Driveline: Section

TRANSMISSION & DRIVELINE
SECTION DLN DRIVELINE

B
DLN
E
CONTENTS
TRANSFER: TY21C INFORMATION DISPLAY (COMBINATION F
METER) : 4WD Warning .........................................18
PRECAUTION ............................................... 6 INFORMATION DISPLAY (COMBINATION
METER) : 4WD Torque Distribution Indicator ..........19 G
PRECAUTIONS ................................................... 6
Precaution for Supplemental Restraint System WARNING/INDICATOR/CHIME LIST ........................19
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- WARNING/INDICATOR/CHIME LIST : Warning
SIONER" ................................................................... 6 Lamp/Indicator Lamp ...............................................19 H
Precaution for Battery Service .................................. 6 WARNING/INDICATOR/CHIME LIST : Warning/
Precaution for Procedure without Cowl Top Cover...... 6 Indicator (On Information Display) ...........................20
Service Notice or Precautions for Transfer ............... 6 I
DIAGNOSIS SYSTEM (4WD CONTROL
PREPARATION ............................................ 8 UNIT) ................................................................. 21
CONSULT Function .................................................21
PREPARATION ................................................... 8 J
Special Service Tool ................................................. 8 ECU DIAGNOSIS INFORMATION .............. 23
Commercial Service Tool .......................................... 8
4WD CONTROL UNIT ....................................... 23 K
SYSTEM DESCRIPTION ............................. 11 Reference Value ......................................................23
Fail-Safe ..................................................................25
COMPONENT PARTS .......................................11 Protection Function ..................................................26
Component Parts Location ...................................... 11 DTC Inspection Priority Chart ..................................26 L
4WD Control Unit .................................................... 12 DTC Index ...............................................................26
Electric Controlled Coupling .................................... 12
4WD Solenoid ......................................................... 12 WIRING DIAGRAM ...................................... 28 M
4WD Mode Switch ................................................... 12
4WD SYSTEM ................................................... 28
STRUCTURE AND OPERATION .......................13 Wiring Diagram ........................................................28
Sectional View ......................................................... 13 N
Operation Description ............................................. 13 BASIC INSPECTION ................................... 33
SYSTEM .............................................................15 DIAGNOSIS AND REPAIR WORK FLOW ....... 33
O
Work Flow ................................................................33
4WD SYSTEM ........................................................... 15 Diagnostic Work Sheet ............................................34
4WD SYSTEM : System Description ...................... 15
4WD SYSTEM : Control in Each Mode ................... 16 ADDITIONAL SERVICE WHEN REPLACING P
4WD SYSTEM : Circuit Diagram ............................. 17 4WD CONTROL UNIT ....................................... 36
4WD SYSTEM : Fail-Safe ....................................... 17 Description ...............................................................36
4WD SYSTEM : Protection Function ...................... 18 Work Procedure .......................................................36
INFORMATION DISPLAY (COMBINATION UNIT CHARACTERISTICS WRITING .............. 37

METER) ..................................................................... 18 Description ...............................................................37
Work Procedure .......................................................37
DLN-1
DTC/CIRCUIT DIAGNOSIS ......................... 38 Diagnosis Procedure ............................................... 60
C1201 4WD CONTROL UNIT ............................ 38 4WD INDICATOR LAMP ................................... 63

DTC Description ..................................................... 38 Component Function Check ................................... 63
Diagnosis Procedure .............................................. 38 Diagnosis Procedure ............................................... 63
C1203 ABS ACTUATOR AND ELECTRIC LOCK INDICATOR LAMP ................................. 64

UNIT (CONTROL UNIT) .................................... 39 Component Function Check ................................... 64
DTC Description ..................................................... 39 Diagnosis Procedure ............................................... 64
Diagnosis Procedure .............................................. 39
SYMPTOM DIAGNOSIS ............................ 65
C1204 4WD SOLENOID .................................... 40
DTC Description ..................................................... 40
HEAVY TIGHT-CORNER BRAKING SYMP-
Diagnosis Procedure .............................................. 40 TOM OCCURS ................................................... 65
Component Inspection ............................................ 42 Description .............................................................. 65
Diagnosis Procedure ............................................... 65
C1209 MODE SW .............................................. 43
DTC Description ..................................................... 43 VEHICLE DOES NOT ENTER 4WD MODE ...... 66
Diagnosis Procedure .............................................. 43 Description .............................................................. 66
Component Inspection ............................................ 45 Diagnosis Procedure ............................................... 66
C1210 ECM ........................................................ 46 4WD HIGH TEMP IS DISPLAYED ON INFOR-

DTC Description ..................................................... 46 MATION DISPLAY ............................................ 67
P1804 4WD CONTROL UNIT ............................ 47 TIRE SIZE INCORRECT IS DISPLAYED ON

DTC Description ..................................................... 47 INFORMATION DISPLAY ................................. 68
Diagnosis Procedure ............................................... 68
P1808 WHEEL SPEED SENSOR ...................... 48
DTC Description ..................................................... 48 NOISE, VIBRATION AND HARSHNESS
Diagnosis Procedure .............................................. 48 (NVH) TROUBLESHOOTING ............................ 69
NVH Troubleshooting Chart .................................... 69
P1809 4WD CONTROL UNIT ............................ 49
DTC Description ..................................................... 49 PERIODIC MAINTENANCE ....................... 70
TRANSFER OIL ................................................. 70
P1811 BATTERY VOLTAGE ............................. 50 Inspection ................................................................ 70
DTC Description ..................................................... 50 Draining ................................................................... 70
Diagnosis Procedure .............................................. 50 Refilling ................................................................... 70
P181B INCOMPLETE SELFSHUT .................... 53 REMOVAL AND INSTALLATION .............. 72

DTC Description ..................................................... 53
Diagnosis Procedure .............................................. 53 4WD CONTROL UNIT ....................................... 72
Exploded View ........................................................ 72
P181D ENGINE TORQUE SIGNAL ................... 56 Removal and Installation ......................................... 72
DTC Description ..................................................... 56 Adjustment .............................................................. 72
4WD MODE SWITCH ........................................ 73
P181F INCOMPLETE CALIBRATION .............. 57 Exploded View ........................................................ 73
DTC Description ..................................................... 57 Removal and Installation ......................................... 73
TRANSFER COVER OIL SEAL ........................ 74
U1000 CAN COMM CIRCUIT ............................ 58 Exploded View ........................................................ 74
DTC Description ..................................................... 58 Removal and Installation ......................................... 74
Diagnosis Procedure .............................................. 58 Inspection ................................................................ 75
U1010 CONTROL UNIT (CAN) ......................... 59 UNIT REMOVAL AND INSTALLATION .... 76
DTC Description ..................................................... 59
Diagnosis Procedure .............................................. 59 TRANSFER ASSEMBLY ................................... 76
Exploded View ........................................................ 76
POWER SUPPLY AND GROUND CIRCUIT ..... 60 Removal and Installation ......................................... 76
DLN-2
Inspection ................................................................ 77 SYSTEM DESCRIPTION ........................... 105
A
UNIT DISASSEMBLY AND ASSEMBLY ... 78 AWD SYSTEM ................................................ 105
System Diagram .................................................... 105
TRANSFER COVER ...........................................78 System Description ................................................ 106
Exploded View ........................................................ 78 B
Component Parts Location .................................... 108
Disassembly ............................................................ 79 Component Description ......................................... 108
Assembly ................................................................. 80
Inspection ................................................................ 81 DIAGNOSIS SYSTEM (AWD CONTROL C
UNIT) ............................................................... 109
RING GEAR SHAFT ...........................................82 CONSULT Function ............................................... 109
Exploded View ........................................................ 82
Disassembly ............................................................ 83 DLN
DTC/CIRCUIT DIAGNOSIS ....................... 111
Assembly ................................................................. 84
Inspection ................................................................ 85 C1201 AWD CONTROL UNIT ........................ 111
Description ............................................................. 111 E
DRIVE PINION ....................................................86 DTC Logic .............................................................. 111
Exploded View ........................................................ 86 Diagnosis Procedure ............................................. 111
Disassembly ............................................................ 87
C1203 ABS ACTUATOR AND ELECTRIC F
Assembly ................................................................. 87
Adjustment .............................................................. 88 UNIT (CONTROL UNIT) .................................. 112
Inspection ................................................................ 93 Description ............................................................. 112
DTC Logic .............................................................. 112 G
TRANSFER CASE .............................................94 Diagnosis Procedure ............................................. 112
Exploded View ........................................................ 94
Disassembly ............................................................ 95 C1204 AWD SOLENOID ................................. 113 H
Assembly ................................................................. 95 Description ............................................................. 113
Inspection ................................................................ 96 DTC Logic .............................................................. 113
Diagnosis Procedure ............................................. 113
SERVICE DATA AND SPECIFICATIONS Component Inspection ........................................... 115 I
(SDS) ............................................................ 97
C1209 MODE SW ............................................ 116
SERVICE DATA AND SPECIFICATIONS Description ............................................................. 116 J
(SDS) ..................................................................97 DTC Logic .............................................................. 116
General Specifications ............................................ 97 Diagnosis Procedure ............................................. 116
Preload Torque ....................................................... 97 Component Inspection ........................................... 118
K
Backlash .................................................................. 97
Companion Flange Runout ..................................... 97 C1210 ECM ..................................................... 119
TRANSFER: TY30A Description ............................................................. 119
DTC Logic .............................................................. 119 L
PRECAUTION .............................................. 98 Diagnosis Procedure ............................................. 119
PRECAUTIONS ..................................................98 P1804 CONTROL MODULE ........................... 120

DTC Logic .............................................................. 120 M
Precautions for Removing Battery Terminal ........... 98
Precaution for Supplemental Restraint System Diagnosis Procedure ............................................. 120
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
P181F INCOMPLETE CALIBRATION ............ 121 N
SIONER" ................................................................. 99
DTC Logic .............................................................. 121
Precaution for Procedure without Cowl Top Cover.... 99
Diagnosis Procedure ............................................. 121
Service Notice or Precautions for Transfer ............. 99
U1000 CAN COMM CIRCUIT ......................... 122 O
PREPARATION ......................................... 101 Description ............................................................. 122
PREPARATION ................................................ 101 DTC Logic .............................................................. 122
Special Service Tools ............................................ 101 Diagnosis Procedure ............................................. 122 P
Commercial Service Tools .................................... 102 U1010 CONTROL UNIT (CAN) ....................... 123
BASIC INSPECTION ................................. 104 Description ............................................................. 123
DTC Logic .............................................................. 123
DIAGNOSIS AND REPAIR WORKFLOW ....... 104 Diagnosis Procedure ............................................. 123
Work Flow ............................................................. 104
POWER SUPPLY AND GROUND CIRCUIT .. 124
Description ............................................................. 124
DLN-3
Diagnosis Procedure .............................................124 TRANSFER OIL ................................................ 152
Inspection .............................................................. 152
AWD WARNING LAMP ................................... 126 Draining ................................................................. 152
Description .............................................................126 Refilling ................................................................. 152
Diagnosis Procedure .............................................126
REMOVAL AND INSTALLATION ............. 153
AWD MODE INDICATOR LAMP (AWD) ......... 127
Description .............................................................127 AWD CONTROL UNIT ..................................... 153
Diagnosis Procedure .............................................127 Exploded View ...................................................... 153
Removal and Installation ....................................... 153
LOCK INDICATOR LAMP ............................... 128
Description .............................................................128 AWD MODE SWITCH ....................................... 154
Removal and Installation ....................................... 154
ECU DIAGNOSIS INFORMATION ............. 129
UNIT REMOVAL AND INSTALLATION ... 155
AWD CONTROL UNIT ..................................... 129
Reference Value ....................................................129 TRANSFER ASSEMBLY .................................. 155
Wiring Diagram - AWD SYSTEM - ........................131 Exploded View ...................................................... 155
Fail Safe ................................................................140 Removal and Installation ....................................... 155
DTC Inspection Priority Chart ................................141
DTC Index .............................................................141 UNIT DISASSEMBLY AND ASSEMBLY .. 157
SYMPTOM DIAGNOSIS ............................ 143 ADAPTER CASE .............................................. 157
Exploded View ...................................................... 157
AWD SYSTEM SYMPTOMS ........................... 143 Disassembly .......................................................... 158
Symptom Table .....................................................143 Assembly .............................................................. 158
Inspection After Disassembly ................................ 159
AWD WARNING LAMP DOES NOT TURN ON
. 144 RING GEAR SHAFT ......................................... 160
Description .............................................................144 Exploded View ...................................................... 160
Diagnosis Procedure .............................................144 Disassembly .......................................................... 161
Assembly .............................................................. 162
AWD WARNING LAMP DOES NOT TURN Inspection After Disassembly ................................ 163
OFF .................................................................. 145
Description .............................................................145 DRIVE PINION .................................................. 164
Disassembly .......................................................... 165
HEAVY TIGHT-CORNER BRAKING SYMP- Assembly .............................................................. 166
TOM OCCURS ................................................. 146 Adjustment ............................................................ 167
Description .............................................................146 Inspection After Disassembly ................................ 176
TRANSFER CASE ............................................ 177
VEHICLE DOES NOT ENTER AWD MODE ... 147 Exploded View ...................................................... 177
Description .............................................................147 Disassembly .......................................................... 178
Diagnosis Procedure .............................................147 Assembly .............................................................. 178
Inspection .............................................................. 179
AWD WARNING LAMP BLINKS QUICKLY ... 148
Description .............................................................148 SERVICE DATA AND SPECIFICATIONS
AWD WARNING LAMP BLINKS SLOWLY .... 149 (SDS) ......................................................... 180
Description .............................................................149 SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................ 180
NORMAL OPERATING CONDITION .............. 150 General Specifications .......................................... 180
Description .............................................................150 Preload Torque ..................................................... 180
Backlash ............................................................... 180
NOISE, VIBRATION AND HARSHNESS Companion Flange Runout ................................... 180
(NVH) TROUBLESHOOTING .......................... 151 REAR PROPELLER SHAFT: C-CVJ-C
NVH Troubleshooting Chart ..................................151
PRECAUTION ........................................... 181
PERIODIC MAINTENANCE ....................... 152
DLN-4
PRECAUTIONS ................................................ 181 PERIODIC MAINTENANCE ...................... 199
Precautions for Removing Battery Terminal ......... 181 A
Service Notice or Precautions for Propeller Shaft.. 181 REAR DIFFERENTIAL GEAR OIL ................. 199
Inspection .............................................................. 199
SYSTEM DESCRIPTION ........................... 183 Draining ................................................................. 199
B
Refilling .................................................................. 199
STRUCTURE AND OPERATION ..................... 183
Sectional View ....................................................... 183 REMOVAL AND INSTALLATION ............. 200
C
SYMPTOM DIAGNOSIS ............................ 184 FRONT OIL SEAL ........................................... 200
Exploded View ....................................................... 200
NOISE, VIBRATION AND HARSHNESS Removal and Installation ....................................... 200
(NVH) TROUBLESHOOTING .......................... 184 DLN
NVH Troubleshooting Chart .................................. 184 SIDE OIL SEAL ............................................... 202
Exploded View ....................................................... 202
PERIODIC MAINTENANCE ....................... 185 Removal and Installation ....................................... 202 E
REAR PROPELLER SHAFT ............................ 185 ELECTRIC CONTROLLED COUPLING ......... 203
Inspection .............................................................. 185 Exploded View ....................................................... 203
Removal and Installation ....................................... 203 F
REMOVAL AND INSTALLATION ............. 186
UNIT REMOVAL AND INSTALLATION .... 207
REAR PROPELLER SHAFT ............................ 186
G
Exploded View ...................................................... 186 REAR FINAL DRIVE ASSEMBLY .................. 207
Removal and Installation ....................................... 186 Exploded View ....................................................... 207
Inspection .............................................................. 189 Removal and Installation ....................................... 207
H
SERVICE DATA AND SPECIFICATIONS UNIT DISASSEMBLY AND ASSEMBLY . 209
(SDS) .......................................................... 191
ELECTRIC CONTROLLED COUPLING ......... 209 I
SERVICE DATA AND SPECIFICATIONS Exploded View ....................................................... 209
(SDS) ................................................................ 191 Disassembly .......................................................... 210
General Specifications .......................................... 191 Assembly ............................................................... 210
Adjustment ............................................................. 212 J
Propeller Shaft Runout .......................................... 191
Journal Axial Play .................................................. 191 Inspection After Disassembly ................................ 212
REAR FINAL DRIVE: R145 DIFFERENTIAL ASSEMBLY .......................... 213 K
SYMPTOM DIAGNOSIS ............................ 192 Exploded View ....................................................... 213
Disassembly .......................................................... 214
NOISE, VIBRATION AND HARSHNESS Assembly ............................................................... 215
L
(NVH) TROUBLESHOOTING .......................... 192 Inspection After Disassembly ................................ 218
NVH Troubleshooting Chart .................................. 192
DRIVE PINION ................................................ 219
PRECAUTION ............................................ 193 Exploded View ....................................................... 219 M
Disassembly .......................................................... 220
PRECAUTIONS ................................................ 193 Assembly ............................................................... 221
Service Notice or Precautions for Rear Final Drive.. 193 Adjustment ............................................................. 224
N
Precautions for Removing Battery Terminal ......... 193 Inspection After Disassembly ................................ 227
PREPARATION ......................................... 195 SERVICE DATA AND SPECIFICATIONS

(SDS) .......................................................... 229 O
PREPARATION ................................................ 195
Special Service Tools ............................................ 195 SERVICE DATA AND SPECIFICATIONS
Commercial Service Tools .................................... 196 (SDS) ............................................................... 229 P
General Specification ............................................ 229
SYSTEM DESCRIPTION ........................... 198 Drive Gear Runout ................................................. 229
REAR FINAL DRIVE ASSEMBLY ................... 198 Differential Side Gear Clearance ........................... 229
Preload Torque ...................................................... 229
System Diagram .................................................... 198
Backlash ................................................................ 229
Companion Flange Runout .................................... 229
DLN-5
PRECAUTIONS
< PRECAUTION > [TRANSFER: TY21C]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000010590148
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 SR and SB section 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 which 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 the SR section.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Airbag Diagnosis Sensor Unit or other Airbag System sensors with the Igni-
tion ON or engine running, DO NOT 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.
Precaution for Battery Service INFOID:0000000010590149
Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Precaution for Procedure without Cowl Top Cover INFOID:0000000010590150
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc. to prevent damage to
windshield.
PIIB3706J
Service Notice or Precautions for Transfer INFOID:0000000010590151
• After overhaul refill the transfer with new transfer oil.

• Check the oil level or replace the oil only with the vehicle parked on level surface.
• 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 unusual wear tires applies excessive force to vehicle mechanism and can cause lon-
gitudinal vibration.
• Disassembly should be done in a clean work area.
DLN-6
PRECAUTIONS
< PRECAUTION > [TRANSFER: TY21C]
• 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. A
• 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.
• All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
B
reassembly.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new one if necessary.
• Gaskets, seals, O-rings and lock nuts should be replaced any time when the transfer is disassembled. C
• 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. DLN
• Clean and flush the parts sufficiently and blow-dry them.
• Be careful not to damage sliding surfaces and mating surfaces.
• Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
with the operation of the transfer. E
DLN-7
PREPARATION
< PREPARATION > [TRANSFER: TY21C]
PREPARATION
PREPARATION
Special Service Tool INFOID:0000000010590152
The actual shape of the tools may differ from those illustrated here.
Tool number Description
(TechMate No.)
Tool name
ST33061000 Removing ring gear bearing (left) inner race
(J-8107-2) (transfer case side)
Drift
a: 38 mm (1.50 in) dia.
b: 28.5 mm (1.122 in) dia.
ZZA0810D
KV381054S0 Removing ring gear shaft oil seal

(J-34286)
Puller
ZZA0601D
ST3127S000 Measuring preload torque

(J-25765-A)
Preload gauge
ZZA0503D
Commercial Service Tool INFOID:0000000010590153
Tool name Description

Power tool Loosening nuts, screws and bolts
PIIB1407E
Drift Removing gear ring bearing inner race

a: 52 mm (2.05 in) dia. (adapter case side)
b: 44 mm (1.73 in) dia.
ZZA1002D
DLN-8
PREPARATION
A
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.
B
C
NT115
Drift Installing ring gear shaft oil seal

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

(transfer case side)
NT077
H
Drift Installing oil seal (installing pinion bearing
a: 70 mm (2.76 in) dia. seal)
b: 60 mm (2.36 in) dia.
I
J
NT115
Drift Installing side oil seal (installing transfer cover

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

• Removing ring gear bearing (left) inner race
(transfer cover side)
N
ZZA0700D
O
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. P
NT115
DLN-9
PREPARATION
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.
NT115
Drift Installing ring gear bearing (left) outer race

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

a: 87 mm (3.43 in) dia. (transfer cover side)
SCIA5338E
Drift Removing drive pinion

a: 20 mm (0.79 in) dia.
SCIA5338E
Drift Installing pinion bearing

a: 50 mm (1.97 in) dia.
b: 41 mm (1.61 in) dia.
NT115
Drift Installing companion flange

a: 40 mm (1.57 in) dia.
b: 25 mm (0.98 in) dia.
NT115
DLN-10
COMPONENT PARTS
< SYSTEM DESCRIPTION > [TRANSFER: TY21C]
SYSTEM DESCRIPTION A
COMPONENT PARTS
Component Parts Location INFOID:0000000010755224
B
DLN
JSDIA5445ZZ K
Rear wheel house outer panel in lug-

Console switch panel Rear final drive
gage room of left side L
No. Component Function

Mainly transmits the following signals to 4WD control unit via CAN communication. M
• Accelerator pedal position signal
• Engine speed signal
ECM
• Engine status signal
For detailed installation location, refer to ECM-14, "ENGINE CONTROL SYSTEM : N
Component Parts Location" (MR20DD).
Mainly transmits the following signals to 4WD control unit via CAN communication.
Steering angle sensor • steering angle sensor signal O
For detailed installation location, refer to STC-7, "Component Parts Location".
• Parking brake switch signal
P
Mainly receives the following signals from 4WD control unit via CAN communication.
Combination meter • 4WD warning lamp signal
• 4WD mode indicator lamp signal
• Torque distribution indicator signal
For detailed installation location, refer to MWI-6, "Component Parts Location".
DLN-11
COMPONENT PARTS
No. Component Function
• Each wheel speed signal
• Decel G sensor signal
ABS actuator and electric unit (con-
• Side G sensor signal
trol unit)
• Yaw rate sensor signal
For detailed installation location, refer to BRC-8, "Component Parts Location" or BRC-
148, "Component Parts Location".
4WD mode switch Refer to DLN-12, "4WD Mode Switch".
4WD control unit
Refer to DLN-12, "4WD Control Unit".
• 4WD actuator relay
Electric controlled coupling Refer to DLN-12, "Electric Controlled Coupling".
4WD solenoid Refer to DLN-12, "4WD Solenoid".
4WD Control Unit INFOID:0000000010755225
• 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 system. For fail-safe, refer to DLN-17, "4WD
SYSTEM : Fail-Safe".
4WD ACTUATOR RELAY
4WD actuator relay is integrated with 4WD control unit, and supplies 4WD solenoid with voltage.
Electric Controlled Coupling INFOID:0000000010755226
Electric controlled coupling is integrated with rear final drive and transmits driving force to rear final drive. For
operation, refer to DLN-13, "Operation Description".
4WD Solenoid INFOID:0000000010755227
• 4WD solenoid is integrated with electric controlled coupling.

