Driveline: Section

TRANSMISSION & DRIVELINE
SECTION DLN DRIVELINE

B
DLN
E
CONTENTS
TRANSFER: TX91A INFORMATION DISPLAY (COMBINATION F
METER) ......................................................................26
PRECAUTION ............................................... 8 INFORMATION DISPLAY (COMBINATION
METER) : 4WD Warning .........................................26 G
PRECAUTIONS ................................................... 8 INFORMATION DISPLAY (COMBINATION
Precaution for Supplemental Restraint System METER) : ATP Warning ..........................................27
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- INFORMATION DISPLAY (COMBINATION
SIONER" ................................................................... 8 H
METER) : 4WD Indicator .........................................28
Precautions for Removing Battery Terminal ............. 8
Service Notice or Precautions for Transfer ............... 9 WARNING/INDICATOR/CHIME LIST ........................28
WARNING/INDICATOR/CHIME LIST : Warning I
PREPARATION ........................................... 10 Lamp/Indicator Lamp ...............................................28
WARNING/INDICATOR/CHIME LIST : Warning/
PREPARATION ..................................................10 Indicator (On Information Display) ...........................28
Special Service Tools .............................................. 10 J
Commercial Service Tools ...................................... 10 DIAGNOSIS SYSTEM (TRANSFER CON-
Sealant or/and Lubricant ......................................... 10 TROL UNIT) ...................................................... 29
CONSULT Function .................................................29 K
SYSTEM DESCRIPTION ............................. 11
ECU DIAGNOSIS INFORMATION .............. 31
COMPONENT PARTS .......................................11
Component Parts Location ...................................... 11 TRANSFER CONTROL UNIT ........................... 31 L
Transfer Control Unit ............................................... 17 Reference Value ......................................................31
Transfer Rotary Position Sensor ............................. 17 Fail-Safe ..................................................................34
Transfer Motor ......................................................... 17 DTC Inspection Priority Chart ..................................35 M
Mode Sensor ........................................................... 18 DTC Index ...............................................................35
Range Sensor ......................................................... 18
Front Revolution Sensor (Without ABS) .................. 18 WIRING DIAGRAM ...................................... 37
N
4WD Shift Switch .................................................... 18
Park/Neutral Position Switch (M/T Models) ............. 18 4WD SYSTEM ................................................... 37
Wiring Diagram ........................................................37
STRUCTURE AND OPERATION .......................19 O
Sectional View ......................................................... 19 BASIC INSPECTION ................................... 47
Torque Split Mechanism ......................................... 19
DIAGNOSIS AND REPAIR WORK FLOW ....... 47
SYSTEM .............................................................23 Work Flow ................................................................47 P
Diagnostic Work Sheet ............................................48
4WD SYSTEM ........................................................... 23
4WD SYSTEM : System Description ...................... 23 TRANSFER ROTARY POSITION SENSOR
4WD SYSTEM : Circuit Diagram ............................. 25 LEARNING VALUE INITIALIZATION ............... 50
4WD SYSTEM : Fail-Safe ....................................... 25 Description ...............................................................50
Work Procedure .......................................................50
Revision: 2015 March DLN-1 D23

DTC/CIRCUIT DIAGNOSIS ......................... 51 DTC Description ...................................................... 80
Diagnosis Procedure ............................................... 80
P1802, P1803, P1804, P1809 TRANSFER
CONTROL UNIT ................................................ 51 P1820 ENGINE SPEED SIGNAL ...................... 82
DTC Description ..................................................... 51 DTC Description ...................................................... 82
Diagnosis Procedure .............................................. 51 Diagnosis Procedure ............................................... 82
P1808 VEHICLE SPEED SENSOR (ABS) ........ 53 P182A TRANSFER HI-LO POSITION SEN-
DTC Description ..................................................... 53 SOR ................................................................... 83
Diagnosis Procedure .............................................. 53 DTC Description ...................................................... 83
P180C SENSOR POWER SUPPLY (5V) .......... 54 Component Inspection ............................................ 84
DTC Description ..................................................... 54
Diagnosis Procedure .............................................. 54 P1854 VEHICLE SPEED SENSOR (FR) ........... 86
DTC Description ...................................................... 86
P180D TRANSFER ROTARY POSITION Diagnosis Procedure ............................................... 86
SENSOR ............................................................ 56 Component Inspection ............................................ 87
DTC Description ..................................................... 56
Diagnosis Procedure .............................................. 56 P1855 VEHICLE SPEED SENSOR (RR) .......... 88
DTC Description ...................................................... 88
P180F MOTOR SYSTEM ................................... 59 Diagnosis Procedure ............................................... 88
DTC Description ..................................................... 59
Diagnosis Procedure .............................................. 59 P1867 INCOMPLETE SHIFT ............................. 89
Component Inspection ............................................ 60 DTC Description ...................................................... 89
P1811 BATTERY VOLTAGE ............................. 61
DTC Description ..................................................... 61 P186C INCOMP RPS OFFSET LEARNING ..... 91
P1813 4WD MODE SWITCH ............................. 65
DTC Description ..................................................... 65 U1000 CAN COMM CIRCUIT ............................ 92
Component Inspection ............................................ 66 Diagnosis Procedure ............................................... 92
P1814 4WD DETECT SWITCH ......................... 67 U1010 CONTROL UNIT (CAN) ......................... 93
DTC Description ..................................................... 67 DTC Description ...................................................... 93
Diagnosis Procedure .............................................. 67 Diagnosis Procedure ............................................... 93
Component Inspection ............................................ 68
POWER SUPPLY AND GROUND CIRCUIT ..... 94
P1816 TRANSMISSION RANGE SWITCH ....... 69 Diagnosis Procedure ............................................... 94
DTC Description ..................................................... 69
PARK/NEUTRAL POSITION SWITCH ............. 97
Diagnosis Procedure .............................................. 69
Component Function Check ................................... 97
P1817 TRANSFER MOTOR .............................. 70 Diagnosis Procedure ............................................... 97
DTC Description ..................................................... 70 Component Inspection ............................................ 98
4WD WARNING LAMP ..................................... 99
Component Inspection ............................................ 70
Component Function Check ................................... 99
P1818 ACTUATOR POSITION SWITCH .......... 72 Diagnosis Procedure ............................................... 99
DTC Description ..................................................... 72
4WD INDICATOR ............................................. 100
Component Function Check ................................. 100
P1819 ACTUATOR CIRCUIT ............................ 75 Diagnosis Procedure ............................................. 100
DTC Description ..................................................... 75
SYMPTOM DIAGNOSIS ........................... 101
P181B INCOMPLETE SELFSHUT .................... 76 HEAVY TIGHT-CORNER BRAKING SYMP-

DTC Description ..................................................... 76 TOM OCCURS .................................................. 101
Diagnosis Procedure .............................................. 76 Description ............................................................ 101
P181C TRANSFER MOTOR POWER SUP- 4WD MODE DOES NOT CHANGE .................. 102
PLY .................................................................... 80 Description ............................................................ 102

Diagnosis Procedure ............................................. 102 Removal and Installation ....................................... 116
Inspection .............................................................. 116 A
4WD INDICATOR CONTINUES BLINKING .... 103
Description ............................................................ 103 FRONT REVOLUTION SENSOR .................... 117
Diagnosis Procedure ............................................. 103 Exploded View ....................................................... 117
Removal and Installation ....................................... 117 B
4WD WARNING LAMP BLINKS SLOWLY ..... 104 Inspection .............................................................. 117
Description ............................................................ 104
Diagnosis Procedure ............................................. 104 VEHICLE SPEED SENSOR ............................ 118 C
Exploded View ....................................................... 118
ATP WARNING LAMP DOES NOT TURN ON.. 105 Removal and Installation ....................................... 118
Description ............................................................ 105 Inspection .............................................................. 118
Diagnosis Procedure ............................................. 105 DLN
AIR BREATHER .............................................. 119
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING .......................... 106 YD25DDTI ................................................................ 119 E
NVH Troubleshooting Chart .................................. 106 YD25DDTi : Exploded View ................................... 119
YD25DDTi : Removal and Installation ................... 119
PERIODIC MAINTENANCE ....................... 107
YS23DDT, YS23DDTT ............................................. 121 F
TRANSFER FLUID ........................................... 107 YS23DDT, YS23DDTT : Exploded View ............... 122
Inspection .............................................................. 107 YS23DDT, YS23DDTT : Removal and Installation.. 122
Draining ................................................................. 107 G
Refilling ................................................................. 107 UNIT REMOVAL AND INSTALLATION .... 125
REMOVAL AND INSTALLATION ............. 108 TRANSFER ASSEMBLY ................................ 125

Exploded View ....................................................... 125 H
TRANSFER CONTROL UNIT .......................... 108 Removal and Installation ....................................... 125
Exploded View ...................................................... 108 Inspection and Adjustment .................................... 126
Removal and Installation ....................................... 108 I
SERVICE DATA AND SPECIFICATIONS
4WD SHIFT SWITCH ....................................... 109 (SDS) .......................................................... 127
Removal and Installation ....................................... 109
Inspection .............................................................. 109 SERVICE DATA AND SPECIFICATIONS J
(SDS) ............................................................... 127
FRONT OIL SEAL ............................................ 110 General Specifications ........................................... 127
Exploded View ...................................................... 110 FRONT PROPELLER SHAFT: 2F1310 K
Inspection .............................................................. 111 PRECAUTION ............................................ 128
REAR OIL SEAL .............................................. 112 PRECAUTIONS ............................................... 128 L
Exploded View ...................................................... 112 Precautions for Removing Battery Terminal .......... 128
Removal and Installation ....................................... 112 Service Notice or Precautions for Propeller Shaft.. 128
Inspection .............................................................. 112 M
SYSTEM DESCRIPTION ........................... 129
TRANSFER ROTARY POSITION SENSOR .... 113
Exploded View ...................................................... 113 STRUCTURE AND OPERATION ................... 129
Removal and Installation ....................................... 113 Sectional View ....................................................... 129 N
Inspection and Adjustment .................................... 113
SYMPTOM DIAGNOSIS ............................ 130
TRANSFER MOTOR ........................................ 114 O
Exploded View ...................................................... 114 NOISE, VIBRATION AND HARSHNESS
Removal and Installation ....................................... 114 (NVH) TROUBLESHOOTING ......................... 130
Inspection .............................................................. 114 NVH Troubleshooting Chart .................................. 130
P
MODE SENSOR ............................................... 115 PERIODIC MAINTENANCE ...................... 131
Exploded View ...................................................... 115
Removal and Installation ....................................... 115 FRONT PROPELLER SHAFT ........................ 131
Inspection .............................................................. 115 Inspection .............................................................. 131
RANGE SENSOR ............................................. 116 REMOVAL AND INSTALLATION ............. 132

Exploded View ...................................................... 116
FRONT PROPELLER SHAFT ........................ 132

Exploded View .......................................................132 SYSTEM DESCRIPTION .......................... 151
Removal and Installation .......................................133
Disassembly and Assembly ...................................134 STRUCTURE AND OPERATION ..................... 151
Inspection ..............................................................136 Sectional View ...................................................... 151
SERVICE DATA AND SPECIFICATIONS SYMPTOM DIAGNOSIS ........................... 152

(SDS) .......................................................... 138
NOISE, VIBRATION, AND HARSHNESS
SERVICE DATA AND SPECIFICATIONS (NVH) TROUBLESHOOTING ........................... 152
(SDS) ................................................................ 138 NVH Troubleshooting Chart .................................. 152
General Specifications ...........................................138
Propeller Shaft Tube ..............................................138
PERIODIC MAINTENANCE ...................... 153
Journal ...................................................................138 REAR PROPELLER SHAFT ............................ 153
REAR PROPELLER SHAFT: 3S1330 Inspection .............................................................. 153
PRECAUTION ............................................ 139 REMOVAL AND INSTALLATION ............. 154
PRECAUTIONS ............................................... 139 REAR PROPELLER SHAFT ............................ 154
Precautions for Removing Battery Terminal ..........139 Exploded View ...................................................... 154
Service Notice or Precautions for Propeller Shaft..139 Removal and Installation ....................................... 155
Disassembly and Assembly .................................. 155
SYSTEM DESCRIPTION ........................... 140 Inspection .............................................................. 157
STRUCTURE AND OPERATION .................... 140 SERVICE DATA AND SPECIFICATIONS
Sectional View .......................................................140
(SDS) ......................................................... 159
SYMPTOM DIAGNOSIS ............................ 141
NOISE, VIBRATION, AND HARSHNESS (SDS) ................................................................ 159
(NVH) TROUBLESHOOTING .......................... 141 General Specification ............................................ 159
NVH Troubleshooting Chart ..................................141 Propeller Shaft Tube ............................................. 159
Journal .................................................................. 159
PERIODIC MAINTENANCE ....................... 142 FRONT FINAL DRIVE: R180A
REAR PROPELLER SHAFT ........................... 142 PRECAUTION ........................................... 160
Inspection ..............................................................142
PRECAUTIONS ................................................ 160
REMOVAL AND INSTALLATION .............. 143 Precautions for Removing Battery Terminal ......... 160
Service Notice or Precautions for Front Final Drive
REAR PROPELLER SHAFT ........................... 143 . 160
Exploded View .......................................................143
Removal and Installation .......................................144 PREPARATION ......................................... 162
Disassembly and Assembly ...................................145
Inspection ..............................................................146 PREPARATION ................................................ 162
Special Service Tools ........................................... 162
SERVICE DATA AND SPECIFICATIONS Commercial Service Tools .................................... 164
(SDS) .......................................................... 148 Sealant or/and Lubricant ....................................... 165
SERVICE DATA AND SPECIFICATIONS SYSTEM DESCRIPTION .......................... 166

(SDS) ................................................................ 148
General Specification ............................................148 STRUCTURE AND OPERATION ..................... 166
Propeller Shaft Tube ..............................................149 Sectional View ...................................................... 166
Journal ...................................................................149
SYMPTOM DIAGNOSIS ........................... 167
REAR PROPELLER SHAFT: 2S1330
NOISE, VIBRATION AND HARSHNESS
PRECAUTION ............................................ 150 (NVH) TROUBLESHOOTING ........................... 167
PRECAUTIONS ............................................... 150 NVH Troubleshooting Chart .................................. 167
Precautions for Removing Battery Terminal ..........150 PERIODIC MAINTENANCE ...................... 168
Service Notice or Precautions for Propeller Shaft..150
FRONT DIFFERENTIAL GEAR OIL ..............

