (position 1)
A7 – B8 Output signal Low Æ High
A8 Output signal High Æ Low

b Diagnostic Manual • Chassis and Drivetrain • 06/98 2.5 23/1

2.5 Transfer Case Model 163

Electrical Test Program – Test

Connector Layout - 13 position round

connector at transfer case range selection
motor (A55)

A Output signal from position sensor (position 4)

B Intput signal Low Æ High
C Output signal from position sensor (position 3)
D Output signal from position sensor (position 2)
E Output signal from position sensor (position 1)
F Output signal (ground) from position sensor in tranfer
case range selection motor
G Intput signal High Æ Low

P28.19-0203-01

b Diagnostic Manual • Chassis and Drivetrain • 06/98 2.5 23/2