• Controls electric controlled coupling by command current from 4WD control unit.
4WD Mode Switch INFOID:0000000010755228
4WD mode is selectable among 2WD mode, AUTO mode, and LOCK mode by operating the 4WD mode
switch while the engine is running.
DLN-12
STRUCTURE AND OPERATION
A
Sectional View INFOID:0000000010755229
DLN
L
JSDIA3966ZZ
1. Transfer cover 2. Transfer case 3. Ring gear bearing (transfer case side) M
4. Ring gear shaft 5. Pinion bearing 6. Drive pinion
7. Companion flange 8. Ring gear 9. Ring gear bearing (transfer cover
side)
N
Operation Description INFOID:0000000010755230
POWER TRANSFER DIAGRAM O
DLN-13
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-14
SYSTEM
SYSTEM
A
4WD SYSTEM
4WD SYSTEM : System Description INFOID:0000000010755231
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-17, "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-18, "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
Mainly receives the following signals from 4WD control unit via CAN communication.
Combination meter
• 4WD warning lamp signal
• 4WD mode indicator lamp signal
• Torque distribution indicator signal
Steering angle sensor
• steering angle sensor signal
DLN-15
SYSTEM
Component parts Signal item
• Each wheel speed signal
ABS actuator and electric unit (control unit) • Decel G sensor signal
• Side G sensor signal
• Yaw rate sensor signal
ECM
• Engine status signal
TCM • Input shaft revolutional signal
• CVT ratio signal
4WD SYSTEM : Control in Each Mode INFOID:0000000010755232
2WD MODE
• Vehicle is in front-wheel drive.
CAUTION:
If front wheels are slipping in 2WD mode, do not 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.
• 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.
• 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-16
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:0000000010755233
B
DLN
JSDIA6027GB
N
4WD SYSTEM : Fail-Safe INFOID:0000000010755234
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-17
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:0000000010755235
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-18, "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 syste-
mis 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:0000000010755236
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.
See Owner’s Manual
JPNIA1896ZZ
SYNCHRONIZATION WITH MASTER WARNING LAMP

Applicable
For master warning lamp, refer to WCS-7, "WARNING CHIME SYSTEM : System Description".
DLN-18
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:0000000010755237
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:0000000010755238
P
Name Design Layout/Function
For layout: Refer to WCS-5, "Component Parts Location".
4WD indicator lamp For function: Refer to DLN-20, "WARNING/INDICATOR/CHIME LIST : Warning/Indica-
tor (On Information Display)".
DLN-19
SYSTEM
Name Design Layout/Function
For layout: Refer to WCS-5, "Component Parts Location".
LOCK indicator lamp For function: Refer to DLN-20, "WARNING/INDICATOR/CHIME LIST : Warning/Indica-
tor (On Information Display)".
WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display)

INFOID:0000000010755239
Name Function
Refer to DLN-18, "INFORMATION DISPLAY (COMBINATION METER) : 4WD Warn-
4WD warning
ing".
Refer to DLN-19, "INFORMATION DISPLAY (COMBINATION METER) : 4WD Torque
4WD torque distribution indicator
Distribution Indicator".
DLN-20
DIAGNOSIS SYSTEM (4WD CONTROL UNIT)
A
CONSULT Function INFOID:0000000010755240
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-26, "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-21
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.
Monitor item (Unit) Remarks

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-22
4WD CONTROL UNIT
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY21C]
ECU DIAGNOSIS INFORMATION A

4WD CONTROL UNIT
Reference Value INFOID:0000000010755241
B
VALUES ON THE DIAGNOSIS TOOL

NOTE: C
The following table includes information (items) inapplicable to this vehicle. For information (items) applicable
to this vehicle, refer to CONSULT display items.
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: 2WD 2WD
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-23
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
2WD mode Approx. 0.000 A
Engine running
AUTO mode Approx. 0.000 – 2.490 A*
• 3,000 rpm or more constant
LOCK mode Approx. 2.490 A
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-24
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
14 4WD mode switch 4WD mode switch: AUTO 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:0000000010755242
If any malfunction occurs in 4WD electrical system, and control unit detects the malfunction, 4WD warning on M
information display (combination meter) is displayed to indicate system malfunction. And then 4WD control
unit controls becomes the fail-safe mode depending on DTC.
N
•C1201
•C1204
•C1209
O
4WD control changes to front-wheel drive immediately, then 4WD control stops, and the vehicle
•P1804
becomes front-wheel drive.
•P1809
•P1811 P
•P181F
DLN-25
4WD CONTROL UNIT
•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.
Protection Function INFOID:0000000010755243
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-18, "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 syste-
mis 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.
DTC Inspection Priority Chart INFOID:0000000010755244
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
7 • P1804 CONTROL UNIT
• P181B INCOMP SELFSHUT
8
• P181F INCOMP CALIBRATION
DTC Index INFOID:0000000010755245
DTC Display Item Reference

C1201 CONTROLLER FAILURE DLN-38, "DTC Description"
C1203 ABS SYSTEM DLN-39, "DTC Description"
C1204 4WD SOLENOID DLN-40, "DTC Description"
DLN-26
4WD CONTROL UNIT
DTC Display Item Reference
A
C1209 MODE SW DLN-43, "DTC Description"
C1210 ENGINE SIGNAL 1 DLN-46, "DTC Description"
P1804 CONTROL UNIT DLN-47, "DTC Description" B
P1808 VHCL SPEED SEN-ABS DLN-48, "DTC Description"
P1809 CONTROL UNIT DLN-49, "DTC Description"
P1811 BATTERY VOLTAGE DLN-50, "DTC Description" C
P181B INCOMP SELF SHUT DLN-53, "DTC Description"
P181D ENGINE SYSTEM DLN-56, "DTC Description"
DLN
P181F INCOMP CALIBRATION DLN-57, "DTC Description"
U1000 CAN COMM CIRCUIT DLN-58, "DTC Description"
U1010 CONTROL UNIT (CAN) DLN-59, "DTC Description" E
NOTE:
If some DTCs are displayed at the same time, refer to DLN-26, "DTC Inspection Priority Chart".
F
DLN-27
4WD SYSTEM
< WIRING DIAGRAM > [TRANSFER: TY21C]
WIRING DIAGRAM
4WD SYSTEM
Wiring Diagram INFOID:0000000010755246
JRDWC2498GB
DLN-28
4WD SYSTEM
DLN
JRDWC2519GB
DLN-29
4WD SYSTEM
JRDWC2520GB
DLN-30
4WD SYSTEM
DLN
JRDWC2521GB
DLN-31
4WD SYSTEM
JRDWC2522GB
DLN-32
DIAGNOSIS AND REPAIR WORK FLOW
< BASIC INSPECTION > [TRANSFER: TY21C]
BASIC INSPECTION A
Work Flow INFOID:0000000010755247
B
DETAILED FLOW
1.INTERVIEW FROM THE CUSTOMER C
Clarify customer complaints before inspection. First of all, perform an interview utilizing DLN-34, "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-26,
"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
26, "DTC Inspection Priority Chart".
YES >> GO TO 5. N
NO >> Check harness and connectors based on the information obtained by interview. Refer to GI-41,
"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-33
YES >> GO TO 7.
NO >> Check harness and connectors based on the information obtained by interview. Refer to GI-41,
"Intermittent Incident".
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:0000000010755248
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-34
Interview sheet
A
Registration Initial year
Customer number registration
MR/MS
name
Vehicle type VIN
B
Storage date Engine Mileage km (Mile)
Other conditions
C
Memo
DLN
DLN-35
ADDITIONAL SERVICE WHEN REPLACING 4WD CONTROL UNIT
ADDITIONAL SERVICE WHEN REPLACING 4WD CONTROL UNIT
Description INFOID:0000000010755249
When replacing 4WD control unit, unit characteristics writing is required.

Work Procedure INFOID:0000000010755250
1.PERFORM WRITING UNIT CHARACTERISTICS

Perform writing unit characteristics of electric controlled coupling.
>> Refer to DLN-37, "Work Procedure".
DLN-36
UNIT CHARACTERISTICS WRITING
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.
Work Procedure INFOID:0000000010755252
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-37
C1201 4WD CONTROL UNIT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY21C]
DTC/CIRCUIT DIAGNOSIS
C1201 4WD CONTROL UNIT
DTC Description INFOID:0000000010755253
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-38, "Diagnosis Procedure".
NO-1 >> To check malfunction symptom before repair: Refer to GI-41, "Intermittent Incident".
NO-2 >> Confirmation after repair: INSPECTION END
Diagnosis Procedure INFOID:0000000010755254
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-72, "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-38
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-53, "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-72, "Removal and Installation".
NO >> Repair or replace error-detected parts. P
DLN-39
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-40
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-11, "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-41
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-12, "4WD Solenoid".
YES >> GO TO 7.
NO >> 4WD solenoid is malfunctioning. Replace electric controlled coupling. Refer to DLN-76, "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:0000000010755259
1.CHECK 4WD SOLENOID

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
NO >> 4WD solenoid is malfunctioning. Replace electric controlled coupling. Refer to DLN-76, "Exploded
View".
DLN-42
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-45, "Component Inspection".
Is the inspection result normal? N
YES >> GO TO 2.
NO >> Replace 4WD mode switch. Refer to DLN-73, "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-43
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-44
C1209 MODE SW
• Check 4WD control unit pin terminals for damage or loose connection with harness connector.
• 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
4WD mode switch: AUTO
8 2 I
Existed
Is the inspection result normal? J
NO >> Replace 4WD mode switch. Refer to DLN-73, "Removal and Installation".
K
DLN-45
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 ECM-93, "DTC Index" (MR20DD).
NO >> GO TO 2.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC “C1210”
DLN-46
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-47, "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-72, "Removal and Installation".
DLN-47
P1808 WHEEL SPEED SENSOR
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
Perform self-diagnosis for “ABS”.
YES >> Check the DTC. Refer to BRC-53, "DTC Index".
NO >> GO TO 2.
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC “P1808”
DLN-48
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
1. Turn the ignition switch ON. I
K
1.REPLACE 4WD CONTROL UNIT L

CAUTION:
Replace 4WD control unit when DTC “P1809” is detected simultaneously with other items.
M
>> Replace 4WD control unit. Refer DLN-72, "Removal and Installation".
DLN-49
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-50
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-11, "Wiring Diagram -
BATTERY 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-51
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-72, "Removal and Installation".
DLN-52
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

• Malfunction of 4WD control unit power supply circuit (open or short)
• Battery power supply
• Ignition power supply E
FAIL-SAFE
No impact to vehicle behavior. F

1.PRECONDITIONING G
H
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE I
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-41, "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-53
YES >> GO TO 3.
NO >> GO TO 2.
tor.

Continuity
B5 7 M3 7C Existed
4WD control unit

— Continuity
Connector Terminal
IGNITION POWER SUPPLY -".
4WD control unit

Connector Terminal
CAUTION:
4WD control unit

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

Continuity
DLN-54
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-72, "Removal and Installation".
J
DLN-55
P181D ENGINE TORQUE SIGNAL
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
1. Drive the vehicle for a while.
2. Stop the vehicle.
Is DTC “P181D” detected?

With CONSULT
YES >> Check the DTC. Refer to ECM-93, "DTC Index" (MR20DD).
NO >> GO TO 2.
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC “P181D”
DLN-56
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-37, "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-26, "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-57, "DTC Description".
YES >> Replace 4WD control unit. Refer to DLN-72, "Removal and Installation". P
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-57
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-24, "Trouble Diagnosis Flow Chart".
DLN-58
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
Each control unit communicate data but selectively reads required data only.
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-59, "Diagnosis Procedure". L
Diagnosis Procedure INFOID:0000000010755282 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-59
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
IGNITION POWER SUPPLY -".
4WD control unit

Connector Terminal
DLN-60
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-11, "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-61
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-62
4WD INDICATOR LAMP
4WD INDICATOR LAMP
A
Component Function Check INFOID:0000000010755284
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-63, "Diagnosis Procedure".
DLN
With CONSULT E
Perform self-diagnosis for “ALL MODE AWD/4WD”.
YES >> Perform trouble diagnosis for detected DTC. Refer to DLN-26, "DTC Index". F
NO >> GO TO 2.
G
Perform the trouble diagnosis for 4WD mode switch. Refer to DLN-43, "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 power supply and ground circuit. Refer to
MWI-61, "COMBINATION METER : Diagnosis Procedure".
NO >> Replace 4WD control unit. Refer to DLN-72, "Removal and Installation". L
DLN-63
LOCK INDICATOR LAMP
LOCK INDICATOR LAMP
Component Function Check INFOID:0000000010755286
1.LOCK INDICATR LMAP OPERATION CHECK

Check that LOCK indicator lamp turns ON for several seconds after the ignition switch is turned ON.
NO >> Proceed to DLN-64, "Diagnosis Procedure".
With CONSULT
NO >> GO TO 2.
Perform the trouble diagnosis for 4WD mode switch. Refer to DLN-43, "Diagnosis Procedure".
Is the inspection results normal?
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”.
3. Check “4WD MODE MON” in “DATA MONITOR” for “ALL MODE AWD/4WD”.
Does the item on “DATA MONITOR” indicate “LOCK”?
YES >> Perform the trouble diagnosis for combination meter power supply and ground circuit. Refer to
MWI-61, "COMBINATION METER : Diagnosis Procedure".
NO >> Replace 4WD control unit. Refer to DLN-72, "Removal and Installation".
DLN-64
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 ECM-93, "DTC Index" (MR20DD). F
NO >> GO TO 2.
G
With CONSULT
H
YES >> Proceed to DLN-58, "Diagnosis Procedure".
NO >> GO TO 3.
3.CHECK 4WD SOLENOID I
Perform the trouble diagnosis of the 4WD solenoid. Refer to DLN-40, "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-76, "Exploded View".
NO >> Check each harness connector pin terminal for disconnection.
N
DLN-65
VEHICLE DOES NOT ENTER 4WD MODE
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-54, "Work flow".
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 pedal is operation. On
PARKING BRAKE SW SIG
When the parking brake pedal is not operation. Off
YES >> GO TO 3.
NO >> Proceed to PB-67, "Component Inspection".
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-76, "Exploded View".
DLN-66
4WD HIGH TEMP IS DISPLAYED ON INFORMATION DISPLAY
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-26, "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-67
TIRE SIZE INCORRECT IS DISPLAYED ON INFORMATION DISPLAY
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-68
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
A
NVH Troubleshooting Chart INFOID:0000000010755295
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-85, "Inspection", DLN-93, "Inspection"
DLN-85, "Inspection", DLN-93, "Inspection"

C
DLN
DLN-78, "Exploded View"

—
Reference
DLN-70, "Inspection"
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)
H
SUSPECTED PARTS
(Possible cause)
I
J
Noise 1 2 3 3 3
Symptom
Transfer oil leakage 3 1 2 2 2
K
DLN-69
TRANSFER OIL
< PERIODIC MAINTENANCE > [TRANSFER: TY21C]
PERIODIC MAINTENANCE
TRANSFER OIL
Inspection INFOID:0000000010590215
OIL LEAKS
Check that oil is not leaking from transfer assembly or around it.
OIL LEVEL
CAUTION:
Do not start engine while checking oil level.
1. Remove filler plug (1).
: Front
2. Oil level (A) should be level with bottom of filler plug hole. Add
oil if necessary. Refer to MA-59, "Fluids and Lubricants" .
3. Clean threads of filler plug (1) and transfer case.
4. Apply sealant to the threads of the filler plug (1) and install it.
Tighten to specified torque. Refer to DLN-76, "Exploded View" .
Use Genuine Silicone RTV Sealant or equivalent. Refer to
MA-59, "Fluids and Lubricants". ALDIA0383ZZ
Draining INFOID:0000000010590216
CAUTION:
1. Run the vehicle to warm up the transfer unit sufficiently.
2. Stop the engine and remove drain plug (1) and drain the transfer
oil.
: Front
3. Clean threads of drain plug (1) and transfer case.

4. Apply sealant to the threads of the drain plug (1) and install it.
Tighten to specified torque. Refer to DLN-76, "Exploded View".
Use Genuine Silicone RTV Sealant or equivalent. Refer to
MA-59, "Fluids and Lubricants".
ALDIA0382ZZ
Refilling INFOID:0000000010590217
CAUTION:
1. Remove filler plug (1).
2. Fill with new oil to the specified level (A) near the filler plug hole.
: Front
Oil grade and viscosity : Refer to MA-59, "Fluids

and Lubricants".
Oil capacity : Refer to MA-59, "Fluids
and Lubricants".
ALDIA0383ZZ
3. Clean threads of filler plug (1) and transfer case.
4. Apply sealant to the threads of the filler plug (1), and install it. Tighten to specified torque. Refer to DLN-
76, "Exploded View".
DLN-70
TRANSFER OIL
< PERIODIC MAINTENANCE > [TRANSFER: TY21C]
Use Genuine Silicone RTV Sealant or equivalent. Refer to MA-59, "Fluids and Lubricants".
A
DLN
DLN-71
4WD CONTROL UNIT
< REMOVAL AND INSTALLATION > [TRANSFER: TY21C]
REMOVAL AND INSTALLATION

4WD CONTROL UNIT
Exploded View INFOID:0000000010755216
JSDIA5368GB
4WD control unit
: Vehicle front
: N·m (kg-m, in-lb)
Removal and Installation INFOID:0000000010755217
REMOVAL
2. Remove luggage side lower finisher LH. Refer to INT-28, "Exploded View".
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 iadjustment after installation. Refer to DLN-72, "Adjustment".
Adjustment INFOID:0000000010755218
ADJUSTMENT AFTER INSTALLATION

When replaced 4WD control unit, perform writing unit characteristics. Refer to DLN-37, "Work Procedure".
DLN-72
4WD MODE SWITCH
4WD MODE SWITCH
A
DLN
JSDIA5457ZZ
E
4WD mode switch Console switch panel
Removal and Installation INFOID:0000000010755220 F
REMOVAL
1. Remove console switch panel from center console assembly. Refer to IP-18, "Exploded View". G
2. Disconnect 4WD mode switch harness connector.
3. Remove 4WD mode switch from console switch panel.
H
INSTALLATION
Install in the reverse order of removal.
I
DLN-73
TRANSFER COVER OIL SEAL
MR20DD
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.
QR25DE
NOTE:
• Replacement on vehicle may cause damage to transfer cover, and may cause a transfer oil leak.
• If transfer cover oil seal requires replacement, remove transfer assembly from the vehicle before replacing
transfer cover oil seal. Refer to DLN-79, "Disassembly".
NOTE:
For QR25DE models only:
• Replacement on vehicle may cause damage to transfer cover, and may cause a transfer oil leak.
• If transfer cover oil seal requires replacement, remove transfer assembly from the vehicle before replacing
transfer cover oil seal. Refer to DLN-79, "Disassembly".
REMOVAL
MR20DD
1. Drain the transfer oil. Refer to DLN-70, "Draining".
2. Remove front drive shaft (right side). Refer to FAX-22, "Exploded View (LH)".
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
MR20DD
DLN-74
1. Using drift (commercial service tool), install transfer cover oil
seal (outer/inner) with the directions below. A
A : Installation dimension for transfer cover oil seal (inner)

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

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

• 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-22, "Removal and Installation (LH)".
3. Refill the transfer oil to transfer assembly. Refer to DLN-70, "Refilling". E
4. Perform inspection after installation. Refer to DLN-70, "Inspection".
F
INSPECTION AFTER INSTALLATION

Check oil level and transfer for oil leakage. Refer to DLN-70, "Inspection".
G
DLN-75
TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: TY21C]
UNIT REMOVAL AND INSTALLATION

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

*: Apply anti-corrosion oil.
REMOVAL
MR20DD
1. Remove exhaust front tube. Refer to EX-11, "Removal and Installation".
2. Remove front drive shaft (RH). Refer to FAX-63, "Removal and Installation (RH)".
CAUTION:
Oil may leak from the opening. Use cap and/or plug to prevent leakage.
3. Remove propeller shaft from transfer assembly. Refer to DLN-186, "Exploded View" .
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-76
TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: TY21C]
• 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-76, "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-76, "Exploded View". (MR20DD)
• Perform inspection after installation. Refer to DLN-77, "Inspection". F
INSPECTION AFTER INSTALLATION G

When oil leaks while removing/installing transfer assembly, check oil level after the installation. Refer to DLN-
70, "Inspection".
H
DLN-77
TRANSFER COVER
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY21C]
UNIT DISASSEMBLY AND ASSEMBLY

TRANSFER COVER
MR20DD models
JSDIA5341GB
Pinion lock nut Companion flange Dust cover

Oil seal Pinion bearing assembly O-ring
Drive pinion adjusting shim Drive pinion O-ring
Oil seal Dowel pin Plug
Gasket Transfer case Baffle plate
Ring gear bearing adjusting shim Ring gear bearing (transfer case Ring gear
(transfer case side) side)
Ring gear shaft Ring gear shaft oil seal Ring gear bearing (transfer cover
side)
Ring gear bearing adjusting shim Oil seal O-ring
Transfer cover Oil seal Filler plug
Drain plug
Oil seal lip Comply with the assembly procedure
when tightening. Refer to DLN-87,
"Assembly".