Inspection .............................................................. 168 PRECAUTIONS ............................................... 203
Draining ................................................................. 168 Precautions for Removing Battery Terminal .......... 203 A
Refilling ................................................................. 168 Service Notice or Precautions for Rear Final Drive.. 203
REMOVAL AND INSTALLATION ............. 169 PREPARATION ......................................... 205

B
FRONT OIL SEAL ............................................ 169 PREPARATION ............................................... 205
Exploded View ...................................................... 169 Special Service Tools ............................................ 205
Removal and Installation ....................................... 169 Commercial Service Tools ..................................... 206 C
Inspection .............................................................. 172 Sealant or/and Lubricant ....................................... 207
SIDE OIL SEAL ................................................ 173 SYSTEM DESCRIPTION ........................... 208
Exploded View ...................................................... 173 DLN
Removal and Installation ....................................... 173 STRUCTURE AND OPERATION ................... 208
Inspection .............................................................. 174 Sectional View ....................................................... 208
E
AIR BREATHER ............................................... 175 SYMPTOM DIAGNOSIS ............................ 209
Exploded View ...................................................... 175
Removal and Installation ....................................... 175 NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ......................... 209 F
UNIT REMOVAL AND INSTALLATION .... 177 NVH Troubleshooting Chart .................................. 209
FRONT FINAL DRIVE ASSEMBLY ................. 177 PERIODIC MAINTENANCE ...................... 210 G
Exploded View ...................................................... 177
Removal and Installation ....................................... 177 REAR DIFFERENTIAL GEAR OIL ................. 210
Inspection .............................................................. 178 Inspection .............................................................. 210
Draining ................................................................. 210 H
UNIT DISASSEMBLY AND ASSEMBLY . 179 Refilling .................................................................. 210
SIDE SHAFT ..................................................... 179 REMOVAL AND INSTALLATION ............. 211 I

Exploded View ...................................................... 179
Disassembly and Assembly .................................. 180 FRONT OIL SEAL ........................................... 211
Inspection .............................................................. 181 Exploded View ....................................................... 211
Removal and Installation ....................................... 211 J
DIFFERENTIAL ASSEMBLY ........................... 182 Inspection .............................................................. 213
Exploded View ...................................................... 182
Disassembly and Assembly .................................. 183 AIR BREATHER .............................................. 214 K
Adjustment ............................................................ 188 Exploded View ....................................................... 214
Inspection .............................................................. 192 Removal and Installation ....................................... 214
Inspection .............................................................. 215
DRIVE PINION .................................................. 193 L
Exploded View ...................................................... 193 UNIT REMOVAL AND INSTALLATION .... 216
Disassembly and Assembly .................................. 194
Adjustment ............................................................ 199 REAR FINAL DRIVE ASSEMBLY .................. 216 M
Inspection .............................................................. 200 Exploded View ....................................................... 216
SERVICE DATA AND SPECIFICATIONS Inspection .............................................................. 217
N
(SDS) .......................................................... 201
UNIT DISASSEMBLY AND ASSEMBLY . 218
DIFFERENTIAL ASSEMBLY .......................... 218 O
(SDS) ................................................................ 201 Exploded View ....................................................... 218
General Specifications .......................................... 201
Disassembly and Assembly ................................... 219
Preload Torque ..................................................... 201
Adjustment ............................................................. 225
Drive Gear Runout ................................................ 201 P
Inspection .............................................................. 229
Backlash ................................................................ 202
Companion Flange Runout ................................... 202 DRIVE PINION ................................................ 231
Differential Side Gear Clearance .......................... 202 Exploded View ....................................................... 231
REAR FINAL DRIVE: H215 Disassembly and Assembly ................................... 231
Adjustment ............................................................. 237
PRECAUTION ............................................ 203 Inspection .............................................................. 238

SERVICE DATA AND SPECIFICATIONS DIFFERENTIAL LOCK CONTROL UNIT ......... 260
(SDS) .......................................................... 239 Reference Value ................................................... 260
Fail-Safe ................................................................ 262
SERVICE DATA AND SPECIFICATIONS DTC Inspection Priority Chart ............................... 262
(SDS) ................................................................ 239 DTC Index ............................................................. 262
General Specifications ...........................................239
Preload Torque ......................................................240 WIRING DIAGRAM ................................... 264
Drive Gear Runout .................................................242
DIFFERENTIAL LOCK SYSTEM ..................... 264
Backlash ................................................................242
Wiring Diagram ..................................................... 264
Companion Flange Runout ....................................242
Differential Side Gear Clearance ...........................242 BASIC INSPECTION ................................. 270
REAR FINAL DRIVE: H215 (DL)
DIAGNOSIS AND REPAIR WORKFLOW ........ 270
PRECAUTION ............................................ 243 Work Flow ............................................................. 270
Diagnostic Work Sheet ......................................... 271
PRECAUTIONS ............................................... 243
Precaution for Supplemental Restraint System DTC/CIRCUIT DIAGNOSIS ....................... 273
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................243 P1836 DIFFERENTIAL LOCK CONTROL
Precautions for Removing Battery Terminal ..........243 UNIT .................................................................. 273
Service Notice or Precautions for Rear Final Drive..244 DTC Description .................................................... 273
Diagnosis Procedure ............................................. 273
PREPARATION .......................................... 245
P1838 DIFFERENTIAL LOCK MODE
PREPARATION ............................................... 245 SWITCH ............................................................ 274
Special Service Tools ............................................245 DTC Description .................................................... 274
Commercial Service Tools .....................................246 Diagnosis Procedure ............................................. 274
Sealant or/and Lubricant .......................................247 Component Inspection .......................................... 276
SYSTEM DESCRIPTION ........................... 248 P1839 DIFFERENTIAL LOCK POSITION
SWITCH ............................................................ 277
COMPONENT PARTS ..................................... 248
DTC Description .................................................... 277
Component Parts Location ....................................248
Differential Lock Control Unit .................................250
Component Inspection .......................................... 278
Differential Lock Solenoid ......................................250
Differential Lock Position Switch ...........................250 P1844 RELAY ................................................... 280
Differential Lock Mode Switch ...............................251 DTC Description .................................................... 280
STRUCTURE AND OPERATION .................... 252
Sectional View .......................................................252 P1848 DIFFERENTIAL LOCK SOLENOID ...... 281
Differential Lock Mechanism .................................253 DTC Description .................................................... 281
SYSTEM ........................................................... 254
Component Inspection .......................................... 283
DIFFERENTIAL LOCK SYSTEM .............................254
DIFFERENTIAL LOCK SYSTEM : System De-
P1849 DIFFERENTIAL LOCK SOLENOID ...... 285
scription .................................................................254 DTC Description .................................................... 285
DIFFERENTIAL LOCK SYSTEM : Circuit Dia-
gram ......................................................................256 Component Inspection .......................................... 287
DIFFERENTIAL LOCK SYSTEM : Fail-Safe .........256 P1850 DIFFERENTIAL LOCK CONTROL
WARNING/INDICATOR/CHIME LIST ......................257 UNIT .................................................................. 289
WARNING/INDICATOR/CHIME LIST : Warning DTC Description .................................................... 289
Lamp/Indicator Lamp .............................................257 Diagnosis Procedure ............................................. 289
DIAGNOSIS SYSTEM (DIFFERENTIAL P1856 VDC SYSTEM ....................................... 291

LOCK CONTROL UNIT) .................................. 258 DTC Description .................................................... 291
CONSULT Function ...............................................258 Diagnosis Procedure ............................................. 291
ECU DIAGNOSIS INFORMATION ............. 260 P18CB DIFFERENTIAL LOCK SOLENOID

POWER SUPPLY ............................................. 292

DTC Description .................................................... 292 Inspection .............................................................. 311
Diagnosis Procedure ............................................. 292 Draining ................................................................. 311 A
Refilling .................................................................. 311
P18CC WHEEL SPEED SIGNAL ..................... 295
DTC Description .................................................... 295 REMOVAL AND INSTALLATION ............. 312
Diagnosis Procedure ............................................. 295 B
DIFFERENTIAL LOCK CONTROL UNIT ....... 312
P18CD SELF SHUTDOWN .............................. 296 Exploded View ....................................................... 312
DTC Description .................................................... 296 Removal and Installation ....................................... 312 C
DIFFERENTIAL LOCK MODE SWITCH ......... 313
P18CE DIFFERENTIAL LOCK POSITION Removal and Installation ....................................... 313
SWITCH ............................................................ 298 DLN
DTC Description .................................................... 298 FRONT OIL SEAL ........................................... 314
Diagnosis Procedure ............................................. 298 Exploded View ....................................................... 314
Component Inspection .......................................... 299 Removal and Installation ....................................... 314 E
Inspection .............................................................. 317
P18D0 ABS SYSTEM ....................................... 301
DTC Description .................................................... 301 AIR BREATHER .............................................. 319
Exploded View ....................................................... 319 F
U1000 CAN COMM CIRCUIT ........................... 302 Inspection .............................................................. 320
DTC Description .................................................... 302 G
Diagnosis Procedure ............................................. 302 UNIT REMOVAL AND INSTALLATION .... 321
U1010 CONTROL UNIT (CAN) ........................ 303 REAR FINAL DRIVE ASSEMBLY .................. 321
DTC Description .................................................... 303 Exploded View ....................................................... 321 H
Diagnosis Procedure ............................................. 303 Removal and Installation ....................................... 321
Inspection .............................................................. 322
POWER SUPPLY AND GROUND CIRCUIT .... 304 I
Diagnosis Procedure ............................................. 304 UNIT DISASSEMBLY AND ASSEMBLY . 323
DIFFERENTIAL LOCK INDICATOR LAMP ..... 307 DIFFERENTIAL ASSEMBLY .......................... 323
Component Function Check .................................. 307 Exploded View ....................................................... 323 J
Diagnosis Procedure ............................................. 307 Disassembly and Assembly ................................... 324
Adjustment ............................................................. 331
SYMPTOM DIAGNOSIS ............................ 308 Inspection .............................................................. 335 K
DIFFERENTIAL LOCK INDICATOR LAMP DRIVE PINION ................................................ 336
DOES NOT TURN ON ...................................... 308 Exploded View ....................................................... 336
Description ............................................................ 308 Disassembly and Assembly ................................... 337 L
Diagnosis Procedure ............................................. 308 Adjustment ............................................................. 342
Inspection .............................................................. 343
DIFFERENTIAL LOCK INDICATOR LAMP M
FLASHES WHILE DRIVING ............................. 309 SERVICE DATA AND SPECIFICATIONS
Description ............................................................ 309 (SDS) .......................................................... 344
SERVICE DATA AND SPECIFICATIONS N
NOISE, VIBRATION AND HARSHNESS (SDS) ............................................................... 344
(NVH) TROUBLESHOOTING .......................... 310 General Specifications ........................................... 344
NVH Troubleshooting Chart .................................. 310 Preload Torque ...................................................... 344 O
Drive Gear Runout ................................................. 345
PERIODIC MAINTENANCE ....................... 311 Backlash ................................................................ 345
REAR DIFFERENTIAL GEAR OIL .................. 311 Companion Flange Runout .................................... 345 P

PRECAUTIONS
< PRECAUTION > [TRANSFER: TX91A]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000011268757
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING:
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precautions for Removing Battery Terminal INFOID:0000000011268758
When disconnecting the battery terminal, pay attention to the following.

• Always use a 12V battery as power source.
• Never disconnect battery terminal while engine is running.
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
• For vehicles with the engine listed below, remove the battery termi-
nal after a lapse of the specified time:
D4D engine : 20 minutes YS23DDT : 4 minutes

HRA2DDT : 12 minutes YS23DDTT : 4 minutes
K9K engine : 4 minutes ZD30DDTi : 60 seconds
M9R engine : 4 minutes ZD30DDTT : 60 seconds
R9M engine : 4 minutes
SEF289H
V9X engine : 4 minutes
YD25DDTi : 2 minutes
NOTE:
ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait
for at least 15 minutes to remove the battery terminal.
NOTE:
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF.
• Example of high-load driving
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more.

PRECAUTIONS
< PRECAUTION > [TRANSFER: TX91A]
- Driving for 30 minutes or more on a steep slope.
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON A
the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon-
B
nected, 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. C
Service Notice or Precautions for Transfer INFOID:0000000011106354
• Never reuse transfer fluid, once it has been drained. DLN

• Check the fluid level or replace the fluid only with the vehicle parked on level ground.
• During removal or installation, keep inside of transfer clear of dust or dirt.
• Replace all tires at the same time. Always use tires of the proper size and the same brand and pattern. Fit- E
ting improper size and unusually worn tires applies excessive force to vehicle mechanism and can cause
longitudinal vibration.
• Disassembly should be done in a clean work area, it is preferable to work in dustproof area.
• Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal F
parts from becoming contaminated by dirt or other foreign matter.
• All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly. G
• Check for the correct installation status prior to removal or disassembly. If matching marks are required, be
certain they do not interfere with the function of the parts when applied.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary. H
• Gaskets, seals and O-rings should be replaced any time the transfer is disassembled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tight-
ening sequence is specified, use it. I
• Observe the specified torque when assembling.
• Clean and flush the parts sufficiently and blow-dry them.
• Be careful not to damage sliding surfaces and mating surfaces.
J
• Clean inner parts with lint-free cloth or towels. Do not use cotton work gloves and rags to prevent adhering
fibers.

PREPARATION
< PREPARATION > [TRANSFER: TX91A]
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000011257139
Tool number
Description
Tool name
KV40104710 Installing rear oil seal
Drift
a: 76.3 mm (3.004 in) dia.
b: 67.9 mm (2.673 in) dia.
ZZA1003D
Commercial Service Tools INFOID:0000000011257140
Tool name Description

Drift Installing front oil seal
a: 70 mm (2.76 in) dia.
b: 63 mm (2.48 in) dia.
ZZA1003D
Flange wrench Removing and installing self-lock nut
NT035
Sealant or/and Lubricant INFOID:0000000011376255
Name Description
Sealant • Thread of filler plug
(Hylomar 102 silicone or equivalent) • Thread of drain plug

COMPONENT PARTS
< SYSTEM DESCRIPTION > [TRANSFER: TX91A]
SYSTEM DESCRIPTION A
COMPONENT PARTS
Component Parts Location INFOID:0000000011106358
B
M/T MODELS
LHD Models C
DLN
JSDIA7257ZZ
N
Transfer

COMPONENT PARTS
No. Component Function

Mainly transmits the following signals to transfer control unit via CAN communication.
ABS actuator and electric unit
• Each wheel speed signal
(control unit)
For detailed installation location, refer to BRC-24, "Component Parts Location" (without
(With ABS or VDC)
VDC), BRC-126, "Component Parts Location" (with VDC).
• Vehicle speed signal
• Sleep wake up signal (Models without Intelligent Key)
• Stop lamp switch signal (Models without Intelligent Key)
Mainly receives the following signals from transfer control unit via CAN communication.
Combination meter
• 4WD warning lamp signal
• 4WD mode indicator lamp signal
• Sleep-ready signal (Models without Intelligent Key)
For detailed installation location, refer to MWI-8, "METER SYSTEM : Component Parts
Location".
4WD shift switch Refer to DLN-18, "4WD Shift Switch".
Park/Neutral position switch Refer to DLN-18, "Park/Neutral Position Switch (M/T Models)".
Transfer control unit Refer to DLN-17, "Transfer Control Unit".

ECM • Engine speed signal
For detailed installation location, refer to EC-422, "Component Parts Location".
• Sleep wake up signal
• Stop lamp switch signal
BCM
(Models with Intelligent Key)
• Sleep-ready signal
For detailed installation location, refer to BCS-7, "BODY CONTROL SYSTEM : Compo-
nent Parts Location".
Range sensor Refer to DLN-18, "Range Sensor".
Transfer motor Refer to DLN-17, "Transfer Motor".

Front revolution sensor
Refer to DLN-18, "Front Revolution Sensor (Without ABS)".
(Without ABS)
Transfer rotary position sensor Refer to DLN-17, "Transfer Rotary Position Sensor".
Mode sensor Refer to DLN-18, "Mode Sensor".
RHD Models

COMPONENT PARTS
DLN
JSDIA7263ZZ
K
Transfer
L
4WD shift switch Refer to DLN-18, "4WD Shift Switch". M
• Sleep wake up signal (Models without Intelligent Key)
• Stop lamp switch signal (Models without Intelligent Key) N
Combination meter
O
Location".
Transfer control unit Refer to DLN-17, "Transfer Control Unit". P
BCM

COMPONENT PARTS
• Engine speed signal
ECM For detailed installation location, refer to EC-422, "Component Parts Location"
(YD25DDTi), EC-758, "YS23DDT : Component Parts Location" (YS23DDT), EC-762,
"YS23DDTT : Component Parts Location" (YS23DDTT).
ABS actuator and electric unit
(control unit)
For detailed installation location, refer to BRC-24, "Component Parts Location" (without
(With ABS or VDC)
Park/Neutral position switch Refer to DLN-18, "Park/Neutral Position Switch (M/T Models)".

Front revolution sensor
Refer to DLN-18, "Front Revolution Sensor (Without ABS)".
(Without ABS)
A/T MODELS
LHD Models
JSDIA7258ZZ

COMPONENT PARTS
Transfer A

B
ABS actuator and electric unit • Each wheel speed signal
(control unit) For detailed installation location, refer to BRC-24, "Component Parts Location" (without
VDC), BRC-126, "Component Parts Location" (with VDC). C
• 4WD warning lamp signal DLN
Combination meter
• ATP warning lamp signal
E
Location".
Mainly transmits the following signals to transfer control unit via CAN communication. F
• Gear position signal
TCM • Output shaft revolution signal
For detailed installation location, refer to TM-413, "A/T CONTROL SYSTEM : Compo-
nent Parts Location". G
H
For detailed installation location, refer to EC-422, "Component Parts Location".
• Sleep wake up signal I
BCM Mainly receives the following signals from transfer control unit via CAN communication.
J
K

L
RHD Models
M

COMPONENT PARTS
JSDIA6817ZZ
Transfer

Combination meter
• ATP warning lamp signal
Location".
BCM Mainly receives the following signals from transfer control unit via CAN communication.

COMPONENT PARTS
A
ECM For detailed installation location, refer to EC-422, "Component Parts Location"
(YD25DDTi), EC-758, "YS23DDT : Component Parts Location" (YS23DDT), EC-762, B
"YS23DDTT : Component Parts Location" (YS23DDTT).
ABS actuator and electric unit • Each wheel speed signal
(control unit) For detailed installation location, refer to BRC-24, "Component Parts Location" (without
C
• Gear position signal DLN
TCM • Output shaft revolution signal
For detailed installation location, refer to TM-413, "A/T CONTROL SYSTEM : Compo-
E

F
G
Transfer Control Unit INFOID:0000000011256204
Transfer control unit controls 4WD mode (2WD ⇔ 4H ⇔ 4LO) by input signals of each sensor and each
switch, and it directs shifts from 4WD shift switch. H
Transfer Rotary Position Sensor INFOID:0000000011256205
• Transfer rotary position sensor is installed to back side of transfer I

assembly.
• Transfer rotary position sensor detects rotation status of transfer
motor and transmits signal to transfer control unit. J
L
JSDIA6759ZZ
Transfer Motor INFOID:0000000011256206
M
• Transfer motor is installed to left side of transfer assembly.
• Transfer motor operates according to signal from transfer control
unit and switches 4WD mode (2WD ⇔ 4H ⇔ 4LO).
N
P
JSDIA6760ZZ

COMPONENT PARTS
Mode Sensor INFOID:0000000011106360
• Mode sensor is installed to top of transfer assembly.

• Mode sensor detects engagement status of 2WD-4H sleeve and
transmits signal to transfer control unit.
4WD mode
Item
2WD 4H 4LO
Mode sensor OFF ON ON
JSDIA6761ZZ
Range Sensor INFOID:0000000011106361
• Range sensor is installed to top of transfer assembly.

• Range sensor detects engagement status of 4H-4LO sleeve and
transmits signal to transfer control unit.
4WD mode
Item
2WD 4H (N)* 4LO
Switch 1 OFF OFF OFF ON
Range sensor
Switch 2 OFF OFF ON ON
*: This is neutral position of 4H ⇔ 4LO.
JSDIA6762ZZ
Front Revolution Sensor (Without ABS) INFOID:0000000011828113
• Front revolution sensor is installed to back side of transfer assem-

bly.
• Front revolution sensor detects a number of output revolution on
the front side of transfer.
JSDIA7259ZZ
4WD Shift Switch INFOID:0000000011106362
• The 4WD shift switch is installed to cluster lid C lower.

• Operating the 4WD shift switch at an engine start enables the
selection of 4WD mode (2WD ⇔ 4H ⇔ 4LO).
JSDIA6778ZZ
Park/Neutral Position Switch (M/T Models) INFOID:0000000011370719
• Park/neutral position switch is installed to manual transmission assembly.

• Park/neutral position switch detects that the transmission gear position is in neutral position and transmits
signal to transfer control unit.

STRUCTURE AND OPERATION
A
Sectional View INFOID:0000000011256208
DLN
L
JSDIA6746ZZ
Seal guard Main shaft Extension case M

Rear bearing Drive chain Sprocket
2-4 sleeve H-L sleeve Sun gear
Front case Input bearing Input shaft N
Internal gear Range fork Front companion flange
Actuator shaft Rear case Front bearing
O
Transfer motor Shift rail gear Mode fork
Shift rail bearing
P
Torque Split Mechanism INFOID:0000000011256209
TORQUE DISTRIBUTION FLOW

2WD Mode

JSDIA6793ZZ
2-4 sleeve H-L sleeve

From transmission To rear propeller shaft
4H Mode

DLN
JSDIA6794ZZ
K

From transmission To rear propeller shaft To front propeller shaft L
4LO Mode
M

JSDIA6795ZZ

From transmission To rear propeller shaft To front propeller shaft

SYSTEM
SYSTEM
A
4WD SYSTEM
4WD SYSTEM : System Description INFOID:0000000011256483
B
• 4WD mode is selectable among 2WD mode, 4H mode, and 4LO mode by operating the 4WD shift switch.
• In accordance with fail-safe function, when system is malfunctioning, 4WD warning lamp on combination
meter turns ON and 4WD control stops. For fail-safe function, refer to DLN-34, "Fail-Safe". C
SYSTEM DIAGRAM
DLN
JSDIA7255GB L
*1: A/T models
*2: M/T models
*3: Without ABS
*4: With ABS or VDC M
Signal with Communication Line

Major signal transmission between each unit via CAN communication lines are shown in the following table.
N
Component parts Signal item
ECM O
• Sleep wake up signal (Models without Intelligent Key) P
• Stop lamp switch signal (Models without Intelligent Key)
Combination meter Mainly receives the following signals from transfer control unit via CAN communication.
• ATP warning lamp signal (A/T models)

SYSTEM
BCM
ABS actuator and electric unit (control
unit)
(With ABS or VDC)
TCM
• Gear position signal
(A/T models)
• Output shaft revolution signal
OPERATIONAL CONDITIONS FOR 4WD MODE
4WD mode Shifting condition

2WD ⇔ 4H Shifting between the 2WD and 4H modes must be performed at speed below 100 km/h (62 MPH).
• Engine: Running (Stop the vehicle)
• Vehicle speed: 0 km/h (0 MPH)
• Clutch pedal: Depress (M/T models)
4H ⇔ 4LO
• Brake pedal: Depress
• Selector lever: N position
• Steering wheel: Straight-ahead position
NOTE:
The indicator blinks when shifting between 4H and 4LO.

SYSTEM
4WD SYSTEM : Circuit Diagram INFOID:0000000011287128
DLN
JSDIA7498GB
P
4WD SYSTEM : Fail-Safe INFOID:0000000011287130
DTC Vehicle condition

P1802 4WD mode cannot be switched by operating 4WD shift switch. (Breakdown in transfer control unit)

SYSTEM
P1804 No impact to vehicle behavior.
P1808 4WD mode cannot be switched by operating 4WD shift switch.
P180C 4WD mode cannot be switched by operating 4WD shift switch.
P180D 4WD mode cannot be switched by operating 4WD shift switch.
P180F 4WD mode cannot be switched by operating 4WD shift switch.
When malfunction occurs due to duplicate input, the control continues according to the 4WD mode priority (2WD
P1813
→ 4H → 4LO). (For malfunction with no input, 4WD mode running at the occurrence of malfunction is maintained.)
After a malfunction is confirmed, 4WD mode can be switchable. (4WD mode temporarily not switchable only during
P1814
diagnosis)
P181B 4WD mode cannot be switched by operating 4WD shift switch.
P182A
diagnosis)
U1000 4H – 4LO switching is prohibited when a malfunction occurs in communications of ECM, TCM, or BCM.
U1010 4WD mode cannot be switched by operating 4WD shift switch.
INFORMATION DISPLAY (COMBINATION METER)

INFORMATION DISPLAY (COMBINATION METER) : 4WD Warning INFOID:0000000011377224
DESIGN/PURPOSE
4WD warning is displayed when the 4WD system has a malfunction. 4WD warning indicates that the vehicle is
in fail-safe mode.
Symbol Message Condition
4WD Error
4WD system malfunction.
See Owner’s Manual
JPNIA1896ZZ
SYNCHRONIZATION WITH MASTER WARNING LAMP

Applicable
For master warning lamp, refer to MWI-52, "WARNING LAMPS/INDICATOR LAMPS : Master Warning Lamp".