DLN-78
TRANSFER COVER
: Select with proper thickness.

A
*: Apply anti-corrosive oil.
B
Disassembly INFOID:0000000010755195
C
1. Remove transfer cover mounting bolts ( ).
DLN
F
AWDIA1139ZZ
2. Lightly tap transfer cover with a plastic hammer to remove G

transfer cover.
3. Remove O-ring from transfer cover.
CAUTION: H
• Never use a suitable tool.
• Never damage transfer cover.
I
ALDIA0446ZZ J
4. Lightly tap the metal part of oil seals with punch from back
side of transfer cover to remove oil seals. K
CAUTION:
When removing, never damage the transfer cover by scoop-
ing it out with a suitable tool.
L
JSDIA3990ZZ
N
5. Remove the ring gear bearing adjusting shim (transfer cover
side) and ring gear bearing outer race (transfer cover side)
using suitable tool.
6. Remove drain plug and gasket. O
7. Remove filler plug and gasket.
8. Perform inspection after disassembly. Refer to DLN-81, "Inspec-
tion". P
JSDIA3992ZZ
DLN-79
TRANSFER COVER
Assembly INFOID:0000000010755196
1. Select the ring gear bearing adjusting shim (transfer cover side). Refer to DLN-88, "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-88, "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.
8. 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
AWDIA1140ZZ
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)

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:
• When checking the total preload torque, measure it with- JSDIA3993ZZ
out the oil seal, then install the oil seal.
DLN-80
TRANSFER COVER
• Never reuse the oil seal.
• When installing, never incline oil seal. A
• 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. B
CAUTION:
• Never reuse gasket.
• Install filler plug after oil is filled.
C
INSPECTION AFTER DISASSEMBLY DLN

Check items below. If necessary, replace them with new ones.
Transfer cover
Check the bearing mounting surface for wear, cracks and damages. E
DLN-81
RING GEAR SHAFT
RING GEAR SHAFT
MR20DD models
JSDIA5341GB

side)
Drain plug
"Assembly".

DLN-82
RING GEAR SHAFT

A
B
1. Remove transfer cover assembly. Refer to DLN-79, "Disassembly". C

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-79, "Disassembly".
3. Remove ring gear shaft assembly from the transfer case. DLN
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-95, "Disassembly".
5. Remove ring gear bearing inner race (transfer cover side) from E
ring gear shaft using suitable tool (A) and suitable tool.
JPDIE0030ZZ H
6. Remove ring gear bearing inner race (transfer case side) from
ring gear shaft with suitable tool (A) and Tool. I
Tool number : ST33061000

7. Remove the ring gear mounting bolts. J
JPDIE0031ZZ
L
8. Lightly tap ring gear with a plastic hammer to remove ring gear
from the ring gear shaft.
M
O
SDIA1807J
DLN-83
RING GEAR SHAFT
9. Remove ring gear shaft oil seal from the ring gear shaft with the
Tool (A).
Tool number : KV381054S0

tion".
JPDIE0032ZZ
1. Using suitable tool (A), install ring gear shaft oil seal within the
dimension (L) shown as follows.
L : 2.0 +0.6/−0 mm (0.079 +0.024/−0 in)

CAUTION:
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lips, and transfer
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
DLN-88, "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-95, "Assembly".
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-80, "Assembly".
CAUTION:
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
DLN-84
RING GEAR SHAFT
7. Install the ring gear bearing inner race (transfer case side) to
ring gear shaft with suitable tool (A). A
CAUTION:
B
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- C
ing.
JSDIA1055ZZ
DLN
a. Apply multi-purpose grease to spline part indicated in the figure.
G
JSDIA4195ZZ
b. Wrap piece of vinyl to spline part only indicated in the figure. H

[(A): limit line]
CAUTION:
Never wrap sliding surfaces on oil seal.
I
9. Install transfer cover to check and adjust each part. Refer to
DLN-80, "Assembly".
NOTE:
At this timing, O-ring installing to transfer cover is not necessary. J
Install O-ring after backlash and tooth contact are checked.
flange runout. Refer to DLN-88, "Adjustment". JSDIA4196ZZ K
CAUTION:
11. Reinstall transfer cover for installing O-ring. Refer to DLN-80, "Assembly". L
12. After installing transfer case oil seals, remove wrapped vinyl from the spline of ring gear shaft.
M
INSPECTION AFTER DISASSEMBLY
N
Gear and Shaft
Check gear face and shaft for wear, cracks, damage, and seizure.
CAUTION:
O
If malfunction is detected on the ring gear or drive pinion, replace the ring gear and drive pinion as a
set.
Bearing
P
Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other
damage.
CAUTION:
When replacing the bearing, always replace the inner race and outer race as a pair.
Shim
Check for seizure, damage, and unusual wear.
DLN-85
DRIVE PINION
DRIVE PINION
MR20DD models
JSDIA5341GB

side)
Drain plug
"Assembly".

D L N - 8 6
DRIVE PINION

A
B
1. Remove pinion bearing assembly mounting bolts. C
DLN
JSDIA3951ZZ F
2. Lightly tap companion flange with a plastic hammer to remove

drive pinion assembly .
G
3. Remove the O-ring from pinion bearing.
4. Remove the pinion lock nut.
H
JSDIA3952ZZ
J
5. Remove drive pinion from pinion bearing assembly using suit-
able tool (A) and suitable tool (B).
6. Remove adjusting shim.
K
7. Remove companion flange.
8. Remove the dust cover.
9. Remove the oil seal. L
tion".
M
JSDIA3953ZZ
N
1. Select drive pinion adjusting shim. Refer to DLN-88, "Adjustment".
2. Assemble the selected drive pinion adjusting shim to drive pinion.
3. Install the drive pinion to pinion bearing assembly using suitable tool. O
CAUTION:
• Never reuse pinion bearing assembly.
• Apply transfer oil to pinion bearing part. P
DLN-87
DRIVE PINION
4. Install oil seal to pinion bearing assembly using suitable tool (A).
CAUTION:
5. Install dust cover.
NOTE:
Tighten dust cover together with pinion bearing assembly.
JSDIA3996ZZ
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-
ing preload torque, using a preload gauge.
a. Install pinion lock nut, and then tighten to the specified torque.
Pinion lock nut : 90±9 N·m (9.2±0.92kg-m, 66±7 ft-lb)

tightening torque
CAUTION: 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.
c. Measure the pinion bearing preload.
Pinion bearing preload : Refer to DLN-97, "Preload Torque".

8. Apply multi-purpose grease lightly and evenly onto an O-ring, and install it to the pinion bearing assembly.
CAUTION:
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
DLN-88
DRIVE PINION
Measurement point
A
DLN
L
JSDIA4034ZZ
Select adjusting shim of T1, T2, and T3, respectively, by using the following equation.
M
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)
T2 [Ring gear bearing adjusting shim (transfer cover side)] N
• T2 = −Y +Z +(B +X/2) −C −D −H +(M/100) +0.071 mm (0.0028 in)
T3 (Drive pinion adjusting shim)
• T3 = −Q +(R +S/2) −K +(O/100) O
DLN-89
DRIVE PINION
• Check dimension (M) on the ring gear side face.
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.
JSDIA2495ZZ
• Check dimension (O) on the gear end of drive pinion.

NOTE:
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.
JSDIA2496ZZ
PINION BEARING PRELOAD

CAUTION:
When measuring preload, the rotating speed must be set to 30 rpm.
1. Remove ring gear shaft assembly from the transfer case. Refer to DLN-83, "Disassembly".
2. Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking,
and so on.
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).
Pinion bearing preload : Refer to DLN-97, "Preload

Torque".
Tool number : ST3127S000
CAUTION:
Each rotational part should rotate smoothly with the speci-
fied transfer oil.
• If outside the standard, disassemble the drive pinion assembly
to check and adjust each part. JSDIA2500ZZ
TOTAL PRELOAD
CAUTION:
When measuring preload, the rotating speed must be set to 30 rpm.
1. Measure pinion bearing preload.
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-84, "Assembly"
3. Install transfer cover to check and adjust each part. Refer to DLN-80, "Assembly".
DLN-90
DRIVE PINION
5. Measure the total preload using Tool (A).
A
Total preload : Refer to DLN-97, "Preload
Torque".
Tool number : ST3127S000 B
CAUTION:
fied transfer oil. C
• 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 DLN
total preload after disassembly. Then install transfer case oil seals and transfer cover oil seal.
BACKLASH
1. Install the bolt to the companion flange. E
2. Fit a dial indicator onto the bolt .
3. Measure the circumference backlash of the companion flange.
F
Backlash : Refer to DLN-97, "Backlash".
• If outside the standard, disassemble the transfer assembly to
G
check and adjust each part.
H
JSDIA2501ZZ
TOOTH CONTACT I
1. Remove transfer cover. Refer to DLN-79, "Disassembly".
2. Remove ring gear shaft assembly from transfer case. Refer to DLN-83, "Disassembly".
3. Apply red lead onto the ring gear. J
CAUTION:
Apply red lead to both faces of 3 to 4 gears at 4 locations
evenly spaced on the ring gear. K
4. Assemble the ring gear shaft assembly to the transfer case.
Refer to DLN-84, "Assembly".
5. Install transfer cover to check and adjust each part. Refer to L
DLN-80, "Assembly".
NOTE:
Install O-ring after backlash and tooth contact are checked. JSDIA2188ZZ M
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. N
DLN-91
DRIVE PINION
Tooth Contact Judgment Guide
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.
CAUTION:
If no adjusting shim with the calculated value is available,
select the thicker and closest one.
JSDIA1221ZZ
• 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:
Only one adjusting shim can be selected.
PDIA0440E
DLN-92
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- A
tact.
CAUTION:
B
PDIA0441E
DLN
COMPANION FLANGE RUNOUT
1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
E
2. Rotate the companion flange to check for runout.
Companion flange runout : Refer to DLN-97, "Com- F

panion Flange Runout".
3. Fit suitable tool to the inner side of the companion flange (socket
diameter). G
Companion flange runout : Refer to DLN-97, "Com- H

5. Follow the procedure below to adjust if runout value is outside
the repair limit. I
a. Check for runout while changing the phase between companion
flange and drive pinion in 90° steps. Then search for the mini-
mum point. J
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
K
replace pinion bearing assembly if runout is outside the standard
after the companion flange is replaced.
L

Check items below. If necessary, replace them with new ones. M
Gear and Shaft

CAUTION: N
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 O
damage.
P
Shim
DLN-93
TRANSFER CASE
TRANSFER CASE
MR20DD models
JSDIA5341GB

side)
Drain plug
"Assembly".

DLN-94
TRANSFER CASE

A
B
1. Remove transfer cover. Refer to DLN-79, "Disassembly". C

2. Remove ring gear shaft assembly. Refer to DLN-83, "Disassembly".
3. Remove drive pinion assembly. Refer to DLN-87, "Disassembly".
4. Remove O-ring from transfer case. DLN
CAUTION:
• Never use a suitable tool.
• Never damage transfer case. E
5. Remove oil seals .
CAUTION:
Never damage transfer case. F
H
JSDIA3983ZZ
6. Remove baffle plate . I
JSDIA3982ZZ L
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. M
CAUTION:
Never damage transfer case.
8. Remove plug and gasket. N
tion".
O
JSDIA3984ZZ
Assembly INFOID:0000000010755209 P
1. Select the ring gear bearing adjusting shim (transfer case side). Refer to DLN-88, "Adjustment".
DLN-95
TRANSFER CASE
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-84, "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-87, "Assembly".
6. Install transfer cover to check and adjust each part. Refer to
DLN-80, "Assembly".
NOTE:
JSDIA3982ZZ
Install O-ring after backlash and tooth contact are checked.
7. Check backlash, tooth contact, total preload and companion flange runout. Refer to DLN-88, "Adjust-
ment".
CAUTION:
8. Reinstall transfer cover for installing O-ring. Refer to DLN-80, "Assembly".
9. Install oil seals using suitable tool.
A : 24.8 mm (0.976 in)

B : 10.3 mm (0.406 in)
CAUTION:
• When checking the total preload torque, measure it with-
out the oil seal, then install the oil seal.
JSDIA4047ZZ
• 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.
CAUTION:

Case
Check the bearing mounting surface for wear, cracks and damages.
DLN-96
SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [TRANSFER: TY21C]
SERVICE DATA AND SPECIFICATIONS (SDS) A

General Specifications INFOID:0000000010755212
B
Axle 4WD
C
Applied model Engine MR20DD
Transaxle CVT
Transfer model TY21C DLN
Gear ratio 0.404
Ring gear 42
Number of teeth E
Drive pinion 17
Oil capacity Refer to MA-59, "Fluids and Lubricants".
Preload Torque INFOID:0000000010755213

F
Unit: N·m (kg-m, in-lb)

Item Standard G
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)
H
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:0000000010755214 I
Unit: mm (in)
Item Standard J
Ring gear to drive pinion 0.16 – 0.21 (0.0063 – 0.0083)
Companion Flange Runout INFOID:0000000010755215 K
Unit: mm (in)
Item Standard L
Companion flange face runout 0.15 (0.0059) or less
Inner side of the companion flange runout 0.1 (0.004) or less
M
DLN-97
PRECAUTIONS
< PRECAUTION > [TRANSFER: TY30A]
PRECAUTION
PRECAUTIONS
Precautions for Removing Battery Terminal INFOID:0000000010508557
• 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.
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.
4. Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.
D4D engine : 20 minutes

HRA2DDT : 12 minutes
K9K engine : 4 minutes
M9R engine : 4 minutes
R9M engine : 4 minutes
V9X engine : 4 minutes
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.
5. Remove 12V battery terminal.
CAUTION:
After installing 12V battery, always check self-diagnosis results of all ECUs and erase DTC.
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
1. Unlock the door with intelligent key or remote keyless entry.
NOTE:
At this moment, ACC power is supplied.
2. Open the driver side door.
3. Open the hood.
4. Close the driver side door.
5. Wait at least 3 minutes.
DLN-98
PRECAUTIONS
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of A
CAUTION: B
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000010505230
C
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 DLN
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: E
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. F
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”. G
• 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.
H
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation. I
• 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. J
• 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.
K
Precaution for Procedure without Cowl Top Cover INFOID:0000000010505229
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to L
windshield.
PIIB3706J
O
Service Notice or Precautions for Transfer INFOID:0000000010288327
CAUTION:
• After overhaul refill the transfer with new transfer oil. P
• Check the oil level or replace the oil only with the vehicle parked on level surface.
• 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 pat-
tern. Fitting improper size and unusual wear tires applies excessive force to vehicle mechanism and
can cause longitudinal vibration.
• Disassembly should be done in a clean work area.
DLN-99
PRECAUTIONS
• 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.
• 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.
• All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspec-
tion or reassembly.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace
them with a new one if necessary.
• Gaskets, seals, O-rings and lock nuts should be replaced any time when the transfer is disassem-
bled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to out-
side. If tightening sequence is specified, use it.
• Observe the specified torque when assembling.
• Be careful not to damage sliding surfaces and mating surfaces.
• Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could
interfere with the operation of the transfer.
DLN-100
PREPARATION
< PREPARATION > [TRANSFER: TY30A]
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000010288328
B
Tool number
Description C
Tool name
ST30720000 • Installing adapter case oil seal (inner/outer)
Drift • Installing drive pinion oil seal
a: φ77 mm (3.03 in) dia. DLN
b: φ55.5 mm (2.185 in) dia.
E
NT115
ST27861000 • Installing adapter case oil seal (inner/outer)

Drift • Installing drive pinion oil seal F
a: φ62 mm (2.44 in) dia.
b: φ52 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: φ22 mm (0.87 in) dia. (front side)
b: φ28 mm (1.10 in) dia.
NT116
ST01530000 Installing ring gear M

Drift
a: φ48 mm (1.89 in) dia.
b: φ41 mm (1.61 in) dia.
N
ZZA0534D O
ST35272000 • Installing ring gear
Drift • Installing outer race of drive pinion bearing
a: φ72 mm (2.83 in) dia. (front side) P
b: φ40 mm (1.57 in) dia.
c: φ35.5 mm (1.398 in) dia.
NT107
DLN-101
PREPARATION
Tool number
Description
Tool name
KV10111400 Installing inner race of ring gear shaft bearing
Drift (transfer case side)
a: φ25 mm (0.98 in) dia.
b: φ20.8 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: φ38 mm (1.50 in) dia.
b: φ33 mm (1.30 in) dia.
ZZA0534D

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: φ51 mm (2.01 in) dia.
ZZA0938D
Commercial Service Tools INFOID:0000000010288329
DLN-102
PREPARATION
A
Drift Installing adapter case oil seal (inner)
a: φ63 mm (2.48 in) dia.
b: φ58 mm (2.28 in) dia.
B
C
ZZA1003D
Drift Installing adapter case oil seal (outer)

a: φ90 mm (3.54 in) dia.
b: φ88 mm (3.46 in) dia. DLN
ZZA1003D
Drift Removing inner race of ring gear shaft bear- F

a: φ12 mm (0.47 in) dia. ing (transfer case side)
b: φ18 mm (0.71 in) dia.
ZZA1178D
H
Drift Removing inner race of ring gear shaft bear-
a: φ49 mm (1.93 in) dia. ing (adapter case side)
b: φ67 mm (2.64 in) dia.
I
J
NT660
Drift Installing outer race of ring gear shaft bearing

a: φ80 mm (3.15 in) dia. (adapter case side) K
b: φ50 mm (1.97 in) dia.
ZZA1000D
Drift Installing inner race of ring gear shaft bearing M

a: φ57 mm (2.24 in) dia. (adapter case side)
b: φ47 mm (1.85 in) dia.
N
ZZA1003D
O
Installing outer race of drive pinion bearing
Drift (front side)
a: φ61 mm (2.40 in) dia. P
b: φ48 mm (1.89 in) dia.
ZZA1000D
DLN-103
DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [TRANSFER: TY30A]
BASIC INSPECTION
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000010288262
DETAILED FLOW
1.INTERVIEW FROM THE CUSTOMER
Clarify customer complaints before inspection. First of all, reproduce symptoms, and understand them fully.
Ask customer about his/her complaints carefully. Check symptoms by driving vehicle with customer, if neces-
sary.
CAUTION:
Customers are not professional. Never guess easily like “maybe the customer means that...,” or
“maybe the customer mentions this symptom”.
>> GO TO 2.
2.CHECK AWD WARNING LAMP
Start engine and drive at 30 km/h (19 MPH) or more for approx. 1 minute.
Does AWD warning lamp turn ON?
YES >> GO TO 3.
NO >> GO TO 6.
With CONSULT
1. Perform AWD control unit self-diagnosis.
2. Perform malfunction detected by self-diagnosis.
3. Erase AWD control unit self-diagnosis results.
>> GO TO 4.
Check pin terminals for damage or loose connection with harness connector.
>> GO TO 5.
5.CHECK SYMPTOM REPRODUCTION
With CONSULT
Perform DTC reproduction procedure for the error system.
Is any error detected?
YES >> GO TO 2.
NO >> GO TO 6.
6.PERFORM SYMPTOM DIAGNOSIS
Perform the symptom diagnosis for each system.
Is any malfunction present?
YES >> GO TO 2.
NO >> GO TO 7.
7.FINAL CHECK
With CONSULT
Check input/output signal standard of AWD control unit.
Is the input/output the standard value?
NO >> GO TO 2.
DLN-104
AWD SYSTEM
< SYSTEM DESCRIPTION > [TRANSFER: TY30A]
AWD SYSTEM
System Diagram INFOID:0000000010288263
B
CONTROL DIAGRAM
C
DLN
K
E1DIA0343GB
*: With ESP L
CROSS-SECTIONAL VIEW (M/T)

M
DLN-105
AWD SYSTEM
JSDIA0206ZZ
1. Transfer case 2. Adapter case 3. Ring gear shaft

4. Ring gear 5. Companion flange 6. Drive pinion
System Description INFOID:0000000010288264
DESCRIPTION
• AWD controls distribution of drive power between front-wheel drive (100:0) and AWD (50:50) conditions
according to signals from sensors.
• It transmits/receives each signal from the following control unit via CAN communication line.
Component parts Function

Transmits the following signals via CAN communication to AWD control unit.
ABS actuator and electric unit (control unit) • Vehicle speed signal
• Stop lamp switch signal (brake signal)
ECM • Accelerator pedal position signal
Transmits conditions of parking brake switch signal via CAN communication to AWD con-
Combination meter
trol unit.
Transmits conditions of steering angle sensor signal via CAN communication to AWD
Steering angle sensor*
control unit.
*: With ESP
AUTO Mode
• Electronic control allows optimal distribution of torque to front/rear wheels to match road conditions.
• AWD mode makes possible stable driving, with no wheel spin, on snowy roads or other slippery surfaces.
• On roads which do not require AWD, AUTO mode contributes to improved fuel economy by driving in condi-
tions close to front-wheel drive.
• Sensor inputs determine the vehicle's turning condition, and tight cornering/braking are controlled by distrib-
uting optimum torque to rear wheels.
LOCK Mode
DLN-106
AWD SYSTEM
• Front/rear wheel torque distribution is fixed, ensuring stable driving when climbing slopes.
• Vehicle will switch automatically to AUTO mode if vehicle speed increases. If vehicle speed then decreases, A
the vehicle automatically returns to direct 4-wheel driving conditions.
NOTE:
If there is a significant difference in pressure or wear between tires, full vehicle performance is not available.
B
LOCK mode may be prohibited, or speeds at which LOCK mode is enabled may be restricted detecting tire
conditions.
2WD Mode
C
Vehicle is in front-wheel drive.
NOTE:
• If front wheels are slipping in 2WD mode, do not switch to AUTO or LOCK. This can cause difficulties for the
system. DLN
• Even if the AWD mode switch is in 2WD mode, the AWD control unit occasionally automatically change to
AUTO mode depending on the driving condition (For example; Depressing the acceleration firmly). This is
not malfunction. However, AWD indicator lamp dose not illuminate. E
POWER TRANSFER DIAGRAM
JSDIA0208ZZ
I
1. Engine 2. Transaxle 3. Transfer
4. Propeller shaft 5. Electric controlled coupling 6. Rear final drive
OPERATION PRINCIPLE J
Electric Controlled Coupling

1. The AWD control unit supplies command current to electric con- K
trolled coupling (AWD solenoid).
2. The control clutch is engaged by electromagnet and torque is
detected in control clutch. L
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 M
pressing power.
SFIA0284E N
• Transmission torque to the rear wheels is determined accord-

ing to command current. O
SDIA1844E
DLN-107
AWD SYSTEM
Component Parts Location INFOID:0000000010288265
E1DIA0342ZZ
1. Combination meter 2. Steering angle sensor 3. ABS actuator and electric control unit
4. ECM 5. AWD lock switch 6. AWD control unit
7. Electric controled coupling 8. AWD solenoid
A. Instrument lower panel LH B. Rear wheel house outer panel in lug- C. Rear final drive assembly
gage room of teh left side
Component Description INFOID:0000000010288266
Component parts Reference/Function

AWD control unit DLN-111, "Description"
Wheel sensors BRC-9, "Wheel Sensor and Sensor Rotor"
AWD solenoid DLN-113, "Description"
Electric controlled coupling Transmits driving force to rear final drive.
AWD warning lamp DLN-126, "Description"
AWD indicator lamp DLN-127, "Description"
LOCK indicator lamp DLN-128, "Description"
AWD mode switch DLN-116, "Description"
ABS actuator and electric unit (control unit) DLN-112, "Description"
ECM DLN-119, "Description"
Combination meter DLN-127, "Description"
DLN-108
DIAGNOSIS SYSTEM (AWD CONTROL UNIT)
A
CONSULT Function INFOID:0000000010288267
FUNCTION B
CONSULT can display each diagnostic item using the diagnostic test modes shown following.
Diagnostic test mode Function C

ECU part number AWD control unit part number can be read.
Self-diagnostic results Self-diagnostic results can be read and erased quickly.
Data monitor Input/Output data in the AWD control unit can be read. DLN
Diagnostic Test Mode in which CONSULT drives some actuators apart from the AWD control unit
Active test
and also shifts some parameters in a specified range.
E
SELF-DIAG RESULT MODE
Drive at 30 km/h or more for approximately 1 minute before performing the self-diagnosis.
Display Item List F
Items
DTC Diagnostic item is detected when... Possible cause
(CONSULT screen terms) G
Internal malfunction of AWD
C1201 CONTROLLER FAILURE Malfunction has occurred inside AWD control unit.
control unit
ABS malfunction H
Malfunction related to wheel sensor has been de-
C1203 ABS SYSTEM tected by ABS actuator and electric unit (control
• Stop lamp switch signal
unit).
(brake signal) error
I
Malfunction related to AWD solenoid has been de- Internal malfunction of elec-
C1204 AWD SOLENOID
tected. tronic controlled coupling
Malfunction has been detected from AWD actuator
Internal malfunction of AWD J
C1205 AWD ACTUATOR RLY relay integrated with AWD control unit, or malfunc-
control unit
tion related to AWD solenoid has been detected.
Malfunction of AWD mode
More than two switch inputs are simultaneously
C1209 MODE SW switch or AWD mode switch K
detected due to short circuit of AWD mode switch.
circuit.
Malfunction of engine control
system L
C1210 ENGINE SIGNAL 1 Malfunction has been detected from ECM. • Accelerator pedal position
signal error
• Engine speed signal error
When AWD control unit is not transmitting or re- • CAN communication error
M
U1000 CAN COMM CIRCUIT ceiving CAN communication signal for 2 seconds • Malfunction of AWD control
or more. unit
When detecting error during the initial diagnosis of Malfunction of AWD control N
CAN controller of AWD control unit. unit
How to Erase Self-Diagnostic Results

Before erasing DTC memory, start the engine and drive at 30 km/h or more for approximately 1 minute. Check O
that ABS warning lamp turns OFF.
NOTE:
Make sure that ABS warning lamp turns OFF by driving for a minute at vehicle speed of 30 km/h (19 MPH) or P
more after turning ignition switch OFF if AWD warning lamp turns ON with system malfunction of “ABS SYS-
TEM [C1203]”. AWDAWD warning lamp may not turn OFF if it is normal unless ignition switch turns OFF at
once and engine restarts after that.
DATA MONITOR MODE
Display Item List
DLN-109
×: Applicable : Optional item
Monitor Menu
Monitor item (Unit) ECU INPUT MAIN Remarks
SIGNALS SIGNALS
Wheel speed calculated by front wheel sensor RH sig-
FR RH SENSOR [km/h] or [mph] × ×
nal is displayed.
Wheel speed calculated by front wheel sensor LH sig-
FR LH SENSOR [km/h] or [mph] × ×
nal is displayed.
Wheel speed calculated by rear wheel sensor RH sig-
RR RH SENSOR [km/h] or [mph] × ×
nal is displayed.
Wheel speed calculated by rear wheel sensor LH sig-
RR LH SENSOR [km/h] or [mph] × ×
nal is displayed.
BATTERY VOLT [V] Power supply voltage for AWD control unit
THRTL POS SEN [%] Throttle opening status is displayed.
ETS SOLENOID [A] Monitored value of current at AWD solenoid
Stop lamp switch signal status via CAN communication

STOP LAMP SW [On/Off]
line is displayed.
ENG SPEED SIG [Run/Stop] Engine status is displayed.
Operating condition of AWD actuator relay (integrated

ETS ACTUATOR [On/Off]
in AWD control unit) is displayed.
AWD WARN LAMP [On/Off] Control status of AWD warning lamp is displayed.
AWD MODE SW [2WD/AUTO/LOCK] Mode switch is not equipped, but displayed.
AWD MODE MON [2WD/AUTO/LOCK] Control status of AWD is displayed.
DIS-TIRE MONI [mm] Improper size tire installed condition is displayed.

Parking switch signal status via CAN communication
P BRAKE SW [On/Off]
line is displayed.
ACTIVE TEST MODE

Description
Use this mode to determine and identify the details of a malfunction based on self-diagnostic results or data
monitor. AWD control unit gives drive signal to actuator with receiving command from CONSULT to check
operation of actuator.
Test Item
Test item Condition Description

Change command current value to AWD solenoid, and then change driving
mode. (Monitor value is normal if it is within approximately ±10% of command
• Vehicle stopped value.)
ETS S/V
• Engine running • Qu: Increase current value in increments of 0.1 A
(Detects AWD solenoid)
• No DTC detected • Qd: Decrease current value in increments of 0.1 A
• 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.
DLN-110
C1201 AWD CONTROL UNIT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TY30A]
DTC/CIRCUIT DIAGNOSIS A
C1201 AWD CONTROL UNIT
B
• Controls driving force distribution by signals from each sensor from front wheel driving mode (100:0) to AWD
mode (50:50).
• 2WD mode is available by fail-safe function if malfunction is detected in AWD system. C
DTC Logic INFOID:0000000010288269
DLN
DTC DETECTION LOGIC
Items
DTC Diagnostic item is detected when... Possible cause E
(CONSULT screen terms)
Malfunction has occurred inside AWD
C1201 CONTROLLER FAILURE Internal malfunction of AWD control unit
control unit.
F
G
With CONSULT
H
I
1.PERFORM SELF-DIAGNOSIS J
With CONSULT
2. Turn ignition switch OFF, and then wait 10 seconds or more. K
YES >> Replace AWD control unit. Refer to DLN-153, "Exploded View". L
NO >> Check AWD control unit pin terminals for damage or loose connection with harness connector. If
any items are damaged, repair or replace damaged parts.
M
DLN-111
• Vehicle speed signal
DTC DETECTION LOGIC
Items
ABS malfunction
Malfunction related to wheel sensor has
C1203 ABS SYSTEM been detected by ABS actuator and
electric unit (control unit).
error

With CONSULT
1. Start engine and drive at 30 km/h (19 MPH) or more for approx. 1 minute.
1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS

With CONSULT
Perform ABS actuator and electric unit (control unit) self-diagnosis.
Is any error system detected?
YES >> Check the error system.
NO >> GO TO 2.
With CONSULT
2. Start engine and drive vehicle at 30 km/h (19 MPH) for at least 1 minute.
3. Make sure that ABS warning lamp turns OFF.
4. Perform AWDAWD control unit self-diagnosis.
YES >> Replace AWD control unit. Refer to DLN-153, "Exploded View".
any items are damaged, repair or replace damaged parts.
DLN-112
C1204 AWD SOLENOID
C1204 AWD SOLENOID
A
Controls electric controlled coupling by command current from AWD control unit. B
DTC DETECTION LOGIC C
Items
(CONSULT screen terms) DLN
Malfunction related to AWD solenoid has Internal malfunction of electronic con-
C1204 AWDAWD SOLENOID
been detected. trolled coupling
E
With CONSULT F
Is DTC “C1204” detected? G
H
1.CHECK AWD SOLENOID POWER SUPPLY I

2. Disconnect AWD control unit harness connector.
J
CAUTION:
4. Check the voltage between AWD control unit harness connector and ground.
K
AWD control unit
Ground Voltage (Approx.)
Connector Terminal
L
YES >> GO TO 2. M
NO >> Check the following. If any items are damaged, repair or replace damaged parts.
• 10A fuse (#28) open
- Short among 10A fuse (#28) connector, AWD control unit harness connector No. 9 terminal and
N
the ground
- Open between the battery and AWD control unit harness connector No. 9 terminal
2.CHECK AWD SOLENOID GROUND O
2. Check the continuity between AWD control unit harness connector and ground.
P
AWD control unit
Ground Continuity
Connector Terminal
10
B1 Ground Existed
11
YES >> GO TO 3.
DLN-113
C1204 AWD SOLENOID
3.CHECK AWD SOLENOID CIRCUIT (1)
Check the resistance between AWD control unit harness connector terminals.
AWD control unit

Connector Terminal
B1 1 2 2.45 Ω
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK AWD SOLENOID CIRCUIT (2)
1. Disconnect AWD solenoid harness connector.
2. Check the continuity between AWD control unit harness connector and AWD solenoid harness connector.
AWD control unit AWD solenoid

Continuity
1 2
B1 C1 Existed
2 1
3. Check the continuity between AWD control unit harness connector and the ground.
AWD control unit

Ground Continuity
Connector Terminal
1
B1 Ground Not existed
2
YES >> GO TO 5.
5.CHECK AWDAWD SOLENOID
Check the resistance between AWD solenoid harness connector terminals.
AWD solenoid
Connector Terminal
C1 2 1 2.45 Ω
YES >> GO TO 6.
NO >> AWD solenoid is malfunctioning. Replace electric controlled coupling. Refer to DLN-209,
"Exploded View".
1. Check AWD control unit pin terminals for damage or loose connection with harness connector.
2. Check AWD solenoid pin terminals for damage or loose connection with harness connector.
YES >> GO TO 7.
7.CHECK AWD CONTROL UNIT OUTPUT VOLTAGE
1. Connect AWD control unit harness connector.
2. Check voltage between AWD control unit and ground.
DLN-114
C1204 AWD SOLENOID
AWD control unit A

Ground Condition Voltage (Approx.)
Connector Terminal
Engine speed: 3,000 rpm or more constant
B1 1 Ground 8V B
Lock indicator lamp: ON
YES >> GO TO 8. C
NO >> Replace AWD control unit.
8.CHECK AWD CONTROL UNIT GROUND CIRCUIT
Check continuity between AWD control unit and ground. DLN
AWD control unit

Ground Continuity E
Connector Terminal
B1 2 Ground Existed
Is the inspection result normal? F
YES >> INSPECTION END.
NO >> Replace AWD control unit.
G
1.CHECK AWD SOLENOID

H
2. Disconnect AWD solenoid harness connector.
3. Check the resistance between AWD solenoid harness connector terminals.
I
AWD solenoid
Connector Terminal
J
C1 2 1 2.45 Ω
YES >> INSPECTION END K
NO >> AWD solenoid is malfunctioning. Replace electric controlled coupling. Refer to DLN-209,
"Exploded View".
L
DLN-115
C1209 MODE SW
C1209 MODE SW
Able to select 2WD, AUTO or LOCK mode.

DTC DETECTION LOGIC
Items
More than two switch inputs are simulta-
Malfunction of AWD mode switch or
C1209 MODE SW neously detected due to short circuit of
AWD mode switch circuit.
AWD mode switch.

With CONSULT
1.CHECK AWD MODE SWITCH

2. Remove AWD mode switch.
3. Check the continuity between AWD mode switch connector terminals.
AWD mode switch

Continuity
Connector Terminal Condition
AWD mode switch: 2WD Existed
2 3
Except the above Not existed
AWD mode switch: 2WD Not existed
AWD mode switch: AUTO
M1*1 2 6
AWD mode switch: LOCK Existed
M108*2
AWD mode switch: LOCK
Existed
2 8 (State of hold of LOCK position)
*1: For RUSSIA
*2: Except for RUSSIA

YES >> GO TO 2.
NO >> Replace AWD mode switch.
2.CHECK AWD MODE SWITCH CIRCUIT (1)
Check the continuity between AWD mode switch harness connector and ground.
DLN-116
C1209 MODE SW
AWD mode switch A

Ground Continuity
Connector Terminal
M1*1
2 Ground Existed B
M108*2
*1: For RUSSIA
*2: Except for RUSSIA C

YES >> GO TO 3.
NO >> Repair or replace damaged parts. DLN
3.CHECK AWD MODE SWITCH CIRCUIT (2)

1. Disconnect AWD control unit harness connector. E
2. Check the continuity between AWD control unit harness connector and AWD mode switch harness con-
nector.
F
AWD control unit AWD mode switch
Continuity
14 3 Not existed G
14 6 Not existed
14 8 Existed
H
5 3 Not existed
M1*1
B1 5 6 Existed
M108*2
5 8 Not existed I
12 3 Existed
12 6 Not existed
J
12 8 Not existed
*1: For RUSSIA

K
AWD control unit L

Ground Continuity
Connector Terminal
14
M
12
YES >> GO TO 4.
4.CHECK AWD CONTROL UNIT OUTPUT SIGNAL O
1. Connect AWD control unit harness connector.
3. Check the voltage between AWD mode switch harness connector and ground. P
DLN-117
C1209 MODE SW
AWD mode switch

Connector Terminal
3
M1*1
6 Ground Battery voltage
M108*2
8
*1: For RUSSIA

YES >> Check each harness connector pin terminal for disconnection.
NO >> Replace AWD control unit. Refer to DLN-153, "Exploded View".

2. Remove AWD mode switch.
3. Check the continuity between AWD mode switch connector terminals.
AWD mode switch

Continuity
Connector Terminal Condition
AWD mode switch: 2WD Existed
2 3
AWD mode switch: 2WD Not existed
AWD mode switch: AUTO
M1*1 2 6
AWD mode switch: LOCK Existed
M108*2
Existed
2 8 (State of hold of LOCK position)
*1: For RUSSIA

NO >> Replace AWD mode switch.
DLN-118
C1210 ECM
C1210 ECM
A
Transmits the following signals via CAN communication to AWD control unit. B
DTC Logic INFOID:0000000010288286 C
DTC DETECTION LOGIC

DLN
Items
Malfunction of engine control system E
Malfunction has been detected from
C1210 ENGINE SIGNAL 1 • Accelerator pedal position signal error
ECM.

With CONSULT G
1. Start the engine. Drive the vehicle for a while.
Is DTC “C1210” detected? H
Diagnosis Procedure INFOID:0000000010288287 I

J
With CONSULT
Perform ECM self-diagnosis.
K
NO >> GO TO 2.
2.PERFORM SELF-DIAGNOSIS L
With CONSULT
2. Turn the ignition switch OFF. M
3. Start the engine. Drive the vehicle for a while.
4. Make sure that malfunction indicator (MI) turns OFF.
5. Stop the vehicle. Perform AWD control unit self-diagnosis.
N
any items are damaged, repair or replace damaged parts. O
DLN-119
P1804 CONTROL MODULE
P1804 CONTROL MODULE
DTC DETECTION LOGIC
DTC Display item Malfunction detected condition Possible cause

Malfunction is detected in the memory
Internal malfunction of AWD control
P1804 CONTROL UNIT 3 (EEOROM) system of AWD control
module.
module.

1.PRECONDITIONING
>> GO TO 2.
2.PERFORM DTC CONFIRMATION
With CONSULT
YES >> Proceed to DLN-120, "Diagnosis Procedure".
1.PERFORM SELF-DIAGNOSIS AGAIN

With CONSULT
Perform “DTC CONFIRMATION PROCEDURE” (self-diagnosis) again. Refer to DLN-120, "DTC Logic".
YES >> Replace AWD control module. Refer to DLN-153, "Exploded View".
NO >> Check AWD control module pin terminals for damage or loose connection with harness connector.
If any items are damaged, repair or replace error-detected parts.
DLN-120
A
DTC Display item Malfunction detected condition Possible cause

When incomplete writing unit character- Writing unit characteristics is incom- C
P181F INCOMP CALIBRATION
istics of rear final drive is detected. plete.

DLN
1.PRECONDITIONING
wait at least 10 seconds before conducting the next test. E
>> GO TO 2.
F
2.PERFORM DTC CONFIRMATION
With CONSULT
1. Turn the ignition switch OFF to ON. G
YES >> Proceed to DLN-121, "Diagnosis Procedure". H
I
1.PERFORM WRITING UNIT CHARACTERISTICS
1. Erase self-diagnostic result for “ALL MODE AWD/4WD”.
2. Perform writing unit characteristics. Refer to DLN-109, "CONSULT Function". J
Is any DTC except “P181F” detected?
K
NO >> GO TO 2.
2.PERFORM SELF-DIAGNOSIS AGAIN L
With CONSULT
Perform “DTC CONFIRMATION PROCEDURE” (self-diagnosis) again. Refer to DLN-121, "DTC Logic".
Is DTC “P181F” detected? M
YES >> Replace AWD control module. Refer to DLN-153, "Exploded View".
NO >> Check AWD control module pin terminals for damage or loose connection with harness connector.
If any items are damaged, repair or replace error-detected parts. N
DLN-121
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.
Each control unit transmits/receives data but selectively reads required data only.
DTC DETECTION LOGIC
Items
When AWD control unit is not transmit-
U1000 CAN COMM CIRCUIT ting or receiving CAN communication
• Malfunction of AWD control unit
signal for 2 seconds or more.

With CONSULT
With CONSULT
Perform AWD control unit self-diagnosis.
YES >> CAN specification chart. Refer to LAN-24, "Trouble Diagnosis Flow Chart".
DLN-122
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
Each control unit transmits/receives data but selectively reads required data only.
DLN
DTC DETECTION LOGIC

E
Items
When detecting error during the initial di-
U1010 CONTROL UNIT (CAN) agnosis of CAN controller of AWDAWD Malfunction of AWD control unit F
control unit.
DTC CONFIRMATION PROCEDURE G

With CONSULT
1. Turn the ignition switch OFF to ON. H
YES >> Proceed to diagnosis procedure. Refer to DLN-123, "Diagnosis Procedure". I
J
1.CHECK AWD CONTROL UNIT

Check AWD control unit harness connector for disconnection and deformation. K
NO >> Repair or replace damaged parts. L
DLN-123
Supplies power to AWD control unit.