SYSTEM
SYSTEM DIAGRAM
A
DLN
E
JSDIA6825GB
SIGNAL PATH
F
• The transfer control unit judges and decides a mode from among normal mode and fail-safe mode, accord-
ing to signals received from each switch, sensor, and control unit.
• The transfer control unit transmits 4WD warning signal to the combination meter via CAN communication
when judging fail-safe mode. G
• The combination meter displays 4WD warning on the information display when receiving 4WD warning sig-
nal transmitted from the transfer control unit.
WARNING CONDITION H
4WD warning is displayed when the 4WD system goes into fail-safe 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) : ATP Warning INFOID:0000000011377238
DESIGN/PURPOSE K
When the A/T shift selector is in P position, the vehicle may move if the transfer in neutral. ATP warning is dis-
played to inform this condition to the driver.
Symbol Message Condition

L
— Pull the parking brake A/T is in the parking condition and transfer gear is in the neutral.
SYNCHRONIZATION WITH MASTER WARNING LAMP M

Applicable
For master warning lamp, refer to MWI-52, "WARNING LAMPS/INDICATOR LAMPS : Master Warning Lamp".
SYSTEM DIAGRAM N
JSDIA6826GB
SIGNAL PATH
• The transfer control unit judges and decides position of A/T and transfer gear, according to signals received
from each sensor and TCM.

SYSTEM
• The transfer control unit transmits ATP warning signal to the combination meter via CAN communication
when judging A/T is in the parking condition and transfer gear is in the neutral.
• The combination meter displays ATP warning on the information display when receiving ATP warning signal
transmitted from the transfer control unit.
WARNING CONDITION
ATP warning is displayed when the A/T is in the parking condition and transfer gear is in the neutral.
WARNING CANCEL CONDITION
When any of the conditions listed below is satisfied:
• Ignition switch is in a position other than ON.
• Transfer gear is in a position other than neutral.
• A/T is in a position other than parking condition.
INFORMATION DISPLAY (COMBINATION METER) : 4WD Indicator INFOID:0000000011377225
DESIGN/PURPOSE
Design Purpose
• Displays driving conditions selected by the 4WD shift switch while engine is run-
ning. When the 4WD warning lamp is turned ON, all 4WD indicator will turn OFF.
• Indicator flashes if transfer gear does not shift completely into 4H ⇔ 4LO. In this
condition, the transfer gear may be in neutral.
JSDIA6839ZZ
WARNING/INDICATOR/CHIME LIST
WARNING/INDICATOR/CHIME LIST : Warning Lamp/Indicator Lamp INFOID:0000000011378175
Name Design Layout/Function

For layout: Refer to MWI-11, "METER SYSTEM : Design".
4WD warning lamp For function: Refer to MWI-30, "WARNING LAMPS/INDICATOR LAMPS : 4WD Warn-
ing Lamp".
ATP warning lamp* For function: Refer to MWI-33, "WARNING LAMPS/INDICATOR LAMPS : ATP Warn-
ing Lamp".
*: For A/T models only
WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display)

INFOID:0000000011378176
Name Function
Refer to DLN-26, "INFORMATION DISPLAY (COMBINATION METER) : 4WD Warn-
4WD warning
ing".
Refer to DLN-27, "INFORMATION DISPLAY (COMBINATION METER) : ATP Warn-
ATP warning*
ing".
Refer to DLN-28, "INFORMATION DISPLAY (COMBINATION METER) : 4WD Indica-
4WD indicator
tor".
*: For A/T models only

DIAGNOSIS SYSTEM (TRANSFER CONTROL UNIT)
A
CONSULT Function INFOID:0000000011256485
FUNCTION B
CONSULT can display each diagnostic item using the diagnostic test modes as follows.
Mode Function C
All DTC Reading Display all DTCs or diagnostic items that all ECUs are recording and judging.
Work Support This mode enables a technician to adjust some devices faster and more accurately.
Self Diagnostic Results Retrieve DTC from ECU and display diagnostic items. DLN
Data Monitor Monitor the input/output signal of the control unit in real time.
CAN Diagnosis This mode displays a network diagnosis result about CAN by diagram.
E
CAN Diagnosis Support Monitor It monitors the status of CAN communication.
ECU Identification Display the ECU identification number (part number etc.) of the selected system.
F
ECU IDENTIFICATION
Transfer control unit part number can be read.
SELF DIAGNOSTIC RESULT G
Refer to DLN-35, "DTC Index".
When "0" is displayed on self-diagnosis result.
• The system is presently malfunctioning. H
When except "0" is displayed on self-diagnosis result.

• System malfunction in the past is detected, but the system is presently normal.
I
NOTE:
Each time when ignition switch is turned OFF to ON, numerical number increases in 1→2→3...110→111.
When the operation number of times exceeds 111, the number do not increase and “111” is displayed until
self-diagnosis is erased*. J
*: For “U1000” and “U1010”, the maximum value is “39”.
DATA MONITOR
K
NOTE:
The following table includes information (items) inapplicable to this vehicle. For information (items) applicable
to this vehicle, refer to CONSULT display items.
L
Monitor item (Unit) Remarks
4L SWITCH [On/Off] 4WD shift switch signal (4LO) is displayed.
4H SWITCH [On/Off] 4WD shift switch signal (4H) is displayed.
M
2WD SWITCH [On/Off] 4WD shift switch signal (2WD) is displayed.

Control status of 4WD mode is displayed.
4WD MODE [BOTNG/SWTNG/2WD/4L/LOCK] N
(LOCK means 4H of 4WD mode)
IGN SW [On/Off] Ignition switch status is displayed.
MT N SW [On/Off] Park/neutral position switch status is displayed. (For M/T models) O
BRAKE SWITCH [On/Off] Stop lamp switch signal status via CAN communication line is displayed.
SLCT LVR POSI [D/N/R/P] A/T shift selector position via CAN communication line is displayed.
MODE SENSOR [On/Off] Mode sensor status is displayed. P
RANGE SENSOR 2 [On/Off] Range sensor status is displayed.
RANGE SENSOR 1 [On/Off] Range sensor status is displayed.
Control status of 4WD mode indicator lamp is displayed.
4WD MODE IND [2WD/LOCK/4L]
(LOCK means 4H of 4WD mode)
4WD FAIL LAMP [On/Off] Control status of 4WD warning lamp is displayed.

ATP IND [On/Off] Control status of ATP warning lamp is displayed.
MOTOR DRIVE A [HI/LO/PWM] Driving status of transfer motor is displayed. (Drive side)
MOTOR DRIVE B [HI/LO/PWM] Driving status of transfer motor is displayed. (Reverse side)
FLUID TEMP SE [V] This item is not equipped, but displayed.
C/U POWER SUP [V] Power supply voltage value of transfer control unit is displayed.
MOTOR POWER SUP [V] Power supply voltage value of transfer motor unit is displayed.
ROTARY POSITION SENSOR [%] Transfer rotary position sensor signal is displayed.
AT R SPEED [km/h] This item is not equipped, but displayed. (For A/T models)
COMPR VHCL SPEED [km/h] Vehicle speed calculated by transfer control unit is displayed.
VHCL/S SEN-FR [km/h] Wheel speed (front) average calculated by transfer control unit.
VHCL/S SEN-RR [km/h] Wheel speed (rear) average calculated by transfer control unit.
ENGINE SPEED SIG [rpm] Engine status via CAN communication line is displayed.
WORK SUPPORT
Function Description
RPS OFFSET LEARNING VALUE CLEAR Transfer rotary position sensor learning value is cleared.

TRANSFER CONTROL UNIT
< ECU DIAGNOSIS INFORMATION > [TRANSFER: TX91A]
ECU DIAGNOSIS INFORMATION A

Reference Value INFOID:0000000011256531
B
VALUES ON THE DIAGNOSIS TOOL

NOTE: C
Monitor item Condition Value/Status DLN

4WD shift switch: 4LO On
4L SWITCH
4WD shift switch: Except 4LO Off
E
4WD shift switch: 4H On
4H SWITCH
4WD shift switch: Except 4H Off
4WD shift switch: 2WD On F
2WD SWITCH
4WD shift switch: Except 2WD Off
4WD is booting BOTNG
G
4WD mode is switching SWTNG
4WD MODE Ignition switch: ON 4WD mode: 2WD 2WD
4WD mode: 4H LOCK H
4WD mode: 4LO 4L
Ignition switch: ON On
IGN SW I
Ignition switch: OFF Off
M/T control lever: Neutral On
MT N SW
M/T control lever: Except Neutral Off J
Brake pedal: Depressed On
BRAKE SWITCH
Brake pedal: Released Off
A/T shift selector: D D
K
A/T shift selector: N N
SLCT LVR POSI
A/T shift selector: R R L
A/T shift selector: P P
4WD shift switch: Except 2WD On
MODE SENSOR
4WD shift switch: 2WD Off M
RANGE SENSOR 2
N
RANGE SENSOR 1
4WD shift switch: 2WD 2WD O
4WD MODE IND 4WD shift switch: 4H LOCK
4WD shift switch: 4LO 4L
P
4WD warning lamp: ON On
4WD FAIL LAMP
4WD warning lamp: OFF Off
ATP warning lamp: ON On
ATP IND
ATP warning lamp: OFF Off

Monitor item Condition Value/Status
When transfer motor is driving. (100% duty controlled) HI
MOTOR DRIVE A When transfer motor is driving in reversal or stopping. LO
When transfer motor is driving. (PWM output) PWM
When transfer motor is driving in reversal. (100% duty controlled) HI
MOTOR DRIVE B When transfer motor is driving or stopping. LO
When transfer motor is driving in reversal. (PWM output) PWM
FLUID TEMP SE Always 255 V
C/U POWER SUP Ignition switch: ON Battery voltage
MOTOR POWER SUP Ignition switch: ON Battery voltage
4WD mode: 2WD 11 - 14%
ROTARY POSITION SENSOR 4WD mode: 4H 34 - 44%
4WD mode: 4LO 75 - 85%
AT R SPEED Always 255 km/h
Vehicle driving Approx. equal to the indication
CAUTION: on speedometer (inside of
COMPR VHCL SPEED Check air pressure of tire under standard condition. ±10%)
Vehicle stopped 0.00 km/h (0.00 mph)
VHCL/S SEN-FR Check air pressure of tire under standard condition. ±10%)
VHCL/S SEN-RR Check air pressure of tire under standard condition. ±10%)
Approx. equal to the indication
ENGINE SPEED SIG Engine: Running
on tachometer (inside of ±10%)
TERMINAL LAYOUT
JSDIA2078ZZ
PHYSICAL VALUES
Terminal No.
Description
(Wire color)
Condition Value (Approx.)
Input/
+ - Signal name
Output
1 Power supply (Trans-
Ground Input Always Battery voltage
(R) fer control unit)
2
Ground Ground — Always 0V
(B)
3
(B)

Terminal No.
Description
(Wire color) A
Input/
+ - Signal name
Output
4 Ignition switch: ON Battery voltage B
(W)*1 Ground Ignition switch Input
Ignition switch: OFF 0V
(B)*2
5 Ignition switch: ON 5V C
Transfer rotary posi-
(LG/Y)*1 Ground tion sensor power Output
supply Ignition switch: OFF 0V
(GR)*2
6
DLN
Transfer rotary posi-
(W/B)*1 Ground — Always 0V
tion sensor (GND)
(Y)*2
E
9 Power supply (4WD Ignition switch: ON 5V
Ground Output
(L) shift switch) Ignition switch: OFF 0V
10 Power supply (Trans- F
Ground Input Always Battery voltage
(W) fer motor)
11
Ground Motor drive A Output Transfer motor: Driving 0 V - Battery voltage
(G/R)
G
12
Ground Motor drive B Output Transfer motor: Driving 0 V - Battery voltage
(G/Y)
13 Input/ H
— CAN-H — —
(L) Output
14 Input/
— CAN-L — —
(P) Output
I
15
Rotary position sen- J
(BR/Y)*1 Ground Input Ignition switch: ON
sor input
(BR)*2
K
JPDIE0268GB
Approx. 1 V
16*3 Ground
Front revolution sen-
Input
4WD shift Vehicle speed: 30 km/h
(Voltage rises in response to ve-
(W) sor (+) switch: 4H (19 MPH) L
hicle speed.)
17*3 Ground
Front revolution sen-
— Ignition switch: ON Less than 1 V
(B) sor (-)
M
4WD shift switch: 2WD 5V
18 Ignition
Ground 4WD shift SW (2WD) Input 4WD shift switch: Except
(G) switch: ON 0V
2WD
N
4WD shift switch: 4H 5V
19 Ignition
Ground 4WD shift SW (4H) Input 4WD shift switch: Except
(BG) switch: ON 0V
4H O
4WD shift switch: 4LO 5V
20 Ignition
Ground 4WD shift SW (4LO) Input 4WD shift switch: Except
(SB) switch: ON 0V
4LO P
21 4WD shift switch: 4LO 0V
Ignition
(BR/SB)*1 Ground Range sensor 2 input Input 4WD shift switch: 4H 5V
switch: ON
(V)*2 4WD shift switch: 2WD 5V