1.CHECK AWD CONTROL UNIT POWER SUPPLY

AWD control unit

Connector Terminal
B1 7 Ground 0V
CAUTION:
AWD control unit

Connector Terminal
YES >> GO TO 2.
the ground
- Open between the ignition switch and AWD control unit harness connector No. 7 terminal
• Ignition switch. Refer to DLN-124, "Diagnosis Procedure".
2.CHECK AWD SOLENOID POWER SUPPLY
AWD control unit

Connector Terminal
CAUTION:
AWD control unit

Connector Terminal
YES >> GO TO 3.
the ground
DLN-124
- Open between the battery and AWD control unit harness connector No. 9 terminal
3.CHECK AWD SOLENOID VALVE GROUND A

B
AWD control unit

Ground Continuity
Connector Terminal C
10
B1 Ground Existed
11
DLN
E
DLN-125
AWD WARNING LAMP
AWD WARNING LAMP
• Turns ON when there is a malfunction in AWD system. It indicates that fail-safe mode is engaged and vehi-
cle change to front-wheel drive or shifting driving force-AWD (rear wheels still have some driving torque).
• Also turns ON when ignition switch is turned ON, for purpose of lamp check. Turns OFF after the engine
starts if system is normal.
AWD WARNING LAMP INDICATION
Condition AWD warning lamp

Turns ON when ignition switch is turned ON. Turns OFF after
Lamp check
engine start.
AWD system malfunction ON
Protection function is activated due to heavy load to electric controlled
Quick blinking: 2 times/second
coupling. (AWD system is not malfunctioning and AWD system chang-
(Blinking in approx. 1 minute and then turning OFF)
es to 2WD mode.)
Slow blinking: 1 time/2 seconds
Large difference in diameter of front/rear tires
(Continuing to blink until turning ignition switch OFF)
Other than above (system normal) OFF
CAUTION:
AWD warning lamp also turns ON due to data reception error, CAN communication error etc.
1.CHECK POWER SUPPLY AND GROUND CIRCUIT

Perform the trouble diagnosis for power supply and ground circuit. Refer to DLN-124, "Diagnosis Procedure".
YES >> GO TO 2.
NO >> Repair or replace the malfunctioning part.
With CONSULT
NO >> GO TO 3.
3.CHECK AWD WARNING LAMP SIGNAL
With CONSULT
CAUTION:
2. Check “AWD WARN LAMP” of AWD control unit CONSULT “DATA MONITOR”.
Does the item on “DATA MONITOR” indicate “On”?
YES >> GO TO 4.
NO >> Replace AWD control unit. Refer to DLN-153, "Exploded View".
4.CHECK COMBINATION METER POWER SUPPLY CIRCUIT
Perform the trouble diagnosis for combination meter power supply circuit. Refer to MWI-61, "COMBINATION
METER : Diagnosis Procedure".
DLN-126
AWD MODE INDICATOR LAMP (AWD)
AWD MODE INDICATOR LAMP (AWD)
A
The following is the indications of indicator lamp after engine start. B

AWD INDICATOR LAMP AND LOCK INDICATOR LAMP
Condition AWD indicator lamp LOCK indicator lamp C

2WD mode OFF OFF
AUTO mode ON OFF
DLN
LOCK mode ON ON
E
Does AWD warning lamp turn ON? F
YES >> Go to DLN-126, "Diagnosis Procedure".
NO >> GO TO 2.
G
Perform the trouble diagnosis for AWD mode switch. Refer to DLN-116, "Diagnosis Procedure".
Is the inspection result normal? H
YES >> GO TO 3.
3.CHECK AWD INDICATOR LAMP SIGNAL I
With CONSULT
1. Start the engine. J
CAUTION:
Stop the vehicle.
2. Change AWD mode switch in “AUTO” from “2WD”.
3. Check “AWD MODE MON” of AWD control unit CONSULT “DATA MONITOR”. K
Does the item on “DATA MONITOR” indicate “AUTO”?
YES >> GO TO 4.
NO >> Replace AWD control unit. Refer to DLN-153, "Exploded View". L
Perform the trouble diagnosis for combination meter power supply circuit. Refer to MWI-61, "COMBINATION M
YES >> INSPECTION END N
DLN-127
LOCK INDICATOR LAMP
LOCK INDICATOR LAMP
The following is the indications of indicator lamp after engine start.

AWDAWD INDICATOR LAMP AND LOCK INDICATOR LAMP
Condition AWD indicator lamp LOCK indicator lamp

2WD mode OFF OFF
AUTO mode ON OFF
LOCK mode ON ON

YES >> Go to DLN-126, "Diagnosis Procedure".
NO >> GO TO 2.
Perform the trouble diagnosis for AWD mode switch. Refer to DLN-116, "Diagnosis Procedure".
YES >> GO TO 3.
3.CHECK LOCK INDICATOR LAMP SIGNAL
With CONSULT
CAUTION:
Stop the vehicle.
2. Change AWD mode switch in “LOCK” from “AUTO”.
3. Check “AWD MODE MON” of AWD control unit CONSULT “DATA MONITOR”.
Does the item on “DATA MONITOR” indicate “LOCK”?
YES >> GO TO 4.
NO >> Replace AWD control unit. Refer to DLN-124, "Diagnosis Procedure".
Perform the trouble diagnosis for combination meter power supply circuit. Refer to MWI-61, "COMBINATION
DLN-128
AWD CONTROL UNIT
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TY30A]
ECU DIAGNOSIS INFORMATION A

AWD CONTROL UNIT
Reference Value INFOID:0000000010288306
B
VALUES ON THE DIAGNOSIS TOOL

C
FR RH SENSOR Vehicle running Approximately equal to the indi- DLN

CAUTION: cation on speedometer (Inside
Check air pressure of tire under standard condition. of ±10%)
Vehicle stopped 0.00 km/h (0.00 mph) E
FR LH SENSOR Vehicle running Approximately equal to the indi-
F
RR RH SENSOR Vehicle running Approximately equal to the indi-

G
RR LH SENSOR Vehicle running Approximately equal to the indi- H

BATTERY VOLT Always Battery voltage
I
When depressing accelerator pedal
THRTL POS SEN 0 – 100%
(Value rises gradually in response to throttle position.)
AWDAWD mode switch: 2WD Approx. 0.000 A J
Engine running
AWD indicator lamp: ON Approx. 0.000 A
• At idle speed
LOCK indicator lamp: ON Approx. 0.000 A
ETS SOLENOID
AWD mode switch: 2WD Approx. 0.000 A K
Engine running
• When depressing accelerator AWD indicator lamp: ON R9M: Approx. 0.000 – 2.000 A*
pedal
LOCK indicator lamp: ON R9M: Approx. 2.000 A
L
Brake pedal: Depressed On
STOP LAMP SW
Brake pedal: Released Off
Engine stopped M
Stop
(Engine speed: Less than 400 rpm)
ENG SPEED SIG
Engine running
Run
(Engine speed: 400 rpm or more) N
Engine stopped (Ignition switch: ON) Off
ETS ACTUATOR
Engine running On
AWD warning lamp: ON On O
4WD WARN LAMP
AWD warning lamp: OFF Off
AWD mode switch: 2WD 2WD
P
AWD mode switch: AUTO AUTO
4WD MODE SW
LOCK
DLN-129
AWD CONTROL UNIT
AWD mode switch: 2WD 2WD
AWD mode switch: AUTO AUTO
4WD MODE SW AWD mode switch: AUTO ⇒ LOCK

AUTO ⇒ LOCK
(State of AWD indicator lamp turn ON)
AWD mode switch: AUTO ⇒ LOCK
LOCK ⇒ AUTO
(State of LOCK indicator lamp turn ON)
Vehicle running with normal size tire installed 0 – 4 mm
DIS-TIRE MONI Vehicle running with improper size tire installed (Front/rear tire
4 – 8 mm, 8 – mm
size difference, wear condition)
Parking brake operated On
PARKING BRAKE SW SIG
Parking brake not operated Off
TERMINAL LAYOUT
JSDIA0057ZZ
PHYSICAL VALUES
Terminal No.
Description
(Wire color)
Input/
+ - Signal name
Output
AWD mode switch: 2WD 0V
Engine speed: At idle AWD indicator lamp: ON 0V
1 AWD solenoid power sup- LOCK indicator lamp: ON 0V

Ground Output
(LG) ply AWD mode switch: 2WD 0V
Engine speed: 3,000
AWD indicator lamp: ON 2.5 V*
rpm or more constant
LOCK indicator lamp: ON 8V
2 Engine speed: At idle 0V

Ground AWD solenoid ground —
(L) Engine speed: 3,000 rpm or more constant 0V
AWD mode switch: 2WD Battery voltage
5 AWD mode switch: AUTO 0V
Ground AWD mode switch (AUTO) Output Ignition switch: ON
(V)
0V
7 Ignition switch: ON Battery voltage

Ground Ignition switch Input
(P) Ignition switch: OFF 0V
8 Input/
— CAN-H — —
(L) Output
9 Power supply (AWD sole- Ignition switch: ON Battery voltage

Ground Input
(G) noid) Ignition switch: OFF Battery voltage
DLN-130
AWD CONTROL UNIT
Terminal No.
Description
(Wire color) A
Input/
+ - Signal name
Output
10 B
(B)
11
(B) C
AWD mode switch: 2WD 0V
12 AWD mode switch: AUTO Battery voltage
Ground AWD mode switch (2WD) Output Ignition switch: ON
(BR) DLN
Battery voltage
AWD mode switch: 2WD Battery voltage
E
14 AWD mode switch: AUTO Battery voltage
Ground AWD mode switch (LOCK) Output Ignition switch: ON
(Y)
0V
F
16 Input/
— CAN-L — —
(P) Output
G
CAUTION:
When using circuit tester to measure voltage for inspection, be sure not to extend forcibly any connector terminals.
Wiring Diagram - AWD SYSTEM - INFOID:0000000010288307

H
FOR RUSSIA
I
DLN-131
AWD CONTROL UNIT
JRDWC2166GB
DLN-132
AWD CONTROL UNIT
DLN
JRDWC2213GB
DLN-133
AWD CONTROL UNIT
JRDWC2214GB
DLN-134
AWD CONTROL UNIT
DLN
JRDWC2215GB
P
EXCEPT FOR RUSSIA
DLN-135
AWD CONTROL UNIT
JRDWC2167GB
DLN-136
AWD CONTROL UNIT
DLN
JRDWC2216GB
DLN-137
AWD CONTROL UNIT
JRDWC2217GB
DLN-138
AWD CONTROL UNIT
DLN
JRDWC2218GB
DLN-139
AWD CONTROL UNIT
JRDWC2219GB
Fail Safe INFOID:0000000010288308
AWD system
• If any malfunction occurs in AWD electrical system, and control unit detects the malfunction, AWD warning
lamp on combination meter turns ON to indicate system malfunction.
DLN-140
AWD CONTROL UNIT
• When AWD warning lamp is ON, vehicle changes to front-wheel drive or shifting driving force-AWD (rear
wheels still have some driving torque). A
• AWD system activates its protection function (shuts down AWD system temporarily) if AWD system detects
high load continuously or the front wheel tire size differs from the rear tire size. (AWD system is automati-
cally restored if AWD system no longer detects any overload or the tire size difference is eliminated.)
B
Warning
Mode DTC Detected area (Error area) Error area and root cause
lamp
Transfer assembly in protection mode C
Protection Blinking*1 — AWD control unit
(Internal temperature rise of electronic controlled coupling)
function
Blinking*2 — AWD control unit Malfunction in each tire or different tire diameter
DLN
C1201 AWD control unit Internal malfunction of AWD control unit
ABS malfunction
ABS actuator and electric
C1203 • Vehicle speed signal error
unit (control unit) E
• Stop lamp switch signal (brake signal) error
C1204 AWD solenoid Internal malfunction of electronic controlled coupling
C1205 AWD control unit Internal malfunction of AWD control unit
F
C1209 AWD mode switch Malfunction of AWD mode switch or AWD mode switch circuit
Fail-safe ON Malfunction of engine control system
C1210 ECM • Accelerator pedal position signal error G
P1804 AWD CONTROL UNIT Internal malfunction of AWD control module
P181F AWD CONTROL UNIT Writing unit characteristics is incomplete H
U1000 CAN communication line
• Malfunction of AWD control unit
U1010 AWD control unit Malfunction of AWD control unit I
*1: Quick blinking: 2 times/second (blinking for approx. 1 minute and then turned OFF)
*2: Slow blinking: 1 time/2 seconds (Continuing to blink until ignition switch is turned OFF)
J
DTC Inspection Priority Chart INFOID:0000000010288309
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
K
chart.
Priority Detected items (DTC)

L
• U1000 CAN COMM CIRCUIT
1
• U1010 CONTROL UNIT (CAN)
• C1201 CONTROLLER FAILURE
2 M
• C1205 AWD ACTUATOR RLY
• C1203 ABS SYSTEM
3
• C1210 ENGINE SIGNAL 1
• C1204 AWD SOLENOID N
4
• C1209 MODE SW
• P1804 CONTROL UNIT 3
5
• P181F INCOMP CALIBRATION O
DTC Index INFOID:0000000010288310
P
Items
DTC Reference
C1201 CONTROLLER FAILURE DLN-111, "Description"
C1203 ABS SYSTEM DLN-112, "Description"
C1204 AWD SOLENOID DLN-113, "Description"
DLN-141
AWD CONTROL UNIT
Items
DTC Reference
C1209 MODE SW DLN-116, "Description"
C1210 ENGINE SIGNAL 1 DLN-119, "Description"
P1804 CONTROL UNIT 3 DLN-120, "DTC Logic"
P181F INCOMP CALIBRATION DLN-121, "DTC Logic"
U1000 CAN COMM CIRCUIT DLN-122, "Description"
U1010 CONTROL UNIT (CAN) DLN-123, "Description"
DLN-142
AWD SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [TRANSFER: TY30A]
SYMPTOM DIAGNOSIS A
AWD SYSTEM SYMPTOMS
Symptom Table INFOID:0000000010288311
B
If AWD warning lamp turns ON, perform self-diagnosis.
Symptom Condition Check item Reference
C
Power supply and ground for AWD con-
trol unit
AWD warning lamp does not turn ON when
CAN communication line DLN-144, "De-
the ignition switch is turned to ON. Ignition switch: ON DLN
scription"
(AWD warning lamp check) AWD control unit
Combination meter
AWD control unit self-diagnosis E
AWD warning lamp does not turn OFF sev- AWD warning lamp DLN-145, "De-
Engine running
eral seconds after engine started. scription"
Power supply and ground for AWD con-
trol unit F
ECM self-diagnosis
Heavy tight-corner braking symptom occurs • While driving AWD control unit self-diagnosis
when the vehicle is driven and the steering • Steering wheel is DLN-146, "De- G
wheel is turned fully to either side after the turned fully to either AWD solenoid scription"
engine is started. (See NOTE.) sides Mechanical malfunction of electric con-
trolled coupling (clutch sticking etc.) H
CAN communication line
AWD solenoid
Vehicle does not enter AWD mode even DLN-147, "De-
While driving I
though AWD warning lamp turned to OFF. Mechanical malfunction of electric con- scription"
trolled coupling (Mechanical engage-
ment of clutch is not possible.)
Protection function is activated due to J
While driving, AWD warning lamp blinks heavy load to electric controlled cou-
quickly. (When blinking in approx. 1 minute pling. (AWD system is not malfunction- DLN-148, "De-
While driving
and then turning OFF.) ing. Also, optional distribution of torque scription"
Quick blinking: 2 times/second sometimes becomes rigid before lamp K
blinks quickly, but it is not malfunction.)
While driving, AWD warning lamp blinks
• While driving
slowly. (When continuing to blink until turn- Tire size is different between front and DLN-149, "De- L
• Vehicle speed: 20 km/h
ing ignition switch OFF) rear of vehicle. scription"
(12 MPH) or more
Slow blinking: 1 time/2 seconds
NOTE:
M
DLN-143
AWD warning lamp does not turn ON when the ignition switch is turned to ON.

Perform the trouble diagnosis for AWD warning lamp. Refer to DLN-126, "Diagnosis Procedure".
YES >> Check each harness connector pin terminal for malfunction or disconnection.
DLN-144
AWD WARNING LAMP DOES NOT TURN OFF
AWD WARNING LAMP DOES NOT TURN OFF
A
AWD warning lamp does not turn OFF several seconds after engine started. B
1.PERFORM SELF-DIAGNOSIS C
With CONSULT
DLN
NO >> GO TO 2.
E
Perform the trouble diagnosis of the AWD warning lamp. Refer to DLN-126, "Diagnosis Procedure".
Is the inspection result normal? F
YES >> GO TO 3.
3.CHECK AWD CONTROL UNIT POWER SUPPLY AND GROUND CIRCUIT G
Perform the trouble diagnosis of the power supply and ground circuit. Refer to DLN-124, "Diagnosis Proce-
dure".
H
YES >> Check each harness connector pin terminal for malfunction or disconnection.
NO >> Repair or replace the malfunctioning part. I
DLN-145
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:

With CONSULT
Perform ECM self-diagnosis.
NO >> GO TO 2.
With CONSULT
NO >> GO TO 3.
3.CHECK AWD SOLENOID
Perform the trouble diagnosis of the AWD solenoid. Refer to DLN-113, "Diagnosis Procedure".
YES >> GO TO 4.
4.CHECK ELECTRIC CONTROLLED COUPLING
2. Set the transaxle to neutral. Release the parking brake.
3. Lift up the vehicle.
4. Rotate the propeller shaft by hand.
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
DLN-203, "Exploded View".
DLN-146
VEHICLE DOES NOT ENTER AWD MODE
VEHICLE DOES NOT ENTER AWD MODE
A
Vehicle does not enter AWD mode even though AWD warning lamp turned to OFF. B
1.CHECK AWD WARNING LAMP C

Turn the ignition switch ON.
DLN
YES >> GO TO 2.
NO >> Go to DLN-144, "Diagnosis Procedure".
2.PERFORM SELF-DIAGNOSIS E
With CONSULT
Is DTC “U1000” detected? F
NO >> GO TO 3.
3.CHECK AWD SOLENOID G
Perform the trouble diagnosis of the AWD solenoid. Refer to DLN-113, "Diagnosis Procedure".
Is the inspection result normal? H
YES >> GO TO 4.
4.CRUISE TEST I
Drive the vehicle for a period of time.
Does any symptom occur?
J
YES >> Replace electric controlled coupling for mechanical malfunction (mechanical engagement of
clutch is not possible). Refer to DLN-203, "Exploded View".
K
DLN-147
AWD WARNING LAMP BLINKS QUICKLY
AWD WARNING LAMP BLINKS QUICKLY
While driving, AWD warning lamp blinks 2 times in 1 second and it turns OFF after 1 minute.
• This symptom protects drive train parts when a heavy load is applied to the electric controlled coupling and
before lamp blinks quickly. Both cases are not malfunction.
• When this symptom occurs, stop vehicle and allow it to idle for some times. Blinking will stop and system will
be restored.
DLN-148
AWD WARNING LAMP BLINKS SLOWLY
AWD WARNING LAMP BLINKS SLOWLY
A
AWD warning lamp blinks at approximately 2 seconds intervals while driving. B

1.CHECK TIRE C
Check the following.
• Tire pressure
• Wear condition DLN
• Longitudinal tire size (There is no difference between longitudinal tires.)
YES >> GO TO 2. E
NO >> Drive at vehicle speed of 20 km/h (12 MPH) or more for 5 seconds or more after repairing or
replacing damaged parts. (Initialize improper size tire information.)
2. CHECK INPUT SIGNAL OF TIRE DIAMETER F
With CONSULT
1. Start engine.
2. Drive at 20 km/h (12 MPH) or more for approx. 200 seconds. G
3. Check “DIS-TIRE MONI” of AWD control unit CONSULT “DATA MONITOR”.
Does the item on “DATA MONITOR” indicate “0 - 4 mm”?
H
NO >> GO TO 3.
3.TERMINAL INSPECTION I
Check AWD control unit harness connector for disconnection.
YES >> Replace AWD control unit. Refer to DLN-153, "Exploded View". J
DLN-149
NORMAL OPERATING CONDITION
NORMAL OPERATING CONDITION
While driving, AWD warning lamp blinks 2 times in 1 second and it turns OFF after 1 minute.
• This symptom protects drive train parts when a heavy load is applied to the electric controlled coupling and
before lamp blinks quickly. Both cases are not malfunction.
• When this symptom occurs, stop vehicle and allow it to idle for some times. Blinking will stop and system will
be restored.
DLN-150
A
NVH Troubleshooting Chart INFOID:0000000010288324
M/T MODELS B
Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspec-
tion. If necessary, repair or replace these parts.
C
DLN-163, "Inspection After Disassembly"
DLN-163, "Inspection After Disassembly"

DLN

E
DLN-152, "Inspection"
Reference
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-151
TRANSFER OIL
< PERIODIC MAINTENANCE > [TRANSFER: TY30A]
PERIODIC MAINTENANCE
TRANSFER OIL
OIL LEAKAGE
Check transfer surrounding area (oil seal, drain plug, filler plug, and transfer case, etc.) for oil leakage.
OIL LEVEL
1. Remove filler plug (1) and gasket. Then check that oil is filled up
(A) from mounting hole for the filler plug.
2. Before installing filler plug, set a new gasket. Install filler plug on
transfer and tighten to the specified torque. Refer to DLN-157,
"Exploded View" .
CAUTION:
Never reuse gaskets.
SDIA3060J
1. Run the vehicle to warm up the transfer unit sufficiently.