Terminal No.
Description
(Wire color)
Input/
+ - Signal name
Output

*1 Ignition
(W/L) Ground Range sensor 1 input Input 4WD shift switch: 4H 5V
switch: ON
(W)*2 4WD shift switch: 2WD 5V

*1 Ignition
(LG/R) Ground Mode sensor input Input 4WD shift switch: 4H 0V
switch: ON
(LG)*2 4WD shift switch: 2WD 5V
M/T shift position: Neu-
24 Battery voltage
Park/neutral position Ignition tral
(G)*1 Ground Input
switch switch: ON M/T shift position: Except
(R)*2 0V
neutral
*1: LHD models
*2: RHD models
*3: Without ABS
CAUTION:
When using circuit tester to measure voltage for inspection, be sure not to extend forcibly any con-
nector terminals.
Fail-Safe INFOID:0000000011256532

P180D 4WD mode cannot be switched by operating 4WD shift switch.
P180F 4WD mode cannot be switched by operating 4WD shift switch.
When malfunction occurs due to duplicate input, the control continues according to the 4WD mode priority (2WD
P1813
→ 4H → 4LO). (For malfunction with no input, 4WD mode running at the occurrence of malfunction is maintained.)
P1814
diagnosis)
P181B 4WD mode cannot be switched by operating 4WD shift switch.
P182A
diagnosis)

A
U1000 4H – 4LO switching is prohibited when a malfunction occurs in communications of ECM, TCM, or BCM.
U1010 4WD mode cannot be switched by operating 4WD shift switch. B
DTC Inspection Priority Chart INFOID:0000000011256533
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority C
chart.
Priority DTC
Item
Reference
DLN
(CONSULT screen terms)
P1802 CONTROL UNIT 1 DLN-51
P1803 CONTROL UNIT 2 DLN-51 E
1 P1804 CONTROL UNIT 3 DLN-51
P1809 CONTROL UNIT 4 DLN-51
F
U1010 CONTROL UNIT (CAN) DLN-93
P180C SEN POWER SUPPLY (5V) DLN-54
P180F MOTOR SYSTEM DLN-59 G
2
P1819 SHIFT ACT CIR DLN-75
P181C MOTOR POWER SUPPLY DLN-80
H
P1808 VHCL SPEED SEN-ABS DLN-53
P180D ROTARY POSITION SEN DLN-56
P1811 BATTERY VOLTAGE DLN-61 I
P1813 4WD MODE SW DLN-65
P1816 T/M RANGE SENSOR A DLN-69
3 P1818 SHIFT ACT POSI SW DLN-72 J
P181B INCOMP SELF SHUT DLN-76
P1820 ENGINE SPEED DLN-82
K
P1854 VHCL SPEED SEN-FR DLN-86
P1855 VHCL SPEED SEN-RR DLN-88
U1000 CAN COMM CIRCUIT DLN-92 L
P1814 4WD DETECT SWITCH DLN-67
P1817 SHIFT ACTUATOR DLN-70
M
4 P182A HI-LO POSITION SEN DLN-83
P1867 INCOMPLETE SHIFT DLN-89
P186C INCOMP RPS OFFSET LEARNING DLN-91 N
DTC Index INFOID:0000000011256534
X: Turn ON —: Turn OFF O
DTC Display Items 4WD warning lamp ATP warning lamp*3 Reference
P1802 CONTROL UNIT 1 X — DLN-51 P
P1803 CONTROL UNIT 2 X — DLN-51
P1804 CONTROL UNIT 3 — — DLN-51
P1808 VHCL SPEED SEN-ABS X — DLN-53
P1809 CONTROL UNIT 4 X — DLN-51
P180C SEN POWER SUPPLY (5V) X — DLN-54

DTC Display Items 4WD warning lamp ATP warning lamp*3 Reference
P180D ROTARY POSITION SEN X — DLN-56
P180F MOTOR SYSTEM X — DLN-59
P1811 BATTERY VOLTAGE X — DLN-61
P1813 4WD MODE SW X — DLN-65
P1814 4WD DETECT SWITCH X — DLN-67
P1816 T/M RANGE SENSOR A X X*1 DLN-69
P1817 SHIFT ACTUATOR X — DLN-70
P1818 SHIFT ACT POSI SW X — DLN-72
P1819 SHIFT ACT CIR X — DLN-75
P181B INCOMP SELF SHUT X — DLN-76
P181C MOTOR POWER SUPPLY X — DLN-80
P1820 ENGINE SPEED X — DLN-82
P182A HI-LO POSITION SEN X X DLN-83
P1854 VHCL SPEED SEN-FR X — DLN-86
P1855 VHCL SPEED SEN-RR X — DLN-88
P1867 INCOMPLETE SHIFT — X*2 DLN-89
INCOMP RPS OFFSET
P186C X — DLN-91
LEARNING
U1000 CAN COMM CIRCUIT X — DLN-92
U1010 CONTROL UNIT (CAN) X — DLN-93
*1: When shifted to P position.
*2: When shifted to P position during the occurrence of malfunction between 4H and 4LO.
*3: Only A/T models

4WD SYSTEM
< WIRING DIAGRAM > [TRANSFER: TX91A]
WIRING DIAGRAM A
4WD SYSTEM
Wiring Diagram INFOID:0000000011106377
B
DLN
JRDWC5203GB

4WD SYSTEM
JRDWC5204GB

4WD SYSTEM
DLN
JRDWC5205GB

4WD SYSTEM
JRDWC5206GB

4WD SYSTEM
DLN
JRDWC5207GB

4WD SYSTEM
JRDWC5208GB

4WD SYSTEM
DLN
JRDWC5209GB

4WD SYSTEM
JRDWC5210GB

4WD SYSTEM
DLN
JRDWC5211GB

4WD SYSTEM
JRDWC5212GB

DIAGNOSIS AND REPAIR WORK FLOW
< BASIC INSPECTION > [TRANSFER: TX91A]
BASIC INSPECTION A
Work Flow INFOID:0000000011256694
B
DETAILED FLOW
1.INTERVIEW FROM THE CUSTOMER C
Clarify customer complaints before inspection. First of all, perform an interview utilizing DLN-48, "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 fail-safe function. Refer to DLN-34, "Fail-
Safe". 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
35, "DTC Inspection Priority Chart".
YES >> GO TO 5. N
NO >> Check harness and connectors based on the information obtained by interview. Refer to GI-47,
"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?

YES >> GO TO 7.
7.FINAL CHECK
With CONSULT
1. Check the reference value for “ALL MODE AWD/4WD”.
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:0000000011256695
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 reg-
Customer
MR/MS number istration
name
Vehicle type VIN
Storage
Engine Mileage km ( Mile)
date
Vehicle does not enter 4WD mode.
4WD warning lamp turns on.
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 Weather Fine Cloud Rain Snow Others ( )

conditions Temperature Hot Warm Cool Cold Temperature [Approx. °C ( °F)]
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)

Interview sheet
A
Registration Initial year reg-
Customer number istration
MR/MS
name
Vehicle type VIN
B
Storage
Engine Mileage km ( Mile)
date
Other conditions C
Memo
DLN

TRANSFER ROTARY POSITION SENSOR LEARNING VALUE INITIALIZATION
TRANSFER ROTARY POSITION SENSOR LEARNING VALUE INITIALIZA-
TION
Description INFOID:0000000011256696
After replacing the following parts, transfer rotary position sensor learning value stored in the transfer control
unit must be erased.
• Transfer assembly
• Transfer rotary position sensor
For how to erase the learning value, refer to DLN-50, "Work Procedure".
Work Procedure INFOID:0000000011256697
1.ERASE TRANSFER ROTARY POSITION SENSOR LEARNING VALUE

With CONSULT
1. Select “WORK SUPPORT” in “ALL MODE AWD/4WD”.
2. Perform “RPS OFFSET LEARNING VALUE CLEAR” to the CONSULT display.
>> WORK END

P1802, P1803, P1804, P1809 TRANSFER CONTROL UNIT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: TX91A]
DTC/CIRCUIT DIAGNOSIS A
DTC Description INFOID:0000000011256900
B
DTC DETECTION LOGIC

C
CONSULT screen terms
DTC DTC detecting condition
(Trouble diagnosis content)
CONTROL UNIT 1 Malfunction is detected in the memory (RAM) system of transfer control
P1802 DLN
(Control unit 1) unit.
CONTROL UNIT 2 Malfunction is detected in the memory (ROM) system of transfer control
P1803
(Control unit 2) unit.
E
CONTROL UNIT 3 Malfunction is detected in the memory (EEPROM) system of transfer con-
P1804
(Control unit 3) trol unit.
CONTROL UNIT 4
P1809 AD converter system of transfer control unit is malfunctioning. F
(Control unit 4)
POSSIBLE CAUSE
Transfer control unit G
FAIL-SAFE
P1802, P1803 H
4WD mode cannot be switched by operating 4WD shift switch. (Breakdown in transfer control unit)
P1804
No impact to vehicle behavior. I
P1809
4WD mode cannot be switched by operating 4WD shift switch.
J
DTC CONFIRMATION PROCEDURE
1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and K
wait at least 10 seconds before conducting the next test.
>> GO TO 2. L
2.DTC REPRODUCTION PROCEDURE
With CONSULT M
1. Turn the ignition switch OFF to ON.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Are DTC′s “P1802, P1803, P1804 or P1809” detected? N
YES >> Proceed to diagnosis procedure. Refer to DLN-51, "Diagnosis Procedure".
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident".
NO-2 >> Confirmation after repair: INSPECTION END
O
Diagnosis Procedure INFOID:0000000011256901
1.PERFORM SELF-DIAGNOSIS P
With CONSULT
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Turn the ignition switch OFF, and then wait 10 seconds and more.
Are DTC′s “P1802, P1803, P1804 or 1809” detected?
YES >> Replace transfer control unit. Refer to DLN-108, "Removal and Installation".

NO >> Check transfer control unit pin terminals for damage or loose connection with harness connector.
If any items are damaged, repair or replace error-detected parts.

P1808 VEHICLE SPEED SENSOR (ABS)
P1808 VEHICLE SPEED SENSOR (ABS)
A
DTC DETECTION LOGIC B

(Trouble diagnosis content) C
VHCL SPEED SEN-ABS Malfunction is detected in vehicle speed signal that is output from ABS ac-
P1808
(Vehicle speed sensor-ABS) tuator and electric unit (control unit) through CAN communication.
POSSIBLE CAUSE DLN

• Harness or connector (CAN communication line)
• ABS actuator and electric unit (control unit)
E
FAIL-SAFE
DTC CONFIRMATION PROCEDURE F
CAUTION:
Be careful of the driving speed.
1.PRECONDITIONING G
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
H
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE I
With CONSULT
1. Start the engine.
2. Drive vehicle and maintain the following conditions for 20 seconds or more. J
Vehicle speed : 30 km/h (19 MPH) or more

3. Perform self-diagnosis for “ALL MODE AWD/4WD”. K
Is DTC “P1808” detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". L
M
1.CHECK DTC OF ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
With CONSULT
N
1. Turn the ignition switch ON.
2. Perform self-diagnosis for “ABS”.
Is any DTCs detected?
O
YES >> Check DTC detected item. Refer to BRC-49, "DTC Index" (without VDC), BRC-184, "DTC Index"
(with VDC).
P

P180C SENSOR POWER SUPPLY (5V)
DTC DETECTION LOGIC

SEN POWER SUPPLY (5V)
P180C Malfunction is detected in 5V power supply circuit.
[Sensor power supply (5V)]
POSSIBLE CAUSE
• Transfer rotary position sensor 5V power supply circuit
• 4WD shift switch 5V power supply circuit
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
Is DTC “P180C” detected?
1.CHECK TRANSFER ROTARY POSITION SENSOR POWER SUPPLY

1. Turn the ignition switch OFF.
2. Connect transfer rotary position sensor harness connector.
CAUTION:
Never start the engine.
4. Check the voltage between transfer rotary position sensor harness connector and ground.
Transfer rotary position sensor

— Voltage
Connector Terminal
F40 2 Ground Approx. 5 V
Is the inspection result normal?
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK TRANSFER ROTARY POSITION SENSOR CIRCUIT
2. Disconnect transfer control unit harness connector.
3. Check the continuity between transfer control unit harness connector and transfer rotary position sensor
harness connector.