2. Stop the engine and remove drain plug (1) and gaskets to drain
the transfer oil.
CAUTION:
Never remove tooth contact test hole plug (2).
3. Before installing drain plug, set a new gasket. Install drain plug
on transfer and tighten to the specified torque. Refer to DLN-
157, "Exploded View" .
CAUTION:
Never reuse gaskets.
SDIA3059J
1. Remove filler plug (1) and gasket. Then fill oil up to mounting
hole (A) for the filler plug.

and Lubricants".
Oil capacity : Refer to DLN-97, "General
Specifications".
CAUTION:
Carefully fill the oil. (Fill up for approximately 3 minutes.)
2. Leave the vehicle for 3 minutes. Then check oil level again. SDIA3060J
3. Before installing filler plug, set a new gasket. Install filler plug on
transfer and tighten to the specified torque. Refer to DLN-157, "Exploded View" .
CAUTION:
Never reuse gasket.
DLN-152
AWD CONTROL UNIT
< REMOVAL AND INSTALLATION > [TRANSFER: TY30A]
REMOVAL AND INSTALLATION A

AWD CONTROL UNIT
B
DLN
JSDIA5368GB
G
AWD control unit

H
: Vehicle front
I
REMOVAL
J
1. Remove luggage side lower finisher (LH). Refer to INT-29, "Luggage side trim".
3. Remove AWD control unit bolts ( ). K
NOTE:
AWD control unit is located on the back side of body panel.
L
: Front
AWDIA1154ZZ N
4. Remove AWD control unit.
INSTALLATION O
Installation is in the reverse order of removal.
CAUTION:
• Do not drop or shock AWD control unit.
P
• When replacing AWD control unit, perform writing unit characteristic. Refer to DLN-109, "CONSULT
Function".
DLN-153
AWD MODE SWITCH
< REMOVAL AND INSTALLATION > [TRANSFER: TY30A]
AWD MODE SWITCH
ALDIA0506ZZ
1. Instrument lower panel LH 2. AWD lock switch Front

Pawl
REMOVAL
1. Remove instrument lower panel LH. Refer to IP-12, "Exploded View".
2. Disconnect AWD lock switch harness connector (A).
3. Remove AWD lock switch from lower switch bracket (2).
: Pawls
AWDIA1151ZZ
INSTALLATION
Install in the reverse order of removal.
DLN-154
TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: TY30A]
UNIT REMOVAL AND INSTALLATION A

TRANSFER ASSEMBLY
B
DLN
JSDIA0267GB J
1. Gusset 2. Transfer assembly 3. O-ring (outer)
: Vehicle front
K

Refer to GI-4, "Components" for symbols not described on the above.
L
REMOVAL M
1. Remove the exhaust front tube. Refer to EX-22, "Exploded View".
2. Separate the rear propeller shaft. Refer to DLN-186, "Exploded View".
N
3. Remove right side drive shaft and support bearing bracket. Refer to RAX-14, "Exploded View".
4. Remove the diesel particle filter. Refer to EX-24, "Exploded View".
5. Remove the gusset. O
6. Remove the rear torque rod. Refer to EM-429, "Exploded View".
DLN-155
TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: TY30A]
7. Remove the mounting bolts ( ) of transaxle assembly and
transfer assembly.
CAUTION:
Never remove the mounting bolts ( ) of adapter case.
8. Remove transfer assembly from the vehicle.
CAUTION:
• Never damage air breather hose.
9. Remove O-ring (outer) from the transfer assembly.
SDIA3225J
INSTALLATION
• Apply multi-purpose grease lightly and evenly onto an O-ring (outer), and install it to the transfer assembly.
CAUTION:
Never reuse O-ring (outer).
• Install mounting bolts according to the standard below when install-
ing transfer assembly to the transaxle assembly.
Bolt symbol A B
Installation direction Transfer ⇒ Transaxle Transaxle ⇒ Transfer
• Check oil level and check for oil leakage after installation. Refer to
DLN-152, "Inspection".
SDIA3070J
DLN-156
ADAPTER CASE
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: TY30A]
UNIT DISASSEMBLY AND ASSEMBLY A

ADAPTER CASE
B
DLN
JSDIA0319GB
M
1. Adapter case oil seal (outer) 2. O-ring (outer) 3. Adapter case oil seal (inner)
4. Adapter case 5. O-ring (inner) 6. Ring gear shaft
N
7. Ring gear adjusting shim 8. Ring gear shaft bearing 9. Ring gear
(adapter case side) (adapter case side)
10. Ring gear nut 11. Ring gear shaft bearing 12. Ring gear adjusting shim
(transfer case side) (transfer case side) O
13. Transfer case 14. Air breather hose 15. Air breather tube
16. Gasket 17. Filler plug 18. Drain plug
19. Plug 20. Drive pinion 21. Drive pinion adjusting shim P
22. Drive pinion bearing (front side) 23. Collapsible spacer 24. Drive pinion bearing (rear side)
25. Drive pinion oil seal 26. Companion flange 27. Lock nut
A: Oil seal lip
: Apply gear oil.

DLN-157
ADAPTER CASE
: Apply anti-corrosive oil.
: Apply Genuine Liquid Gasket, Three Bond 1215 or equivalent.

1. Remove O-ring (outer) from adapter case.

2. Remove adapter case mounting bolts ( ).
SDIA3076J
3. Lightly tap adapter case with a plastic hammer to remove

adapter case.
4. Remove O-ring (inner) from adapter case.
JSDIA0252ZZ
5. Remove adapter case oil seal (outer/inner) with a screwdriver.

CAUTION:
Be careful not to damage adapter case.
SDIA3078J
1. Install O-ring (inner) to adapter case.

CAUTION:
• Never reuse O-ring (inner).
• Apply multi-purpose grease to O-ring (inner).
2. Install adapter case to the transfer case.
DLN-158
ADAPTER CASE
3. Apply anti-corrosive oil onto threads and seats of bolts ( ), and
tighten with the specified torque. A
CAUTION: B
Measure the total preload without the adapter case oil seal
(outer/inner).
C
SDIA3076J
DLN
5. Install adapter case oil seal (inner) (1) to the adapter case with
drifts.
E
A : Drift (SST: ST30720000)
B : Drift (SST: ST27861000)
C : Drift (commercial service tool)
F
Dimension “D” : 0 – 1.0 mm

CAUTION: G
• Never reuse oil seal. JSDIA0259ZZ
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference.
H
• Install adapter case oil seal (inner) in the direction shown in the figure.
6. Install adapter case oil seal (outer) (1) to the adapter case with
drifts so that it becomes flush with adapter case end surface.
I
C : Drift (commercial service tool) J
CAUTION:
• Never reuse oil seal.
• Apply multi-purpose grease onto oil seal lips, and gear oil K
• Install adapter case oil seal (outer) in the direction shown JSDIA0214ZZ
in the figure. L
7. Install O-ring (outer) to the adapter case.
Inspection After Disassembly INFOID:0000000010288350
M
CASE
Check the bearing mounting surface for wear, cracks and damages. N
DLN-159
RING GEAR SHAFT
RING GEAR SHAFT
JSDIA0319GB
(transfer case side) (transfer case side)
19. Plug 20. Drive pinion 21. Drive pinion adjusting shim
A: Oil seal lip
: Apply gear oil.

DLN-160
RING GEAR SHAFT

A
B
1. Remove adapter case. Refer to DLN-158, "Disassembly".
2. Remove adapter case oil seal (outer/inner) from the adapter case. Refer to DLN-158, "Disassembly".
C
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). DLN
CAUTION:
Be careful not to damage adapter case.
4. Remove ring gear shaft assembly from the transfer case. E
5. Remove outer race of ring gear shaft bearing (transfer case
side) and ring gear adjusting shim (transfer case side) from the
transfer case. F
SDIA3079J
6. Remove inner race of ring gear shaft bearing (transfer case

side) from ring gear shaft with drift (A) (commercial service tool) G
and replacer (B) (SST: ST22730000).
SDIA3080J
J
7. Remove ring gear nut (1).
CAUTION:
Never damage ring gear shaft. K
M
SDIA3081J
8. Remove ring gear from ring gear shaft with a drift (A) (SST: N
ST33052000).
SDIA3082J
DLN-161
RING GEAR SHAFT
9. Remove inner race of ring gear shaft bearing (adapter case
side) from ring gear with a drift (A) (commercial service tool) and
replacer.
SDIA3083J
1. Select ring gear adjusting shim (transfer case side). Refer to DLN-167, "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:
• 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-167, "Adjustment".
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).
CAUTION:
• Never reuse ring gear shaft bearing (adapter case side).
• Apply gear oil to the ring gear shaft bearing (adapter case
side).
SDIA3102J
6. Install inner race of ring gear shaft bearing (adapter case side)
to the ring gear with drifts.
A : Press adapter (If necessary)

B : Drift (commercial service tool)
CAUTION:
• Never reuse ring gear shaft bearing (adapter case side).
• Apply gear oil to the ring gear shaft bearing (adapter case
side).
SDIA3097J
7. Apply anti-corrosive oil to the spline of ring gear shaft. Install the
ring gear to ring gear shaft with drifts.

JSDIA0253ZZ
DLN-162
RING GEAR SHAFT
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 A
torque wrench.
CAUTION:
• Never reuse ring gear nut.
B
SDIA3100J
DLN
9. Install inner race of ring gear shaft bearing (transfer case side)
to the ring gear shaft with a drift (A) (SST: KV10111400).
CAUTION:
E
• Never reuse ring gear shaft bearing (transfer case side).
• Apply gear oil to the ring gear shaft bearing (transfer race
side).
10. Assemble the ring gear shaft assembly to the transfer case. F
11. Install adapter case. Refer to DLN-158, "Assembly".
flange runout. Refer to DLN-167, "Adjustment". G
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-158, "Assembly". H
Check items below. If necessary, replace them with new ones. I
GEAR AND SHAFT

Check gear face and shaft for wear, cracks, damage, and seizure. J
CAUTION:
K
BEARING
damage.
L
CAUTION:
Always replace inner race and outer race as a pair when replacing the bearing.
SHIM M
CASE
Check the bearing mounting surface for wear, cracks and damages. N
DLN-163
DRIVE PINION
DRIVE PINION
JSDIA0319GB
A: Oil seal lip
: Apply gear oil.

DLN-164
DRIVE PINION

A
B
C
3. Remove lock nut from the drive pinion.
4. Put matching marks (A) on screw ends of companion flange (1)
and drive pinion.
CAUTION: DLN
Use paint to avoid scratching the surface.
SDIA3084J
5. Remove companion flange from drive pinion with a puller. G
J
SDIA3085J
6. Remove drive pinion oil seal from the transfer case with a puller
(A) (SST: KV381054S0). K
CAUTION:
L
SDIA3089J
N
7. Remove drive pinion assembly from transfer case while tapping
the drive pinion lightly with a plastic hammer.
CAUTION:
O
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-
P
fer case.
SDIA3086J
DLN-165
DRIVE PINION
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
1. Select drive pinion adjusting shim. Refer to DLN-167, "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.
7. Assemble drive pinion assembly into the transfer case, and then
install companion flange (1) to drive pinion.
NOTE:
Align matching marks (A) on the thread edge of companion
flange and drive pinion and install companion flange if drive pin-
ion is reused.
SDIA3084J
DLN-166
DRIVE PINION
8. Tap the companion flange with a plastic hammer as far as the
lock nut can be tightened. A
CAUTION:
Never damage drive pinion oil seal.
9. Apply anti-corrosive oil to the thread and seat of the lock nut, B
and temporarily tighten lock nut to the drive pinion.
CAUTION:
Never reuse lock nut.
C
SDIA3095J
DLN
10. Tighten lock nut within the specified torque range with a preload
gauge (A) (SST: ST3127S000) so that the drive pinion bearing
preload is within standard.
E
Standard
Drive pinion bearing preload : Refer to DLN-180, "Pre-
F
load Torque".
CAUTION:
• Start the tightening of lock nut from lower limit of the G
specified torque. Check the preload every 5° to 10° while SDIA3072J
tightening the lock nut.
• Replace the collapsible spacer and tighten it again to adjust if preload exceeds the specified
value. Never loosen lock nut to adjust preload. H
• After adjustment, rotate the drive pinion back and forth from 2 to 3 times to check for unusual
noise, sticking, binding, and so on.
11. Install ring gear shaft assembly. Refer to DLN-162, "Assembly". I
ment". J
CAUTION:
Measure the total preload without the adapter case oil seal.
K
BACKLASH
L
1. Install the bolt (A) to the companion flange.
2. Fit a dial indicator onto the bolt.
3. Measure the circumference backlash of the companion flange. M
Standard
Backlash : Refer to DLN-180, "Backlash". N
Disassemble the transfer assembly to check and adjust each
part if outside the standard.
O
JSDIA0321ZZ
TOOTH CONTACT
1. Remove adapter case. Refer to DLN-158, "Disassembly". P
DLN-167
DRIVE PINION
2. Remove ring gear shaft assembly from transfer case. Then
apply red lead onto the ring gear.
CAUTION:
Apply red lead to both faces of 3 to 4 gears at 4 locations
evenly spaced on the ring gear.
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. (A: Drive side, B: Reverse side)
SDIA3067J
JSDIA0213GB
DLN-168
DRIVE PINION
7. Follow the procedure below to adjust pinion height (dimension
X) if tooth contact is improper. A
CAUTION:
If no adjusting shim with the calculated value is available,
select the thicker and closest one.
B
SDIA3158J
DLN
• 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. E
CAUTION:
F
G
PDIA0440E
• Thin the drive pinion adjusting shim to move the drive pinion H
farther from the ring gear in case of flank contact or toe con-
tact.
CAUTION: I
8. Assemble the plug to the transfer case.
CAUTION: J
• 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- K
PDIA0441E
fied torque when installing plug.
DRIVE PINION BEARING PRELOAD
L
2. Remove ring gear shaft assembly from the transfer case.
3. Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking, M
and so on.
5. Measure the drive pinion bearing preload with a preload gauge N
(A) (SST: ST3127S000).
Standard O
Drive pinion bearing preload : Refer to DLN-180, "Pre-
load Torque".
CAUTION: P
fied gear oil.
• Disassemble the drive pinion assembly to check and adjust SDIA3072J
each part if outside the standard.
TOTAL PRELOAD
1. Measure drive pinion bearing preload (P1). Refer to “DRIVE PINION BEARING PRELOAD”.
DLN-169
DRIVE PINION
CAUTION:
Check that the drive pinion bearing preload is within the standard.
5. Measure the total preload with a preload gauge (A) (SST:
ST3127S000).
Standard
Total preload
All oil seals are installed : Refer to DLN-180,
"Preload Torque".
Without adapter case oil seal : Refer to DLN-180,
"Preload Torque".
JSDIA0322ZZ
CAUTION:
• Each rotational part should rotate smoothly with the spec-
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.
the propeller shaft bolt holes).
Limit
Companion flange runout : Refer to DLN-180, "Com-
SDIA3074J
3. Fit a test indicator to the inner side of the companion flange

(socket diameter).
Limit
5. Follow the procedure below to adjust if runout value is outside
the repair limit.
Replace collapsible spacer to check and adjust each part

when companion flange is adjusted or replaced.
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.
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
Measuring Point
DLN-170
DRIVE PINION
DLN
JSDIA0256ZZ F
1. Adapter case 2. Ring gear shaft bearing 3. Ring gear shaft bearing
(Adapter case side) (Transfer case side)
G
4. Ring gear shaft 5. Ring gear 6. Transfer case
Ring Gear Adjusting Shim (Adapter Case Side)

1. Measure the dimensions of each measuring point with the following procedure: H
Dimension “A” measurement

• Measure dimension from transfer case mounting surface of
adapter case to adapter case edge surface with a pair of ver- I
nier calipers and straightedge. Refer to “Measuring point”.
SDIA3105J
L
Dimension “B” measurement

• Measure dimension from ring gear adjusting shim mounting
surface of adapter case to adapter case edge surface with a M
pair of vernier calipers and straightedge. Refer to “Measuring
point”.
N
JSDIA0324ZZ
P
Dimension “C” measurement
DLN-171
DRIVE PINION
• 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:
• Never damage transfer case.
• Consider the thickness of a straightedge.
SDIA3108J
Dimension “E” measurement

• Measure dimension from outer race edge surface of ring gear
shaft bearing (adapter case side) to inner race edge surface
with a pair of vernier calipers. Refer to “Measuring point”.
SDIA3109J
2. Calculate dimensions “M” and “N” by the formula below.
Dimension “M” = “A” – “B”

Dimension “N” = “C” × 0.5 mm (0.020 in) + “D”
3. Convert the dimensions “E”, “M” and “N” according to the standards below.
“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).
“N” : Actual value regarding 55.00 mm (2.1654 in) as 0 in increments of 0.01 mm (0.0004 in).
DLN-172
DRIVE PINION
4. Check dimension “Z” (machining difference) on the ring gear
back surface. A
NOTE:
Dimension “Z” indicates difference between optimum engage-
ment and the standard dimensions in increments of 0.01 mm
B
(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.
C
“T1” = (“M” + “N” – “E” – “Z”) × 0.01 mm (0.0004 in)
+ 1.40 mm (0.0551 in) SDIA3129J
DLN
6. Select ring gear adjusting shim (adapter case side).
CAUTION:
• Only one adjusting shim can be selected.
• Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with E
the calculated value is available.
Ring Gear Adjusting Shim (Transfer Case Side)
F
1. Measure the dimensions of each measuring point with the following procedure:
Dimension “C” measurement
• Measure the diameter of drive pinion bearing (rear side) G
mounting area of transfer case with a pair of vernier calipers.
Refer to “Measuring point”.
CAUTION:
H
SDIA3107J J
Dimension “D” measurement

• Measure dimension from adapter case mounting surface of K
transfer case to drive pinion bearing (rear side) mounting sur-
face with a pair of vernier calipers and straightedge. Refer to
“Measuring point”.
L
CAUTION:
• Never damage transfer case.
• Consider the thickness of a straightedge.
M
SDIA3108J N
Dimension “F” measurement

• Measure dimension from adapter case mounting surface of O
transfer case to ring gear adjusting shim mounting surface
with a depth gauge. Refer to “Measuring point”.
CAUTION:
Never damage transfer case. P
SDIA3110J
DLN-173
DRIVE PINION
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

• Measure dimension from ring gear mounting surface of ring
gear shaft to ring gear shaft bearing (transfer case side)
mounting surface with a pair of vernier calipers. Refer to “Mea-
suring point”.
JSDIA0257ZZ
Dimension “J” measurement

• Measure dimension from outer race edge surface of ring gear
shaft bearing (transfer case side) to inner race edge surface
with a pair of vernier calipers. Refer to “Measuring point”.
SDIA3128J
2. Calculate dimension “N” by the formula below.
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.
DLN-174
DRIVE PINION
“F” : Actual value regarding 122.60 mm (4.83 in) as 0 in increments of 0.01 mm (0.0004 in). A
“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).
B
“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).
“N” : Actual value regarding 55.00 mm (2.1654 in) as 0 in increments of 0.01 mm (0.0004 in). C
4. Check dimension “Z” (machining difference) on the ring gear
back surface.
NOTE: DLN
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. E
5. Calculate the thickness of the ring gear adjusting shim (transfer
case side) “T2” by the formula below.
F
“T2” = (“F” – “G” + “H” – “I” – “J” – “N” + “Z”) × 0.01 mm
(0.0004 in) + 1.65 mm (0.0650 in) SDIA3129J
6. Select ring gear adjusting shim (transfer case side). G

CAUTION:
• Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with
H
the calculated value is available.
Drive Pinion Adjusting Shim
1. Check the dimension “U” (machining difference) between old I
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 J
drive pinion adjusting shims when reusing the hypoid gear set.)
NOTE:
Dimension “U” indicates the difference between optimum K
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 L
2. Calculate the thickness of the drive pinion adjusting shim “T” by
the formula below.
M
“T” = T0 + [(t1 – t2) × 0.01 mm (0.0004 in)]
“T” : Thickness of new shim
T0 : Thickness of old shim N
t1 : Dimension “U” displayed on the gear end of
old drive pinion
t2 : Dimension “U” displayed on the gear end of O
new drive pinion
[Example] P
“T” = 3.21 + [(2 + 1) × 0.01 mm (0.0004 in)]
T0 : 3.21
t1 : +2
t2 : −1
3. Select drive pinion adjusting shim.
DLN-175
DRIVE PINION
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-176
TRANSFER CASE
TRANSFER CASE
A
DLN
L
JSDIA0319GB
1. Adapter case oil seal (outer) 2. O-ring (outer) 3. Adapter case oil seal (inner) M
N
O
P
A: Oil seal lip
: Apply gear oil.

DLN-177
TRANSFER CASE


3. Remove drive pinion assembly. Refer to DLN-165, "Disassembly".
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.

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-166, "Assembly".
4. Install ring gear shaft assembly. Refer to DLN-162, "Assembly".
SDIA3092J
DLN-178
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:
• Never damage air breather hose.
E
• Face the paint area (A) in the direction shown in the fig-
ure.
G
JSDIA0325ZZ
H
ment".
CAUTION:
Measure the total preload without the adapter case oil seals.
9. Assemble the plug to the transfer case. I
CAUTION:
• Remove old gasket on mounting surface, then remove any moisture, oil, and foreign material on
the application and mounting surfaces. J
• Apply liquid gasket to the threads of plug.
10. Install gaskets onto filler plug and drain plug and install them into transfer case.
CAUTION: K
• Never reuse gaskets.
• Install filler plug after oil is filled.
Inspection INFOID:0000000010288376 L

CASE M
DLN-179
< SERVICE DATA AND SPECIFICATIONS (SDS) [TRANSFER: TY30A]

4WD
Applied model R9M
M/T
TY30A
Transfer model
0.36 (5/8)
Oil capacity (Approx.) (lmp pt)
0.656
Gear ratio
Drive pinion 32
Number of teeth
Drive gear 21

Standard
Item
M/T
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 seal P1 + 0.55 – 0.75 (0.06 – 0.07, 5 – 6)
Backlash INFOID:0000000010288383
Unit: mm (in)
Item Standard
Ring gear to drive pinion 0.13 – 0.19 (0.0051 – 0.0075)
Companion Flange Runout INFOID:0000000010288384
Unit: mm (in)
Item Limit
Companion flange face (inner side of the propeller shaft bolt holes) 0.1 (0.004)
Inside of companion flange (socket diameter) 0.1 (0.004)
DLN-180
PRECAUTIONS
< PRECAUTION > [REAR PROPELLER SHAFT: C-CVJ-C]
PRECAUTION A
PRECAUTIONS
B
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. C
power before disconnecting the 12V battery terminal, observing
“How to disconnect 12V battery terminal” described below. DLN
NOTE:
switch is turned OFF and ignition power supply is stopped. If the
battery terminal is disconnected before ECU stops, accidental DTC E
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch. F
NOTE:
SEF289H
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. G
NOTE:
The removal of 12V battery may cause a DTC detection error.
H
For vehicles parked by ignition switch OFF, refer to Instruction 2.
I
INSTRUCTION 1
1. Open the hood.
2. Turn key switch to the OFF position with the driver side door opened. J
CAUTION: K
5. Remove 12V battery terminal. L
CAUTION:
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF) M
NOTE:
At this moment, ACC power is supplied. N
3. Open the hood.
4. Close the driver side door. O
CAUTION:
While waiting, never operate the vehicle such as locking, opening, and closing doors. Violation of P
CAUTION:
Service Notice or Precautions for Propeller Shaft INFOID:0000000010763742
• Replace the propeller shaft assembly if there is a breakage or deflection on tube.