Transfer control unit Transfer rotary position sensor A

Continuity
Connector Terminal Connector Terminal
E75 (LHD
models) B
5 F40 2 Existed
M68 (RHD
models)
4. Check the continuity between transfer rotary position sensor harness connector and ground. C

— Continuity DLN
Connector Terminal
F40 2 Ground Not existed
Is the inspection result normal? E
YES >> GO TO 3.
NO >> Repair or replace error-detected parts.
3.CHECK 4WD SHIFT SWITCH POWER SUPPLY F
2. Connect 4WD shift switch harness connector.
3. Turn the ignition switch ON. G
CAUTION:
4. Check the voltage between 4WD shift switch harness connector and ground. H
4WD shift switch

— Voltage
Connector Terminal I
M1 1 Ground Approx. 5 V
J
YES >> INSPECTION END
NO >> GO TO 4.
4.CHECK 4WD SHIFT SWITCH CIRCUIT K
3. Check the continuity between transfer control unit harness connector and 4WD shift switch harness con- L
nector.
Transfer control unit 4WD shift switch M

Continuity
E75 (LHD mod-
els)
9 M1 1 Existed
N
M68 (RHD mod-
els)
4. Check the continuity between 4WD shift switch harness connector and ground. O
4WD shift switch

— Continuity
Connector Terminal P
M1 1 Ground Not existed

P180D TRANSFER ROTARY POSITION SENSOR
DTC DETECTION LOGIC

ROTARY POSITION SEN Deviation exists between actual angle detected by transfer rotary position
P180D
(Rotary position sensor) sensor and the one recognized by transfer control unit.
POSSIBLE CAUSE
• Transfer control unit
NOTE:
The transfer rotary position sensor learning value may be left unerased after the replacement of transfer
assembly or transfer rotary position sensor.
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
Is DTC “P180D” detected?
1.CHECK TRANSFER ROTARY POSITION SENSOR SIGNAL

2. Check the voltage between transfer control unit harness connector and ground.
+
Transfer rotary position sensor − Voltage
Connector Terminal
E75 (LHD mod-

els)
15 Ground
M68 (RHD mod-
els)
JPDIE0268GB

4. On CONSULT screen, select “ALL MODE AWD/4WD” >> “DATA MONITOR” >> “ROTARY POSITION
SENSOR”.

5. Check that the “ROTARY POSITION SENSOR” value.
A
Monitor Item Condition Value
4WD mode: 2WD 11 – 14%
B
ROTARY POSITION SENSOR 4WD mode: 4H 34 – 44%
4WD mode: 4LO 75 – 85%
Is the inspection result normal? C
NO >> GO TO 2.
2.CHECK TRANSFER ROTARY POSITION SENSOR POWER SUPPLY DLN

2. Disconnect transfer rotary position sensor harness connector.
3. Turn the ignition switch ON. E
CAUTION:
4. Check the voltage between transfer rotary position sensor harness connector terminals. F
+ −
Transfer rotary position sensor Voltage G
Connector Terminal
F40 2 1 Approx. 5 V
H
YES >> GO TO 4.
NO >> GO TO 3. I
3.CHECK TRANSFER ROTARY POSITION SENSOR CIRCUIT
2. Disconnect transfer control unit harness connector. J
harness connector.
K
Transfer control unit Transfer rotary position sensor
Continuity
L
E75 (LHD mod- 5 2
els)
F40 Existed
M68 (RHD mod- 6 1
els) M
4. Check the continuity between transfer rotary position sensor harness connector and ground.
Transfer rotary position sensor N

— Continuity
Connector Terminal
1
F40 Ground Not existed O
2
YES >> Replace transfer rotary position sensor. Refer to DLN-113, "Removal and Installation". P
4.CHECK TRANSFER ROTARY POSITION SENSOR SIGNAL CIRCUIT
harness connector.

Transfer control unit Transfer rotary position sensor

Continuity
E75 (LHD mod-
els)
15 F40 3 Existed
M68 (RHD mod-
els)
4. Check the continuity between transfer rotary position sensor harness connector and ground.

— Continuity
Connector Terminal

P180F MOTOR SYSTEM
P180F MOTOR SYSTEM
A

MOTOR SYSTEM
P180F Malfunction is detected in transfer motor system.
(Motor system)
POSSIBLE CAUSE DLN

• Transfer motor
• Harness or connectors (Transfer motor circuit are open or shorted) E
FAIL-SAFE
F
1.PRECONDITIONING
G
H
>> GO TO 2.
With CONSULT I
3. Turn the 4WD shift switch 2WD → 4H → 4LO. J
CAUTION:
Hold the 4WD shift switch at each position for 5 seconds or more.
K
Is DTC “P180F” detected?
L
M
1.CHECK TRANSFER MOTOR CIRCUIT
2. Disconnect transfer control unit harness connector. N
3. Disconnect transfer motor harness connector.
4. Check continuity between transfer control unit harness connector and transfer motor harness connector.
O
Transfer control unit Transfer motor
Continuity
E75 (LHD mod- 11 1 P
els)
F1 Existed
M68 (RHD mod- 12 4
els)
5. Check the continuity between transfer motor harness connector and the ground.

P180F MOTOR SYSTEM
Transfer motor
— Continuity
Connector Terminal
1
F1 Ground Not existed
4
YES >> GO TO 2.
2.CHECK TRANSFER MOTOR
Check the transfer motor. Refer to DLN-60, "Component Inspection".
YES >> Replace the transfer control unit. Refer to DLN-108, "Removal and Installation".
NO >> Replace the transfer motor. Refer to DLN-114, "Removal and Installation".
Component Inspection INFOID:0000000011375325

1. Remove transfer motor. Refer to DLN-114, "Removal and Installation".
2. Check the resistance between transfer motor terminals.
Transfer motor
Resistance
Terminal
1 4 0.25 – 0.3 Ω
NO >> Replace transfer motor. Refer to DLN-114, "Removal and Installation".

P1811 BATTERY VOLTAGE
A

BATTERY VOLTAGE Malfunction is detected in transfer control unit power supply circuit when
P1811
(Battery voltage) the engine is ON.
POSSIBLE CAUSE DLN

Harness or connector (transfer control unit power supply circuit is open or shorted)
FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE H
With CONSULT
1. Start the engine and wait for 2 seconds or more.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”. I
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". J
K
1.CHECK TRANSFER CONTROL UNIT POWER SUPPLY (1)
1. Turn the ignition switch OFF. L
M
Transfer control unit
— Voltage
Connector Terminal
E75 (LHD mod- N
els)
1 Ground Battery voltage
M68 (RHD mod-
els)
O
CAUTION:
5. Check the voltage between transfer control unit harness connector and ground. P


— Voltage
Connector Terminal
E75 (LHD mod-
els)
M68 (RHD mod-
els)
YES >> GO TO 3.
NO >> GO TO 2.
2. Check the 10A fuse (#4).
3. Disconnect fuse block (J/B) harness connector.
4. Check the continuity between transfer control unit harness connector and fuse block (J/B) harness con-
nector.
Fuse block (J/B) Transfer control unit

Continuity
E75 (LHD mod-
els)
M34 4A 1 Existed
M68 (RHD mod-
els)
5. Check the continuity between transfer control unit harness connector and the ground.

— Continuity
Connector Terminal
E75 (LHD mod-
els)
1 Ground Not existed
M68 (RHD mod-
els)
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-12, "Wiring Diagram - BAT-
TERY POWER SUPPLY -".

— Voltage
Connector Terminal
E75 (LHD mod-
els)
4 Ground Approx. 0 V
M68 (RHD mod-
els)
CAUTION:

Transfer control unit A

— Voltage
Connector Terminal
E75 (LHD mod-
els) B
M68 (RHD mod-
els)
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK TRANSFER CONTROL UNIT POWER SUPPLY (4) DLN

E
nector.
F
Continuity
G
E75 (LHD mod-
els)
E36 10F 4 Existed
M68 (RHD mod-
els) H
I
— Continuity
Connector Terminal
E75 (LHD mod- J
els)
M68 (RHD mod-
els)
K
YES >> Perform the trouble diagnosis for ignition power supply circuit. Refer to PG-56, "Wiring Diagram -
IGNITION POWER SUPPLY -".
NO >> Repair or replace error-detected parts. L
5.CHECK TRANSFER CONTROL UNIT GROUND

1. Turn the ignition switch OFF. M
Transfer control unit N

— Voltage
Connector Terminal
E75 (LHD mod- 2
els)
Ground Approx. 0 V
O
M68 (RHD mod- 3
els)
3. Check the continuity between transfer control unit harness connector and ground. P


— Continuity
Connector Terminal
E75 (LHD mod- 2
els)
Ground Existed
M68 (RHD mod- 3
els)

P1813 4WD MODE SWITCH
A

4WD MODE SW
P1813 Multiple signals received from 4WD shift switch are detected.
(4WD mode switch)
POSSIBLE CAUSE DLN

• 4WD shift switch
E
FAIL-SAFE
When malfunction occurs due to duplicate input, the control continues according to the 4WD mode priority
(2WD → 4H → 4LO). (For malfunction with no input, 4WD mode running at the occurrence of malfunction is
maintained.) F

1.PRECONDITIONING G
H
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE I
With CONSULT
2. Start the engine. J
3. Turn the 4WD shift switch 2WD → 4H → 4LO.
CAUTION:
4. Perform self-diagnosis for “ALL MODE AWD/4WD”. K
L
M
1.CHECK 4WD SHIFT SWITCH

Check 4WD shift switch. Refer to DLN-66, "Component Inspection". N
YES >> GO TO 2.
NO >> Replace 4WD shift switch. Refer to DLN-109, "Removal and Installation". O
2.CHECK 4WD SHIFT SWITCH CIRCUIT (1)
P
2. Check the continuity between transfer control unit harness connector and 4WD shift switch harness con-
nector.

Transfer control unit 4WD shift switch

Continuity
1 Not existed
3 Existed
18
5 Not existed
6 Not existed
1 Not existed
E75 (LHD
models) 3 Not existed
19 M1
M68 (RHD 5 Existed
models)
6 Not existed
1 Not existed
3 Not existed
20
5 Not existed
6 Existed
YES >> GO TO 3.
3.CHECK 4WD SHIFT SWITCH CIRCUIT (2)
Check the continuity between 4WD shift switch harness connector and ground.
4WD shift switch

— Continuity
Connector Terminal
3
6
1.CHECK 4WD SHIFT SWITCH

2. Remove 4WD shift switch. Refer to DLN-109, "Removal and Installation".
3. Check the continuity between 4WD shift switch harness connector terminals.
4WD shift switch

Condition Continuity
Terminal
4WD shift switch: 2WD Existed
1 3
4WD shift switch: 4H or 4LO Not existed
4WD shift switch: 4H Existed
1 5
4WD shift switch: 2WD or 4LO Not existed
4WD shift switch: 4LO Existed
1 6
4WD shift switch: 2WD or 4H Not existed
NO >> Replace 4WD shift switch. Refer to DLN-109, "Removal and Installation".

P1814 4WD DETECT SWITCH
A

4WD DETECT SWITCH Mode sensor detects 2WD despite 4WD recognized by transfer rotary po-
P1814
(4WD detect switch) sition sensor.
POSSIBLE CAUSE DLN

• Mode sensor
• Harness or connector (Mode sensor circuit is open or shorted)
E
FAIL-SAFE
After a malfunction is confirmed, 4WD mode can be switchable. (4WD mode temporarily not switchable only
during diagnosis)
F
1.PRECONDITIONING
G
H
>> GO TO 2.
With CONSULT I
2. Set the vehicle to 4WD and wait for 5 seconds or more.
3. Perform self-diagnosis for “ALL MODE AWD/4WD”. J
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". K
L
1.CHECK MODE SENSOR SIGNAL
2. Check the voltage between transfer control unit harness connector and ground. M

— Condition Voltage N
Connector Terminal
E75 (LHD mod- 4WD shift switch: 2WD Approx. 5 V
els)
23 Ground 4WD shift switch: 4H Approx. 0 V O
M68 (RHD mod-
els) 4WD shift switch: 4LO Approx. 0 V

P
NO >> GO TO 2.
2.CHECK MODE SENSOR CIRCUIT
3. Disconnect mode sensor harness connector.

4. Check the continuity between transfer control unit harness connector and mode sensor harness connec-
tor.
Transfer control unit Mode sensor

Continuity
E75 (LHD models)
23 F34 1 Existed
M68 (RHD models)
5. Check the continuity between mode sensor harness connector and ground.
Mode sensor
— Continuity
Connector Terminal
Is inspection result normal?
YES >> GO TO 3.
3.CHECK MODE SENSOR GROUND
Check the continuity between mode sensor harness connector and ground.
Mode sensor
— Continuity
Connector Terminal
F34 2 Ground Existed
YES >> GO TO 4.
4.CHECK MODE SENSOR
Check the mode sensor. Refer to DLN-68, "Component Inspection".
NO >> Repair mode sensor. Refer to DLN-115, "Removal and Installation".
1.CHECK MODE SENSOR

2. Remove mode sensor. Refer to DLN-115, "Removal and Installation".
3. Check the continuity between mode sensor harness connector terminals.
Mode sensor
Terminal
While pushing switch of mode sensor. Existed
1 2
Other than the above. Not existed
NO >> Replace mode sensor. Refer to DLN-115, "Removal and Installation".

P1816 TRANSMISSION RANGE SWITCH
P1816 TRANSMISSION RANGE SWITCH
A

T/M RANGE SENSOR A Malfunction is detected in shift position signal that is output from TCM
P1816
(Transmission range sensor A) through CAN communication.
POSSIBLE CAUSE DLN

• TCM
• A/T shift selector E
FAIL-SAFE
F
1.PRECONDITIONING
G
H
>> GO TO 2.
With CONSULT I
2. Shift the A/T shift selector in P position.
3. Perform self-diagnosis for “ALL MODE AWD/4WD”. J
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". K
L
1.CHECK DTC OF TCM
With CONSULT
M
2. Perform self-diagnosis for “TRANSMISSION”.
N
YES >> Check the DTC. Refer to TM-493, "DTC Index".

P1817 TRANSFER MOTOR
DTC DETECTION LOGIC

SHIFT ACTUATOR
P1817 Malfunction is detected in transfer motor.
(Shift actuator)
POSSIBLE CAUSE
• Transfer motor
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
CAUTION:
1.CHECK TRANSFER MOTOR (1)

2. Remove the transfer motor. Refer to DLN-114, "Removal and Installation".
3. Visually check transfer motor gear for damage.
YES >> GO TO 2.
2.CHECK TRANSFER MOTOR (2)
Check the transfer motor. Refer to DLN-70, "Component Inspection".
YES >> Replace the transfer assembly. Refer to DLN-125, "Removal and Installation".

2. Check the resistance between transfer motor terminals. A
Transfer motor
Resistance
Terminal B
1 4 0.25 – 0.3 Ω
NO >> Replace transfer motor. Refer to DLN-114, "Removal and Installation".
DLN

P1818 ACTUATOR POSITION SWITCH
DTC DETECTION LOGIC

SHIFT ACT POSI SW
P1818 Malfunction is detected in signal from transfer rotary position sensor.
(Shift actuator position switch)
POSSIBLE CAUSE
• Harness or connector (Transfer rotary position sensor circuit is open or shorted)
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1.CHECK TRANSFER ROTARY POSITION SENSOR POWER SUPPLY

2. Disconnect transfer rotary position sensor harness connector.
CAUTION:
4. Check the voltage between transfer rotary position sensor harness connector and ground.
+
Voltage
Transfer rotary position sensor −
(Approx.)
Connector Terminal
F40 2 Ground 5V
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK TRANSFER ROTARY POSITION SENSOR POWER SUPPLY CIRCUIT

harness connector. A
+ −
Transfer rotary position sen- B
Transfer control unit Continuity
sor
E75 (LHD
C
models)
5 F40 2 Existed
M68 (RHD
models) DLN
4. Check harness for short to ground and short to power.
YES >> Perform trouble diagnosis for transfer control unit power supply circuit. Refer to DLN-94, "Diagno- E
sis Procedure".
3.CHECK TRANSFER ROTARY POSITION SENSOR SIGNAL CIRCUIT F
3. Check the continuity between transfer control unit harness connector and transfer rotary position sensor G
harness connector.
+ − H
Transfer rotary position sen-
Transfer control unit Continuity
sor
I
E75 (LHD 6 1
models)
F40 Existed J
M68 (RHD 15 3
models)
4. Check harness for short to ground and short to power.
Is the inspection result normal? K
YES >> GO TO 4.
L
4.CHECK TRANSFER ROTARY POSITION SENSOR SIGNAL
With CONSULT
1. Reconnect all harness connectors disconnected. M
2. Turn ignition switch ON.
SENSOR”.
N
Is the indicated value “100%”?
YES >> GO TO 5.
NO >> GO TO 7.
O
5.CHECK RANGE SENSOR STATUS
With CONSULT
1. Turn ignition switch ON. P
2. On CONSULT screen, select “ALL MODE AWD/4WD” >> “DATA MONITOR” >> “RANGE SENSOR 1”
and “RANGE SENSOR 2”.
3. Check the value of “RANGE SENSOR 1” and “RANGE SENSOR 2”.
Do “RANGE SENSOR 1” and “RANGE SENSOR 2” display “ON”?
YES >> GO TO 6.
NO >> GO TO 7.

6.CHECK ACTUATOR SHAFT ACTUATION

With CONSULT
1. Turn ignition switch OFF.
3. Connect transfer motor connector.
4. Turn ignition switch ON.
SENSOR”.
6. Rotate the actuator shaft clockwise until status below.
ROTARY POSITION SENSOR : 75% – 85%

8. Install transfer motor.
NOTE:
When installing transfer motor, if there is misalignment between transfer motor axis and actuator shaft,
rotate the transfer motor axis by hand.
SENSOR”.
11. Check that the “ROTARY POSITION SENSOR” value.
Monitor Item Condition Value

4WD mode: 2WD 11 – 14%
ROTARY POSITION SENSOR 4WD mode: 4H 34 – 44%
4WD mode: 4LO 75 – 85%
NO >> GO TO 7.
7.REPLACE TRANSFER ROTARY POSITION SENSOR
Replace transfer rotary position sensor. Refer to DLN-113, "Removal and Installation".
>> INSPECTION END

P1819 ACTUATOR CIRCUIT
P1819 ACTUATOR CIRCUIT
A

SHIFT ACT CIR
P1819 Malfunction is detected in transfer motor circuit.
(Shift actuator circuit)
POSSIBLE CAUSE DLN

Harness or connectors
(Transfer motor circuit is open or shorted.)
E
FAIL-SAFE
1.PRECONDITIONING
G
>> GO TO 2. H
With CONSULT
1. Turn ignition switch ON. I
YES >> Proceed to diagnosis procedure. Refer to DLN-75, "Diagnosis Procedure". J
K
1.CHECK TRANSFER MOTOR CIRCUIT L

2. Disconnect transfer control unit harness connector and transfer motor harness connector.
3. Check the continuity between transfer control unit harness connector and transfer motor harness connec-
tor. M
+ −
N
Transfer control unit Transfer motor Continuity
E75 (LHD 11 1 O
models)
F1 Existed
M68 (RHD 12 4
models)
P
4. Check harness for short to power, short to ground, and short to each circuit.

P181B INCOMPLETE SELFSHUT
DTC DETECTION LOGIC

INCOMP SELF SHUT
P181B After ignition switch OFF, transfer control unit cannot perform self-shut.
(Incomplete self-shut)
POSSIBLE CAUSE
• Harness or connector (transfer control unit power supply circuit is open or shorted)
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Turn the ignition switch OFF and wait for 2 seconds or more.
Is DTC “P181B” detected?


— Voltage
Connector Terminal
E75 (LHD mod-
els)
M68 (RHD mod-
els)
CAUTION:


— Voltage
Connector Terminal
E75 (LHD mod-
els) B
M68 (RHD mod-
els)
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK TRANSFER CONTROL UNIT POWER SUPPLY (2) DLN

E
nector.
F
Continuity
G
E75 (LHD mod-
els)
M34 4A 1 Existed
M68 (RHD mod-
els) H
I
— Continuity
Connector Terminal
E75 (LHD mod- J
els)
M68 (RHD mod-
els)
K
NO >> Repair or replace error-detected parts. L

Transfer control unit N

— Voltage
Connector Terminal
E75 (LHD mod-
els)
O
M68 (RHD mod-
els)
3. Turn the ignition switch ON. P
CAUTION:


— Voltage
Connector Terminal
E75 (LHD mod-
els)
M68 (RHD mod-
els)
YES >> GO TO 5.
NO >> GO TO 4.
nector.

Continuity
E75 (LHD mod-
els)
E36 10F 4 Existed
M68 (RHD mod-
els)

— Continuity
Connector Terminal
E75 (LHD mod-
els)
M68 (RHD mod-
els)

— Voltage
Connector Terminal
E75 (LHD mod- 2
els)
Ground Approx. 0 V
M68 (RHD mod- 3
els)
3. Check the continuity between transfer control unit harness connector and ground.


— Continuity
Connector Terminal
E75 (LHD mod- 2
els) B
Ground Existed
M68 (RHD mod- 3
els)
YES >> Replace the transfer control unit. Refer to DLN-108, "Removal and Installation".
DLN

P181C TRANSFER MOTOR POWER SUPPLY
DTC DETECTION LOGIC

MOTOR POWER SUPPLY When starting the engine, abnormality is detected in power source of trans-
P181C
(Motor power supply) fer motor.
POSSIBLE CAUSE
Malfunction of transfer control actuator (transfer motor) power supply circuit
FAIL-SAFE
Switching drive mode by 4WD shift switch operation is prohibited.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1. Start the engine and wait for 2 seconds or more.
1.CHECK TRANSFER MOTOR POWER SUPPLY


— Voltage
Connector Terminal
E75 (LHD mod-
els)
M68 (RHD mod-
els)
CAUTION:


— Voltage
Connector Terminal
E75 (LHD mod-
els) B
M68 (RHD mod-
els)
NO >> GO TO 2.
2.DETECT MALFUNCTIONING ITEM DLN
Check the following.

• Harness for short or open between battery positive terminal and transfer control unit harness connector ter-
E
minal 10. Refer to PG-12, "Wiring Diagram - BATTERY POWER SUPPLY -".
• Battery
• 30A fusible link (#L). Refer to PG-148, "Fuse and Fusible Link Arrangement".
Is the inspection result normal? F
G

P1820 ENGINE SPEED SIGNAL
P1820 ENGINE SPEED SIGNAL
DTC DETECTION LOGIC

ENGINE SPEED SIG Malfunction is detected in engine speed signal that is output from ECM
P1820
(Engine speed signal) through CAN communication.
POSSIBLE CAUSE
• ECM
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Drive vehicle and maintain the following conditions for 30 seconds or more.
Vehicle speed : More than 20 km/h (12 MPH)

1.CHECK DTC OF ECM

With CONSULT
2. Perform self-diagnosis for “ENGINE”.
YES >> Check DTC detected item. Refer to EC-485, "DTC Index" (YD25DDTi), EC-858, "YS23DDT :
DTC Index" (YS23DDT), EC-886, "YS23DDTT : DTC Index" (YS23DDTT).

P182A TRANSFER HI-LO POSITION SENSOR
A

HI-LO POSITION SEN
P182A When deviated from position pattern of range sensor.
(High-low position sensor)
POSSIBLE CAUSE DLN

• Range sensor
• Harness or connector (Range sensor circuit is open or shorted)
E
FAIL-SAFE
After a malfunction is confirmed, 4WD mode can be switchable. (4WD mode temporarily not switchable only
during diagnosis)
F
1.PRECONDITIONING
G
H
>> GO TO 2.
With CONSULT I
3. Turn the 4WD shift switch 2WD → 4H → 4LO. J
CAUTION:
K
Is DTC “P182A” detected?
L
M
1.CHECK RANGE SENSOR SIGNAL
2. Check the voltage between transfer control unit harness connector and ground. N

— Condition Voltage
Connector Terminal O
4WD shift switch: 2WD Approx. 5 V
21 4WD shift switch: 4H Approx. 5 V
E75 (LHD mod- P
els) 4WD shift switch: 4LO Approx. 0 V
Ground
M68 (RHD mod- 4WD shift switch: 2WD Approx. 5 V
els)
22 4WD shift switch: 4H Approx. 5 V
4WD shift switch: 4LO Approx. 0 V

NO >> GO TO 2.
2.CHECK RANGE SENSOR CIRCUIT
3. Disconnect range sensor harness connector.
4. Check the continuity between transfer control unit harness connector and range sensor harness connec-
tor.
Transfer control unit Range sensor

Continuity
E75 (LHD models) 21 1

F38 Existed
M68 (RHD models) 22 2
5. Check the continuity between mode sensor harness connector and ground.
Range sensor
— Continuity
Connector Terminal
1
F38 Ground Not existed
2
YES >> GO TO 3.
3.CHECK RANGE SENSOR GROUND
Check the continuity between mode sensor harness connector and ground.
Range sensor
— Continuity
Connector Terminal
F38 3 Ground Existed
YES >> GO TO 4.
4.CHECK RANGE SENSOR
Check the range sensor. Refer to DLN-84, "Component Inspection".
NO >> Repair range sensor. Refer to DLN-116, "Removal and Installation".
1.CHECK RANGE SENSOR

2. Remove range sensor. Refer to DLN-116, "Removal and Installation".
3. Check the continuity between range sensor harness connector terminals.
Range sensor
Terminal
While pushing switch of range sensor. Existed
1 3
While pushing switch of range sensor. Existed
2 3

YES >> INSPECTION END A
NO >> Replace range sensor. Refer to DLN-116, "Removal and Installation".
DLN

P1854 VEHICLE SPEED SENSOR (FR)
DTC DETECTION LOGIC

VHCL SPEED SEN-FR • Malfunction is detected in front revolution sensor.
P1854
(Vehicle speed sensor-front) • Improper signal is input while driving.
POSSIBLE CAUSE
• Front revolution sensor
• Harness or connectors (Front revolution sensor circuit are open or shorted)
FAIL-SAFE
CAUTION:
1.PRECONDITIONING
>> GO TO 2.
With CONSULT

1.CHECK FRONT REVOLUTION SENSOR CIRCUIT

3. Disconnect front revolution sensor harness connector.
4. Check continuity between transfer control unit harness connector and front revolution sensor harness
connector.
Transfer control unit Front revolution sensor

Continuity
E75 (LHD mod- 16 1
els)
F52 Existed
M68 (RHD mod- 17 2
els)
5. Check the continuity between front revolution sensor harness connector and the ground.