DLN-181
PRECAUTIONS
< PRECAUTION > [REAR PROPELLER SHAFT: C-CVJ-C]
• 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-182
< SYSTEM DESCRIPTION > [REAR PROPELLER SHAFT: C-CVJ-C]
Sectional View INFOID:0000000010763743
B
PART OF JOINT
Universal Type (Shell Type) C
DLN
JSDIA4709ZZ
F
CVJ Type
G
JSDIA5322ZZ
J
DLN-183
Symptom
Reference
×: Applicable
< SYMPTOM DIAGNOSIS >
Noise
Shake
Vibration
Possible cause and SUSPECTED PARTS
NVH Troubleshooting Chart
SYMPTOM DIAGNOSIS
Uneven rotating torque DLN-185, "Inspection"
×
×
Center bearing improper installation DLN-186, "Exploded View"
×
×
×
Excessive center bearing axial end play DLN-185, "Inspection"
×
×
Center bearing mounting (insulator) cracks, damage or deterioration DLN-189, "Inspection"
×
×
DLN-184
Excessive joint angle DLN-185, "Inspection"
×
×
×
Rotation imbalance DLN-185, "Inspection"
×
×
Excessive runout DLN-185, "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:0000000010763744
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
186, "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-189, "Inspec-
tion". O
DLN-185
< 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-11,
"Removal and Installation" (MR20DD), EX-22, "Removal and
Installation" (R9M).
CAUTION:
Remove only near the center bearing mounting bracket of
propeller shaft.
JSDIA5464ZZ
DLN-186
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-187
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-189, "Inspec-
tion".
JSDIA4492ZZ
INSTALLATION
• For non-reusable parts, refer to DLN-186, "Exploded View".
• For each tightening torque, refer to DLN-186, "Exploded View".
• After removing propeller shaft, replace stud bolts on electric controlled coupling. Refer to DLN-76, "Exploded
View".
• 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-188
• 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-189, "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-191, "Propeller

P
Shaft Runout".
JSDIA0193ZZ
DLN-189
• 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)
R9M models
A : 541.5 mm (21.32 in) JPDID0001ZZ
B : 488.7 mm (19.24 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-191, "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.
INSPECTION AFTER INSTALLATION
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-190
< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR PROPELLER SHAFT: C-CVJ-C]

B
MR20DD and R9M MODELS

C
Axle 4WD
Applied model
Transaxle CVT and MT
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) 1182 mm (46.54 in)
Shaft length G
2nd (CVJ joint center to spider) 983 mm (38.70 in)
1st shaft 63.5 mm (2.500 in)
Shaft outer diameter
2nd shaft 70.0 mm (2.756 in) H
Propeller Shaft Runout INFOID:0000000010763750
Unit: mm (in) I
Item Standard
Propeller shaft runout 0.6 (0.024) or less
J
Journal Axial Play INFOID:0000000010763751
Unit: mm (in) K
Item Standard
Journal axial play 0 (0)
L
DLN-191
Symptom
Reference
×: Applicable
< SYMPTOM DIAGNOSIS >
Noise
Possible cause and SUSPECTED PARTS
NVH Troubleshooting Chart
SYMPTOM DIAGNOSIS
Gear tooth rough DLN-227, "Inspection After Disassembly"
×
Gear contact improper DLN-224, "Adjustment"
DLN-192
Tooth surfaces worn DLN-227, "Inspection After Disassembly"
×
Backlash incorrect DLN-224, "Adjustment"
×
Companion flange excessive runout DLN-224, "Adjustment"
×
Gear oil improper DLN-199, "Inspection"
×
PROPELLER SHAFT NVH in DLN section
×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections
×
TIRE NVH in WT section
×
ROAD WHEEL NVH in WT section
×
DRIVE SHAFT NVH in FAX and RAX section

×
BRAKE NVH in BR section

×
Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts.
STEERING NVH in ST section

×
[REAR FINAL DRIVE: R145]
INFOID:0000000010288393
PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: R145]
PRECAUTION A
PRECAUTIONS
Service Notice or Precautions for Rear Final Drive INFOID:0000000010288394
B
CAUTION:
• 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. C
• 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 exte-
rior of the unit, preventing them from entering into the unit during disassembly or assembly. DLN
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace
them with a new one if necessary.
• Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to out- E
side. If tightening sequence is specified, observe it.
• Be careful not to damage sliding surfaces and mating surfaces. F
• When applying sealant, remove the old sealant from the mounting surface; then remove any mois-
ture, oil, and foreign materials from the application and mounting surfaces.
• Always use shop paper for cleaning the inside of components.
• Avoid using cotton gloves or shop rags to prevent entering of lint. G
• 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.
H
or remote keyless entry or by opening/closing the driver side door. In addition, ACC power is supplied even I
after the ignition switch is turned to the OFF position, i.e. ACC power is supplied for a certain fixed time.
power before disconnecting the 12V battery terminal, observing J
“How to disconnect 12V battery terminal” described below.
NOTE:
switch is turned OFF and ignition power supply is stopped. If the K
battery terminal is disconnected before ECU stops, accidental DTC
• For vehicles with the 2-batteries, be sure to connect the main bat- L
tery and the sub battery before turning ON the ignition switch.
NOTE:
SEF289H
main battery and sub battery disconnected, then DTC may be detected. M
• 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. N
For vehicles parked by ignition switch OFF, refer to Instruction 2. O
INSTRUCTION 1
1. Open the hood.
P
2. Turn key switch to the OFF position with the driver side door opened.
4. Wait at least 3 minutes. For vehicle with the engine listed below, remove the battery terminal after a lapse
of the specified time.
D4D engine : 20 minutes

HRA2DDT : 12 minutes
DLN-193
PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: R145]
K9K engine : 4 minutes
M9R engine : 4 minutes
R9M engine : 4 minutes
V9X engine : 4 minutes
CAUTION:
CAUTION:
INSTRUCTION 2 (FOR VEHICLES PARKED BY IGNITION SWITCH OFF)
NOTE:
At this moment, ACC power is supplied.
3. Open the hood.
4. Close the driver side door.
CAUTION:
CAUTION:
DLN-194
PREPARATION
< PREPARATION > [REAR FINAL DRIVE: R145]
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000010288395
B
Tool number
Description C
Tool name
KV38100200 • Installing front oil seal
Drift • Installing side oil seal
a: 65 mm (2.56 in) dia. DLN
b: 49 mm (1.93 in) dia.
E
ZZA1143D
ST27861000 Installing front oil seal

Drift F
a: 62 mm (2.44 in) dia.
b: 52 mm (2.05 in) dia.
G
ZZA0832D
H
ST35271000 Installing center oil seal
Drift
a: 72 mm (2.83 in) dia.
b: 63 mm (2.48 in) dia. I
J
ZZA0814D
ST33052000 Removing side bearing inner race

Drift
K
a: 22 mm (0.87 in) dia.
b: 28 mm (1.10 in) dia.
ZZA1023D
KV38108400 Removing and installing drive pinion nut M

Pinion nut wrench
ZZA1206D O
KV38109500 • Removing and installing drive pinion nut
Drive pinion socket • Measuring preload torque
P
ZZA1205D
DLN-195
PREPARATION
Tool number
Description
Tool name
ST33230000 Installing pinion front bearing outer race
Drift
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.
ZZA1046D
ST23860000 • Installing pinion rear bearing inner race

Drift • Installing pinion front bearing inner race
a: 38 mm (1.50 in) dia.
b: 33 mm (1.30 in) dia.
ZZA0534D

Preload gauge
ZZA0503D
KV389L0010 • Checking backlash

Dummy cover set • Checking drive gear runout
• Checking tooth contact
PDIA0894E
Commercial Service Tools INFOID:0000000010288396

Flange wrench Removing and installing companion flange
lock nut
NT771
Drift Removing and installing gear carrier and rear

a: 54.5 mm (2.146 in) dia. cover (2 pieces are used)
PDIA0893E
DLN-196
PREPARATION
Pin punch Removing and installing lock pin
a: 4.5 mm (0.177 in) dia. A
NT410
C
Drift Installing side bearing inner race
a: 39.7 mm (1.563 in) dia.
b: 35 mm (1.38 in) dia.
DLN
E
ZZA0936D
Stand Installing pinion front bearing inner race

a: Approx. 60 mm (2.36 in)
b: Approx. 90 mm (3.54 in) dia F
JPDID0011ZZ
DLN-197
REAR FINAL DRIVE ASSEMBLY
< SYSTEM DESCRIPTION > [REAR FINAL DRIVE: R145]
SYSTEM DESCRIPTION
System Diagram INFOID:0000000010288397
JSDIA0281ZZ
1. Companion flange 2. Electric controlled coupling 3. 4WD solenoid

4. Center oil seal 5. Pinion front bearing 6. Collapsible spacer
7. Pinion rear bearing 8. Drive pinion 9. Side gear
10. Pinion mate gear 11. Drive gear 12. Pinion mate shaft
13. Side bearing 14. Differential case
D L N - 1 9 8
REAR DIFFERENTIAL GEAR OIL
< PERIODIC MAINTENANCE > [REAR FINAL DRIVE: R145]
PERIODIC MAINTENANCE A
REAR DIFFERENTIAL GEAR OIL
B
OIL LEAKEGE
Make sure that oil is not leaking from final drive assembly or around it. C
OIL LEVEL
• Remove filler plug (1) and check oil level from filler plug mounting
hole as shown in the figure. DLN
CAUTION:
Never start engine while checking oil level.
• Set a new gasket on filler plug and install it on final drive assembly.
E
Refer to DLN-209, "Exploded View".
CAUTION:
Never reuse gasket.
F
JSDIA0198ZZ
G
1. Stop engine.
H
2. Remove drain plug (1) and drain gear oil.
3. Set a new gasket on drain plug and install it to final drive assem-
bly and tighten to the specified torque. Refer to DLN-209,
I
"Exploded View".
CAUTION:
Never reuse gasket.
J
K
JSDIA0197ZZ
L
1. Remove filler plug (1). Fill with new gear oil until oil level reaches
the specified level near filler plug mounting hole.
M
and Lubricants".
Oil capacity : Refer to DLN-229, "Gen- N
eral Specification".
2. After refilling oil, check oil level. Set a new gasket to filler plug,
then install it to final drive assembly. Refer to DLN-209, O
"Exploded View". JSDIA0198ZZ
CAUTION:
Never reuse gasket. P
DLN-199
FRONT OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: R145]

FRONT OIL SEAL
R9M and MR20DD
JPDID0004GB
1. Final drive assembly 2. Front oil seal 3. Companion flange

4. Companion flange lock nut
A: Oil seal lip
: Vehicle front
: Apply gear oil.

REMOVAL
1. Remove rear propeller shaft. Refer to DLN-186, "Exploded View".
2. Put matching mark on the thread edge of electric controlled cou-
pling. The matching mark should be in line with the matching
mark on companion flange.
CAUTION:
For matching mark, use paint. Never damage electric con-
trolled coupling.
PDIA0455E
DLN-200
FRONT OIL SEAL
3. Remove companion flange lock nut, using a flange wrench
(commercial service tool). Then remove companion flange. A
JSDIA0199ZZ
DLN
4. Remove front oil seal from coupling cover, using a flat-bladed
screwdriver.
CAUTION:
E
Be careful not to damage coupling cover.
G
JSDIA0200ZZ
INSTALLATION
H
1. Install front oil seal until it becomes flush with the coupling cover
end, using the drifts.
A : Drift (SST: KV38100200) I

CAUTION:
• Never reuse oil seal. J
onto the circumference of oil seal. K
PDIA0038E
2. Align the matching mark of electric controlled coupling with the

matching mark of companion flange, then install the companion L
flange.
3. Install companion flange lock nut with a flange wrench (commer-
cial service tool), tighten to the specified torque. M
CAUTION:
Never reuse companion flange lock nut.
4. Install rear propeller shaft. Refer to DLN-186, "Exploded View". N
5. When oil leaks while removing, check oil level after the installa-
tion. Refer to DLN-199, "Inspection".
PDIA0455E
O
DLN-201
SIDE OIL SEAL
SIDE OIL SEAL
JSDIA0232ZZ
1. Final drive assembly 2. Side oil seal

A: Oil seal lip
: Vehicle front
: Apply gear oil.

REMOVAL
1. Remove rear drive shafts. Refer to RAX-14, "Exploded View" .
2. Remove side oil seals, using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage gear carrier and rear cover.
PDIA0431E
INSTALLATION
1. Install side oil seals until it becomes flush with the carrier end,
using the drift (A) (SST: KV38100200).
CAUTION:
• Never reuse oil seals.
• When installing, never incline oil seals.
onto the circumference of oil seal.
2. Install rear drive shafts. Refer to RAX-14, "Exploded View".
3. When oil leaks while removing, check oil level after the installa-
tion. Refer to DLN-199, "Inspection".
JSDIA0201ZZ
DLN-202
A
MR20DD and R9M B
DLN
JPDID0005GB G
1. Final drive assembly 2. Center oil seal 3. 4WD solenoid harness

4. Electric controlled coupling 5. Coupling cover 6. Reamer bolt
H
7. Connector bracket 8. Front oil seal 9. Companion flange
A: Oil seal lip
I
: Vehicle front
: Apply gear oil. J

K
REMOVAL L
1. Remove rear propeller shaft. Refer to DLN-186, "Exploded View".
M
3. Remove connector bracket.
mark on the companion flange. N
CAUTION:
trolled coupling. O
NOTE:
When replacing electric controlled coupling, matching mark is
not necessary.
P
PDIA0455E
DLN-203
(commercial service tool).
7. Remove electric controlled coupling breather hose from cou-
pling cover.
JSDIA0199ZZ
8. Remove coupling cover with electric controlled coupling from

final drive assembly.
9. Remove electric controlled coupling from coupling cover.
10. Remove 4WD solenoid harness.
PDIA0458E
11. Remove front oil seal from coupling cover, using a flat-bladed
screwdriver.
CAUTION:
12. Remove center oil seal from final drive assembly.
PDG0213D
INSTALLATION
1. Using the drift (A) (SST: ST35271000), install center oil seal (1)
as shown in the figure.
Dimension “D” : 0.8 – 1.2 mm (0.031 – 0.047 in)

CAUTION:
2. Connect 4WD solenoid harness to electric controlled coupling.
JSDIA0260ZZ
DLN-204
3. Install electric controlled coupling to spline of drive pinion inside
gear carrier. A
CAUTION:
• Align the pin on electric controlled coupling with the
groove of gear carrier.
B
• Be careful not to damage center oil seal.
4. Set 4WD solenoid harness guide to gear carrier.
C
PDIA0463E
DLN
5. Using the drifts, drive front oil seal until it becomes flush with the
coupling cover end.
E
A : Drift (SST: KV38100200)
CAUTION: F
onto the circumference of oil seal. G
PDIA0449E
6. Apply liquid gasket to mating surface of coupling cover. Overlap H

both ends of the bead for at least 3 mm (0.12 in).
CAUTION:
Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adhering I
to the mounting surfaces.
PDIA0613E
K
7. Install coupling cover to final drive assembly with arrow facing
upward, temporarily tighten reamer bolts to the positions shown
in the figure. L
8. Tighten reamer bolts and coupling cover mounting bolts to the
specified torque.
9. Install electric controlled coupling breather hose to coupling M
cover.
10. Install connector bracket, and tighten bolts to the specified
torque. N
11. Connect 4WD solenoid harness connector. SDIA0587E
12. Install companion flange. O

NOTE:
When reusing electric controlled coupling, align the matching
mark of electric controlled coupling with the matching mark of P
companion flange, then install companion flange.
13. Install companion flange lock nut with flange wrench (commer-
cial service tool), tighten to the specified torque.
CAUTION:
14. Check companion flange runout. Refer to DLN-212, "Adjust-
ment". PDIA0455E
DLN-205
15. Install rear propeller shaft. Refer to DLN-186, "Exploded View".
16. When oil leaks while removing, check oil level after the installation. Refer to DLN-199, "Inspection".
DLN-206
< UNIT REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: R145]
UNIT REMOVAL AND INSTALLATION A

B
DLN
JPDID0013GB
H
1. Final drive mounting bracket 2. Washer 3. Final drive assembly
: Vehicle front I
Refer to GI-4, "Components" for symbols in the figure.

J
REMOVAL
1. Remove rear propeller shaft. Refer to DLN-186, "Exploded View". K
2. Remove rear drive shafts. Refer to RAX-14, "Exploded View".
4. Remove rear final drive breather hose and electric controlled coupling breather hose. L
5. Support final drive assembly with a suitable jack.
6. Remove final drive mounting nuts and final drive mounting bolts.
If necessary, remove final drive mounting bracket. M
CAUTION:
Secure final drive assembly to a suitable jack while removing it.
INSTALLATION N
• When installing each breather hoses, refer to the figure and following.
CAUTION: O
Make sure there are no pinched or restricted areas on the breather hose caused by bending or wind-
ing when installing it.
P
DLN-207
< UNIT REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: R145]
- Install rear final drive breather hose (1) to breather connector (2).
Install bracket (3) to the breather connector. Check that the paint
mark (A) of metal connector (4) faces forward of the vehicle as
shown by the arrow.
: Vehicle front
JSDIA0222ZZ
- Install electric controlled coupling breather hose (1) to metal tube

all way to the point shown by the solid arrow ( ). Check that the
coupling cover (2) of metal tube (3) faces forward of the vehicle as
shown by the outline arrow.
: Vehicle front
• When oil leaks while removing final drive assembly, check oil level
after the installation. Refer to DLN-199, "Inspection".
JPDID0014ZZ
DLN-208
< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: R145]
UNIT DISASSEMBLY AND ASSEMBLY A

B
R9M
C
DLN
K
JPDID0006GB
1. Filler plug 2. Gasket 3. Drain plug L

4. Rear cover 5. Side oil seal 6. Side bearing adjusting shim
7. Side bearing 8. Drive gear 9. Differential case
10. Pinion mate thrust washer 11. Pinion mate gear 12. Pinion mate shaft M
13. Lock pin 14. Side gear thrust washer 15. Side gear
16. Drive pinion 17. Pinion rear bearing 18. Drive pinion adjusting shim
19. Collapsible spacer 20. Gear carrier 21. Pinion front bearing N
22. Drive pinion nut 23. Center oil seal 24. 4WD solenoid harness
28. Connector bracket 29. Front oil seal 30. Companion flange O
A: Oil seal lip
B: Screw hole P
: Apply gear oil.
DLN-209
: Apply Genuine Medium Strength Thread Locking Sealant, Three Bond 1322B or equivalent.
1. Remove connector bracket.

mark on companion flange.
CAUTION:
trolled coupling.
NOTE:
When replacing electric controlled coupling, matching mark is
not necessary.
PDIA0455E

5. Remove coupling cover.
PDIA0442E
6. Remove front oil seal from coupling cover, using flat-bladed

screwdriver.
CAUTION:
7. Remove electric controlled coupling.
8. Remove 4WD solenoid harness.
9. Remove center oil seal from gear carrier.
PDG0213D
1. Using the drift (A) (SST: ST35271000), install center oil seal (1)
as shown in the figure.
Dimension “D” : 0.8 – 1.2 mm (0.031 – 0.047 in)

CAUTION:
2. Connect 4WD solenoid harness to electric controlled coupling.
JSDIA0260ZZ
DLN-210
3. Install electric controlled coupling to spline of drive pinion inside
gear carrier. A
CAUTION:
• Align the pin on electric controlled coupling with the
groove of gear carrier.
B
• Be careful not to damage center oil seal.
4. Set 4WD solenoid harness guide to gear carrier.
C
PDIA0463E
DLN
5. Using the drifts, drive front oil seal until it becomes flush with the
coupling cover end.
E
A : Drift (SST: KV38100200)
CAUTION: F
onto the circumference of oil seal. G
PDIA0449E
6. Apply liquid gasket to mating surface of coupling cover. Overlap H

both ends of the bead for at least 3 mm (0.12 in).
CAUTION:
Also remove any moisture, oil, or foreign material adhering I
PDIA0613E
K
7. Install coupling cover to gear carrier with arrow facing upward,
temporarily tighten reamer bolts to the positions shown in the
figure. L
8. Tighten reamer bolts and coupling cover mounting bolts to the
specified torque.
9. Install connector bracket, and tighten bolts to the specified M
torque.
N
SDIA0587E
10. Install companion flange. O

NOTE:
When reusing electric controlled coupling, align the matching
mark of electric controlled coupling with the matching mark of P
companion flange, then install companion flange.
11. Install companion flange lock nut with flange wrench (commer-
cial service tool), tighten to the specified torque.
CAUTION:
12. Check companion flange runout. Refer to DLN-212, "Adjust-
ment". PDIA0455E
DLN-211

the rear propeller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.
Limit
3. Fit a test indicator to the inner side of companion flange (socket
diameter).
PDIA0439E
4. Rotate companion flange to check for runout.
Limit
5. If the runout value is outside the runout limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90° step, and
search for the position where the runout is the minimum.
b. If the runout value is still outside of the limit after the phase has been changed, replace companion flange.
c. If the runout value is still outside of the limit after companion flange has been replaced, possible cause will
be an assembly malfunction of drive pinion and electric controlled coupling, malfunctioning coupling bear-
ing, or malfunctioning of electric controlled coupling.
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.
Content Conditions and Measures

• If the gear teeth do not mesh or line-up correctly, determine the cause and adjust or replace as nec-
essary.
Hypoid gear
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new
drive gear and drive pinion as a set.
If any chipped (by friction), pitted, worn, rusted or scratched mark, or unusual noise from the bearing is
Bearing
observed, replace as a bearing assembly (as a new set).
Side gear and Pinion mate • If any cracks or damage on the surface of the tooth is found, replace.
gear • If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
Side gear thrust washer and
If it is chipped (by friction), damaged, or unusually worn, replace.
pinion mate thrust washer
Differential case If any wear or crack on the contact sides of the differential case is found, replace.
If any chipped mark (about 0.1 mm, 0.004 in) or other damage on the contact sides of the lips of the com-
Companion flange
panion flange is found, replace.
DLN-212
DIFFERENTIAL ASSEMBLY
A
R9M B
DLN
JPDID0006GB
K
1. Filler plug 2. Gasket 3. Drain plug
L
10. Pinion mate thrust washer 11. Pinion mate gear 12. Pinion mate shaft
M
19. Collapsible spacer 20. Gear carrier 21. Pinion front bearing
N
O
A: Oil seal lip
B: Screw hole
P
: Apply gear oil.
DLN-213
1. Remove side oil seals, using flat-bladed screwdriver.

CAUTION:
Be careful not to damage gear carrier and rear cover.
2. Remove rear cover mounting bolts.
PDG0216D
3. Set drifts (commercial service tool) to the right and left side bear-
ing adjusting shims individually. Press differential case assembly
with side bearing to remove gear carrier assembly and rear
cover assembly.
CAUTION:
The pressure shall be as low as possible to remove gear
carrier assembly and rear cover assembly. The maximum
pressure shall be 10 kN (1 ton, 1.0 Imp ton).
NOTE:
Differential case assembly, side bearings, and adjusting shims
are compressed and integrated in gear carrier and rear cover.
PDIA0065E
4. Remove drain plug and filler plug.
5. Remove side bearing adjusting shims and side bearing outer races.
CAUTION:
Mark the side bearing adjusting shims so that the original mounting positions (right/left) can be
identified later.
6. Remove drive gear mounting bolts and then remove drive gear
from differential case.
PDIA0446E
7. Remove side bearing inner races, using pullers and the drift
(SST: ST33052000).
PDIA0459E
DLN-214
8. Pull the lock pin out of pinion mate shaft, using the pin punch
(commercial service tool). A
PDIA0062E
DLN
9. Remove pinion mate shaft, pinion mate gears, pinion mate
thrust washers, side gears, side gear thrust washers from differ-
ential case.
E
G
SDIA0032J
H
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly or reinstall the old ones on
the side gears. I
2. Install side gears and side gear thrust washers into differential
case.
J
K
SDIA0193J
3. Align 2 pinion mate gears in diagonally opposite positions, then L

rotate and install them into differential case after installing pinion
mate thrust washer to pinion mate gear.
M
SDIA0036J O
DLN-215
4. Align the lock pin holes on differential case with shaft, and install
pinion mate shaft.
SDIA0037J
5. Measure side gear end play following the procedure below, and select the appropriate side gear thrust
washers.
a. Place differential case straight up so that side gear to be mea-
sured comes upward.
PDIA0460E
b. Using thickness gauges, measure the clearance between side

gear back and differential case at 3 different positions, while
rotating side gear. Average the 3 readings, and then measure
the clearance. (Measure the clearance of the other side as well.)
Standard
Side gear back clearance : Refer to DLN-229, "Differ-
ential Side Gear Clear-
ance".
CAUTION:
To prevent side gear from tilting, insert thickness gauges
with the same thickness from both sides.
c. If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust.
When the back clearance is large:

Use a thicker thrust washer.
When the back clearance is small:
Use a thinner thrust washer.
CAUTION: SDIA0583E
Select a side gear thrust washer for right and left individu-
ally.
DLN-216
6. Drive a lock pin into pinion mate shaft, using the pin punch
(commercial service tool). A
CAUTION:
Never reuse lock pin.
B
PDIA0062E
DLN
7. Press side bearing inner races to differential case, using the drift
CAUTION:
E
Never reuse side bearing inner races.
G
PDIA0052E
8. Apply locking sealant into the thread hole of drive gear.

H
CAUTION:
The drive gear back and threaded holes shall be cleaned
and decreased sufficiently.
I
SPD554
K
9. Install drive gear to the differential case, and then tighten to the
specified torque.
10. Apply gear oil to side bearings, and install new side bearing L
adjusting shims (2 pieces for one side) with the same thickness
as the ones installed prior to disassembly or re-install the old
ones, with side bearing outer race to differential case. M
If side bearing adjusting shims have been already selected, use
them.
CAUTION:
N
Never reuse side bearing outer race.
PDIA0466E
11. Set the drifts (commercial service tool) to the right and left side O
bearing adjusting shims individually. Compress differential case
assembly and side bearing to install gear carrier assembly to dif-
ferential case assembly. P
CAUTION:
• The drift shall be placed on the center of the adjusting
shims.
• The pressure shall be as low as possible to install differ-
ential assembly into gear carrier assembly. The maximum
• If the adjusting shims are installed by tapping, the gear
PDIA0064E
carrier may be damaged. Avoid tapping.
DLN-217
12. Install dummy cover set, check and adjust drive gear runout, tooth contact, backlash, and total preload
torque. Refer to DLN-224, "Adjustment".
13. Remove dummy cover set.
14. Apply liquid gasket to mating surface of rear cover. Overlap both
ends of the bead for at least 3 mm (0.12 in).
CAUTION:
Also remove any moisture, oil, or foreign material adhering
PDIA0447E
15. Set the drifts (commercial service tool) to the right and left side
bearing adjusting shims individually. Compress differential case
assembly and side bearing to install rear cover.
CAUTION:
• The drift shall be placed on the center of the adjusting
shims.
• The pressure shall be as low as possible to install the rear
cover. The maximum pressure shall be 10 kN (1 ton, 1.0
Imp ton).
• If rear cover is forced in by tapping, rear cover may be
damaged by adjusting shims. Avoid tapping.
PDIA0065E
16. Tighten rear cover mounting bolts to the specified torque.
17. Using the drift (SST: KV38100200), drive side oil seals until it
becomes flush with the carrier end.
CAUTION:
• Never reuse oil seals.
• When installing, do not incline oil seals.
18. Check total preload torque. Refer to DLN-224, "Adjustment".
PDIA0448E
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures
below.

essary.
Hypoid gear
drive gear and drive pinion as a set.
Bearing
Companion flange
DLN-218
DRIVE PINION
DRIVE PINION
A
R9M B
DLN
JPDID0006GB
K
1. Filler plug 2. Gasket 3. Drain plug
L
10. Pinion mate thrust washer 11. Pinion mate gear 12. Pinion mate shaft
M
19. Collapsible spacer 20. Gear carrier 21. Pinion front bearing
N
O
A: Oil seal lip
B: Screw hole
P
: Apply gear oil.
DLN-219
DRIVE PINION
1. Remove electric controlled coupling assembly. Refer to DLN-210, "Disassembly".

2. Remove differential case assembly. Refer to DLN-214, "Disassembly".
3. Fit drive pinion socket (A) (SST: KV38109500) onto drive pinion
spline. Remove drive pinion nut, using the pinion nut wrench (B)
(SST: KV38108400).
JSDIA0265ZZ
4. Press drive pinion assembly out of gear carrier.

CAUTION:
Never drop drive pinion assembly.
5. Remove pinion front bearing inner race.
6. Remove collapsible spacer.
PDIA0445E
7. Remove pinion rear bearing inner race from drive pinion, using
puller and bearing puller.
PDIA0179E
8. Using a brass rod, tap pinion front bearing outer race evenly
from the 2 cutouts on gear carrier and remove pinion front bear-
ing outer race.
CAUTION:
Be careful not to damage gear carrier.
9. Using a brass rod, tap drive pinion adjusting shim evenly from
the 2 cutouts on gear carrier and remove drive pinion adjusting
shim and pinion rear bearing outer race.
CAUTION:
Be careful not to damage the gear carrier.
SDIA0564E
DLN-220
DRIVE PINION
A
1. Install a drive pinion adjusting shim of the same thickness as
was installed prior to disassembly. Press pinion rear bearing
outer race into gear carrier, using the suitable drift. B
CAUTION:
• At first, using a hammer, tap bearing outer race until it
becomes flush to gear carrier.
• Never reuse pinion rear bearing outer race. C
DLN
PDIA0898E
2. Press pinion front bearing outer race into gear carrier, using the E
drift (SST: 33230000).
CAUTION:
• At first, using a hammer, tap bearing outer race until it
becomes flush to gear carrier. F
• Never reuse pinion front bearing outer race.
PDIA0067E H
3. Press pinion rear bearing inner race to drive pinion, using the
drift (SST: ST23860000).
CAUTION: I
Never reuse pinion rear bearing inner race.
PDIA0068E
L
4. After checking and adjusting the tooth contact and backlash of the hypoid gear following the procedure
below.
a. Apply gear oil to the pinion rear bearing, and assemble the drive pinion to the gear carrier.
CAUTION: M
Never assemble a collapsible spacer.
b. Apply gear oil to pinion front bearing, and assemble pinion front
bearing inner race to drive pinion. Using the drifts and stand, N
press pinion front bearing inner race to drive pinion as far as
drive pinion nut can be tightened.
O
B : Drift (commercial service tool)
CAUTION: P
Never reuse pinion front bearing inner race.
c. Temporarily tighten removed drive pinion nut to drive pinion.
JPDID0012ZZ
NOTE:
Use removed drive pinion nut only for the preload measurement.
DLN-221
DRIVE PINION
d. Fit the drive pinion socket (A) (SST: KV38109500) onto the drive
pinion spline. Using the pinion nut wrench (B) (SST:
KV38108400), tighten drive pinion nut to the specified preload
torque.
C : Preload gauge (SST: ST3127S000)
Standard
Pinion bearing preload : Refer to DLN-229,
"Preload Torque".
CAUTION:
Drive pinion nut is tightened with no collapsible spacer. Be
careful not to over tighten it. While measuring the preload,
tighten it by 5° to 10°.
JSDIA0266ZZ
e. Apply gear oil to side bearings, and install new side bearing
adjusting shims with the same thickness or re-install the old
ones to the same mounting position they were in prior to disas-
sembly. Set the drifts (commercial service tool) to the right and
left. Install differential case assembly to gear carrier.
CAUTION:
• The drifts shall be placed on the center of the adjusting
shims.
• The pressure shall be as low as possible to install gear
carrier assembly to differential assembly. The maximum
PDIA0064E
• If adjusting shims are installed by tapping, gear carrier
may be damaged. Avoid tapping.
f. Check and adjust the tooth contact. Refer to DLN-224, "Adjustment".
g. Check and adjust the backlash. Refer to DLN-224, "Adjustment".
h. Remove dummy cover set, and remove differential case assembly.
i. Remove drive pinion nut and press drive pinion assembly out of
gear carrier.
CAUTION:
Never drop drive pinion assembly.
j. Remove pinion front bearing inner race.
PDIA0445E
DLN-222
DRIVE PINION
5. Assemble collapsible spacer to drive pinion.
CAUTION: A
• Be careful of the mounting direction of collapsible spacer.
• Never reuse collapsible spacer.
B
SDIA2525E
DLN
6. Apply gear oil to pinion front bearing, and assemble pinion front
bearing inner race to drive pinion. Using the drifts and stand,
press pinion front bearing inner race to drive pinion as far as
E
drive pinion nut can be tightened.

B : Drift (commercial service tool) F
CAUTION:
Never reuse pinion front bearing inner race.
G
7. Apply anti-corrosive oil to the thread and seat of drive pinion nut,
JPDID0012ZZ
and temporarily tighten drive pinion nut to drive pinion.
CAUTION:
Never reuse drive pinion nut. H
8. Fit the drive pinion socket (A) (SST: KV38109500) onto the drive
pinion spline. Using the pinion nut wrench (B) (SST:
KV38108400), adjust the drive pinion nut tightening torque and I
pinion bearing preload torque.
C : Preload gauge (SST: ST3127S000)

J
Drive pinion tightening :Refer to DLN-219, "Ex-

torque ploded View".
K
Standard
Pinion bearing preload : Refer to DLN-229, "Pre-
load Torque". L
CAUTION:
• Adjust the lower limit of the drive pinion nut tightening
torque first. M
• If the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Never
loosen drive pinion nut to adjust the preload torque.
• After adjustment, rotate drive pinion back and forth 2 to 3 N
times to check for unusual noise, rotation malfunction,
and other malfunctions.
JSDIA0266ZZ
9. Install differential case assembly. Refer to DLN-215, "Assem- O
bly".
CAUTION:
Never install rear cover. P
10. Install dummy cover set, and check drive gear runout, tooth contact, and backlash. Refer to DLN-224,
"Adjustment".
11. Remove dummy cover set, then install rear cover, and side oil seal. Refer to DLN-215, "Assembly".
12. Check total preload torque. Refer to DLN-224, "Adjustment".
13. Install electric controlled coupling assembly. Refer to DLN-210, "Assembly".
14. Check companion flange runout. Refer to DLN-212, "Adjustment".
DLN-223
DRIVE PINION
TOTAL PRELOAD TORQUE

1. Remove electric controlled coupling assembly. Refer to DLN-210, "Disassembly".
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 (A) (SST: 3127S000) and drive
pinion socket (B) (SST: KV38109500).
Standard
Total preload torque : Refer to DLN-229, "Pre-
load Torque".
NOTE: PDIA0048E
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.
When the preload is small

On pinion bearings: Tighten the drive pinion nut.
On side bearings: Use thicker side bearing adjusting shims.
DRIVE GEAR RUNOUT

1. Remove rear cover. Refer to DLN-214, "Disassembly".
2. Following the procedure below, install a 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.
c. Position dummy cover spacers to dummy cover.
d. Tighten rear cover mounting bolts to the specified torque. Refer to DLN-219, "Exploded View".
e. Tighten dummy cover spacer mounting bolts evenly to the specified torque.
: 5.9 N·m (0.6 kg-m, 52 in-lb)

3. Fit a dial indicator to the drive gear back face.
4. Rotate the drive gear to measure runout.
Limit
Drive gear back face : Refer to DLN-229, "Drive
runout Gear Runout".
• If the runout is outside of the repair limit, check drive gear
assembly condition; foreign material may be caught between
drive gear and differential case, or differential case or drive
gear may be deformed, etc. PDIA0050E
CAUTION:
Replace drive gear and drive pinion as a set.
DLN-224
DRIVE PINION
TOOTH CONTACT
1. Remove rear cover. Refer to DLN-214, "Disassembly". A
2. Following the procedure below, install a dummy cover set (SST: KV389L0010) to gear carrier.
B
c. Position dummy cover spacers to dummy cover.
d. Tighten rear cover mounting bolts to the specified torque. Refer to DLN-219, "Exploded View". C
: 5.9 N·m (0.6 kg-m, 52 in-lb) DLN
3. Apply red lead to drive gear.

CAUTION:
E
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.
PDIA0051E
H
4. Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side. I
K
SDIA0570E
DLN-225
DRIVE PINION
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.
PDIA0440E
DLN-226
DRIVE PINION
• 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.
PDIA0441E
DLN
BACKLASH
1. Remove rear cover. Refer to DLN-214, "Disassembly".
2. Following the procedure below, install a dummy cover set (SST: KV389L0010) to gear carrier. E
c. Position dummy cover spacers to dummy cover. F
d. Tighten rear cover mounting bolts to the specified torque. Refer to DLN-219, "Exploded View".
G
: 5.9 N·m (0.6 kg-m, 52 in-lb)
3. Fit a dial indicator to the drive gear face to measure the back- H
lash.
Standard I
Backlash : Refer to DLN-229, "Back-
lash".
• If the backlash is outside of the specified value, change the J
thickness of side bearing adjusting shims.
When the backlash is large: PDIA0049E K

Make drive gear back adjusting shims thicker, and drive
gear front adjusting shims thinner.
L
When the backlash is small:
Make drive gear back adjusting shims thinner, and
drive gear front adjusting shims thicker.
M
Clean up the disassembled parts. Then, inspect if the parts are worn or damaged. If so, follow the measures N
below.

O
essary.
Hypoid gear
drive gear and drive pinion as a set. P
Bearing
DLN-227
DRIVE PINION
Companion flange
DLN-228
< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR FINAL DRIVE: R145]

General Specification INFOID:0000000010288423
B
4WD
C
Applied model R9M MR20DDT
MT CVT
Final drive model R145 DLN
Gear ratio 2.466
Number of teeth (Drive gear/Drive pinion) 37/15
E
Oil capacity (Approx.) (lmp pt) 0.55 (1)
Number of pinion gears 2
Drive pinion adjustment spacer type Collapsible F
Drive Gear Runout INFOID:0000000010288424
Unit: mm (in) G
Item Limit
Drive gear back face runout 0.05 (0.0020)
H
Differential Side Gear Clearance INFOID:0000000010288425
Unit: mm (in) I
Item Standard
0.2 (0.008) or less
Side gear backlash (Clearance between side gear and differential
(Each gear should rotate smoothly without excessive resistance J
case)
during differential motion.)

K
Item Standard
L
Pinion bearing (P1) 0.69 – 1.18 (0.07 – 0.12, 7 – 10)
Side bearing (P2) 0.64 – 0.98 (0.07 – 0.09, 6 – 8)
Side bearing to pinion bearing (Total preload) M
1.33 – 2.16 (0.14 – 0.22, 12 – 19)
(Total preload = P1 + P2)
Backlash INFOID:0000000010288427
N
Unit: mm (in)
Item Standard
Drive gear to drive pinion gear 0.10 – 0.15 (0.0039 – 0.0059)
O
Companion Flange Runout INFOID:0000000010288428
P
Unit: mm (in)
Item Limit
Companion flange face 0.13 (0.0051)
Inner side of the companion flange 0.19 (0.0075)
DLN-229

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TRANSMISSION & DRIVELINE

SECTION DLN DRIVELINE

INFORMATION DISPLAY (COMBINATION UNIT CHARACTERISTICS WRITING .............. 37

C1201 4WD CONTROL UNIT ............................ 38 4WD INDICATOR LAMP ................................... 63

C1203 ABS ACTUATOR AND ELECTRIC LOCK INDICATOR LAMP ................................. 64

C1210 ECM ........................................................ 46 4WD HIGH TEMP IS DISPLAYED ON INFOR-

P1804 4WD CONTROL UNIT ............................ 47 TIRE SIZE INCORRECT IS DISPLAYED ON

P181B INCOMPLETE SELFSHUT .................... 53 REMOVAL AND INSTALLATION .............. 72

PRECAUTIONS ..................................................98 P1804 CONTROL MODULE ........................... 120

PREPARATION ......................................... 195 SERVICE DATA AND SPECIFICATIONS

Service Notice or Precautions for Transfer INFOID:0000000010590151

• After overhaul refill the transfer with new transfer oil.

KV381054S0 Removing ring gear shaft oil seal

ST3127S000 Measuring preload torque

Commercial Service Tool INFOID:0000000010590153

Tool name Description

Drift Removing gear ring bearing inner race

Drift Installing ring gear shaft oil seal

Puller Removing ring gear bearing (left) inner race F

Drift Installing side oil seal (installing transfer cover

Replacer • Removing drive pinion M

Drift Installing ring gear bearing (left) outer race

Drift Installing ring gear bearing (right) outer race

Drift Removing drive pinion

Drift Installing pinion bearing

Drift Installing companion flange

Rear wheel house outer panel in lug-

No. Component Function

4WD solenoid Refer to DLN-12, "4WD Solenoid".

4WD Control Unit INFOID:0000000010755225

• 4WD solenoid is integrated with electric controlled coupling.

POWER TRANSFER DIAGRAM O

Engine Transaxle Transfer

ELECTRIC CONTROLLED COUPLING

• Transmission torque to the rear wheels is determined accord-

4WD SYSTEM : Control in Each Mode INFOID:0000000010755232

DTC Vehicle condition

4WD SYSTEM : Protection Function INFOID:0000000010755235

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

RR RH SENSOR Vehicle running Nearly matches the speed

RR LH SENSOR Vehicle running

1 4WD solenoid power LOCK mode 0V

2 Engine speed: At idle 0V

7 Ignition switch: ON Battery voltage

Protection Function INFOID:0000000010755243

4WD warning (on infor- Contents of protection

Priority Detected items (DTC)

DTC Index INFOID:0000000010755245

DTC Display Item Reference

Climate con- Weather Fine Cloud Rain Snow Others ( )