Front revolution sensor A

— Continuity
Connector Terminal
1
F52 Ground Not existed B
2
YES >> GO TO 2. C
2.CHECK FRONT REVOLUTION SENSOR
DLN
Check front revolution sensor. Refer to DLN-87, "Component Inspection".
YES >> Replace the transfer control unit. Refer to DLN-108, "Removal and Installation". E
NO >> Replace the front revolution sensor. Refer to DLN-117, "Removal and Installation".
F
1.CHECK FRONT REVOLUTION SENSOR
2. Disconnect front revolution sensor harness connector. G
3. Check the resistance between front revolution sensor harness connector terminals.
Front revolution sensor H

Resistance (Approx.)
Terminal
1 2 1.3 – 1.5 kΩ
I
NO >> Replace front revolution sensor. Refer to DLN-117, "Removal and Installation". J

P1855 VEHICLE SPEED SENSOR (RR)
P1855 VEHICLE SPEED SENSOR (RR)
DTC DETECTION LOGIC

VHCL SPEED SEN-RR Malfunction is detected in vehicle speed signal that is output from combi-
P1855
(Vehicle speed sensor-rear) nation meter through CAN communication.
POSSIBLE CAUSE
• Combination meter
FAIL-SAFE
CAUTION:
1.PRECONDITIONING
>> GO TO 2.
With CONSULT

1.CHECK SPEEDOMETER
Drive the vehicle and check speedometer operation.
Is the speedometer operation normal?
YES >> GO TO 2.
NO >> Perform the symptom diagnosis for speedometer. Refer to MWI-278, "Diagnosis Procedure".
2.CHECK COMBINATION METER
Perform the trouble diagnosis of combination meter. Refer to MWI-91, "WITH COLOR INFORMATION DIS-
PLAY : On Board Diagnosis Function" (with color information display), MWI-93, "WITH MONOCHROME
INFORMATION DISPLAY : On Board Diagnosis Function" (with monochrome information display).

P1867 INCOMPLETE SHIFT
A

INCOMPLETE SHIFT
P1867 Malfunction is detected in transfer shift function.
(Incomplete Shift)
POSSIBLE CAUSE DLN

• Transfer motor
E
FAIL-SAFE
No impact to vehicle behavior.
1.PRECONDITIONING
G
>> GO TO 2. H
With CONSULT
1. Turn the ignition switch OFF. I
3. Turn the 4WD shift switch 2WD ⇔ 4H ⇔ 4LO.
CAUTION: J
Is DTC “P1867” detected? K
L
1.CHECK TRANSFER MOTOR CIRCUIT M

3. Disconnect transfer motor harness connector. N
4. Check the continuity between transfer control unit harness connector and transfer motor harness connec-
tor.
O
Transfer control unit Transfer motor
Continuity
E75 (LHD mod- 11 4 P
els)
F1 Not existed
M68 (RHD 12 1
models)
YES >> GO TO 2.

2.CHECK DTC
Perform the “DTC CONFIRMATION PROCEDURE”. Refer to DLN-89, "DTC Description".
YES >> Replace the transfer assembly. Refer to DLN-125, "Removal and Installation".

P186C INCOMP RPS OFFSET LEARNING
P186C INCOMP RPS OFFSET LEARNING
A

INCOMP RPS OFFSET LEARNING When turning the ignition switch ON, rotary position sensor
P186C
(Incomplete rotary position sensor offset learning) offset value memorized by transfer control unit is abnormal.
POSSIBLE CAUSE DLN

FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
With CONSULT
K
1.REPLACE THE TRANSFER CONTROL UNIT
Replace the transfer control unit. Refer to DLN-108, "Removal and Installation". L
>> WORK END

M

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 Transfer control unit is not transmitting/receiving CAN communication sig-
U1000
(CAN communication circuit) nal for 2 seconds or more.
POSSIBLE CAUSE
• CAN communication error
• Each control unit
FAIL-SAFE
4H – 4LO switching is prohibited when a malfunction occurs in communications of ECM, TCM, or BCM.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
Is DTC “U1000” detected?
Proceed to LAN-34, "Trouble Diagnosis Flow Chart".

U1010 CONTROL UNIT (CAN)
A

CONTROL UNIT (CAN) Detecting error during the initial diagnosis of CAN controller of transfer con-
U1010
[Control unit (CAN)] trol unit.
POSSIBLE CAUSE DLN

FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
With CONSULT
K
1.CHECK TRANSFER CONTROL UNIT
Check transfer control unit harness connector for disconnection and deformation. L
NO >> Repair or replace error-detected parts. M

POWER SUPPLY AND GROUND CIRCUIT


— Voltage
Connector Terminal
E75 (LHD mod-
els)
M68 (RHD mod-
els)
CAUTION:

— Voltage
Connector Terminal
E75 (LHD mod-
els)
M68 (RHD mod-
els)
YES >> GO TO 3.
NO >> GO TO 2.
nector.

Continuity
E75 (LHD mod-
els)
M34 4A 1 Existed
M68 (RHD mod-
els)

— Continuity
Connector Terminal
E75 (LHD mod-
els)
M68 (RHD mod-
els)

3.CHECK TRANSFER CONTROL UNIT POWER SUPPLY (3) A

B

— Voltage
Connector Terminal C
E75 (LHD mod-
els)
M68 (RHD mod-
els)
DLN

CAUTION:
E

F
— Voltage
Connector Terminal
E75 (LHD mod-
G
els)
M68 (RHD mod-
els)
H
YES >> GO TO 5.
NO >> GO TO 4.
I
2. Check the 10A fuse (#33). J
nector.
K

Continuity
Connector Terminal Connector Terminal L
E75 (LHD mod-
els)
E36 10F 4 Existed
M68 (RHD mod-
els) M
N
— Continuity
Connector Terminal
E75 (LHD mod- O
els)
M68 (RHD mod-
els)
P


— Voltage
Connector Terminal
E75 (LHD mod- 2
els)
Ground Approx. 0 V
M68 (RHD mod- 3
els)
3. Check the continuity between transfer control unit harness connector and ground.

— Continuity
Connector Terminal
E75 (LHD mod- 2
els)
Ground Existed
M68 (RHD mod- 3
els)

PARK/NEUTRAL POSITION SWITCH
A
Component Function Check INFOID:0000000011378347
1.CHECK 4WD SYSTEM B

CAUTION:
Never drive the vehicle. C
2. Turn the 4WD shift switch 4H ⇔ 4LO.
3. Check the 4WD shift switch position and the indication of the 4WD indicator mutually coincide. Refer to
DLN-28, "INFORMATION DISPLAY (COMBINATION METER) : 4WD Indicator".
DLN
NO >> GO TO 2. E
2. CHECK 4WD WARNING LAMP
Check 4WD warning lamp.
Is 4WD warning lamp turned ON? F
YES >> Perform diagnosis of 4WD system. Refer to DLN-47, "Work Flow".
NO >> Proceed to diagnosis procedure. Refer to DLN-97, "Diagnosis Procedure".
G
1.CHECK PARK/NEUTRAL POSITION SWITCH POWER SUPPLY (1) H

2. Disconnect park/neutral position switch harness connector.
3. Turn the ignition switch ON. I
4. Check the voltage between park/neutral position sensor harness connector and ground.
+ J
Park/neutral position switch − Voltage
Connector Terminal
F35 1 Ground Battery voltage K
YES >> GO TO 3. L
NO >> GO TO 2.
2.CHECK PARK/NEUTRAL POSITION SWITCH POWER SUPPLY (2)
3. Disconnect IPDM E/R harness connector.
4. Check the continuity between IPDM E/R harness connector and park/neutral position switch harness con- N
nector.
IPDM E/R Park/neutral position switch

Continuity O
E60 13 F35 1 Existed
5. Check the continuity between IPDM E/R harness connector and ground P
IPDM E/R
— Continuity
Connector Terminal
E60 13 Ground Not existed

3.CHECK PARK/NEUTRAL POSITION SWITCH
Check park/neutral position switch. Refer to DLN-98, "Component Inspection".
YES >> GO TO 4.
NO >> Replace park/neutral position switch. Refer to TM-25, "Removal and Installation".
4.CHECK PARK/NEUTRAL POSITION SENSOR CIRCUIT
2. Check the continuity between park/neutral position switch harness connector and transfer control unit har-
ness connector.
Park/neutral position switch Transfer control unit

Continuity
E75 (LHD mod-
els)
F35 2 24 Existed
M68 (RHD mod-
els)
3. Check the continuity between park/neutral position switch harness connector and ground
Park/neutral position switch

— Continuity
Connector Terminal
YES >> Check intermittent incident. Refer to GI-47, "Intermittent Incident".
1.CHECK PARK/NEUTRAL POSITION SWITCH

1. Disconnect park/neutral position switch harness connector.
2. Check the continuity between park/neutral position switch harness connector terminals.
Park/neutral position switch Condition Continuity

Control lever in neutral position Existed
1 2
Control lever in except neutral position Not existed
Is the inspection results normal?
NO >> Replace park/neutral position switch. Refer to TM-25, "Removal and Installation".

4WD WARNING LAMP
4WD WARNING LAMP
A
1.CHECK 4WD WARNING LAMP FUNCTION B

Check that 4WD warning lamp turns ON until the engine started.
C
NO >> Proceed diagnosis procedure. Refer to DLN-99, "Diagnosis Procedure".
DLN
1.CHECK DTC OF TRANSFER CONTROL UNIT

With CONSULT E
Is any DTCs detected? F
YES >> Check DTC detected item. Refer to DLN-35, "DTC Index".
NO >> GO TO 2.
2.CHECK DIFFERENTIAL LOCK INDICATOR LAMP SIGNAL G
With CONSULT
CAUTION: H
Stop the vehicle.
2. Check “4WD FAIL LAMP” in “DATA MONITOR” for “ALL MODE AWD/4WD”.
Does the item on “DATA MONITOR” indicate “Off”? I
YES >> Check input/output signals of combination meter. Refer MWI-102, "Reference Value" (with Intelli-
gent Key system), MWI-113, "EXCEPT BCM FUNCTION : Reference Value" (color display mod-
els without Intelligent Key), MWI-147, "EXCEPT BCM FUNCTION : Reference Value" J
(monochrome information display models without Intelligent Key).
NO >> Replace transfer control unit. Refer to DLN-108, "Removal and Installation".
K

4WD INDICATOR
4WD INDICATOR
1.CHECK 4WD INDICATOR FUNCTION

1. Start the engine
CAUTION:
Never drive the vehicle.
3. Check the 4WD shift switch position and the indication of the 4WD indicator mutually coincide. Refer to
DLN-28, "INFORMATION DISPLAY (COMBINATION METER) : 4WD Indicator".
NO >> Proceed to diagnosis procedure. Refer to DLN-100, "Diagnosis Procedure".

With CONSULT
NO >> GO TO 2.
2.CHECK PARK/NEUTRAL POSITION SWITCH (M/T MODELS)
Check the park/neutral position switch. Refer to DLN-97, "Diagnosis Procedure".
YES >> GO TO 3.
NO >> Replace the park/neutral position switch. Refer to TM-25, "Removal and Installation".
3.CHECK 4WD INDICATOR SIGNAL
With CONSULT
CAUTION:
Never drive the vehicle.
3. Check “4WD MODE IND” of CONSULT “DATA MONITOR” for “ALL MODE AWD/4WD”.
Monitor item Condition Status

4WD shift switch: 2WD 2WD
4WD MODE IND 4WD shift switch: 4H LOCK
4WD shift switch: 4LO 4L
YES >> Check input/output signals of combination meter. Refer MWI-102, "Reference Value" (with Intelli-
gent Key system), MWI-113, "EXCEPT BCM FUNCTION : Reference Value" (color display mod-
els without Intelligent Key), MWI-147, "EXCEPT BCM FUNCTION : Reference Value"
(monochrome information display models without Intelligent Key).
NO >> Replace transfer control unit. Refer to DLN-108, "Removal and Installation".

HEAVY TIGHT-CORNER BRAKING SYMPTOM OCCURS
< SYMPTOM DIAGNOSIS > [TRANSFER: TX91A]
SYMPTOM DIAGNOSIS A
HEAVY TIGHT-CORNER BRAKING SYMPTOM OCCURS
B
Heavy tight-corner braking symptom may occur depending on driving conditions (4WD mode is 4H and 4LO).
This is not malfunction.
NOTE: C
• Light tight-corner braking symptom may occur depending on driving conditions. This is not malfunction.
• 4WD warning lamp may blink.
DLN

4WD MODE DOES NOT CHANGE
4WD MODE DOES NOT CHANGE
Vehicle does not enter 4-wheel drive mode even though 4WD warning lamp turned to OFF.

With CONSULT
NO >> GO TO 2.
2.CHECK INFORMATION DISPLAY (COMBINATION METER)
NO >> Repair or replace the error-detected parts.

4WD INDICATOR CONTINUES BLINKING
4WD INDICATOR CONTINUES BLINKING
A
After shift the 4WD mode 4H to 4L, 4WD indicator continues to blink. B
1.CHECK OPERATION CONDITION OF 4WD MODE C

2. Shift the 4WD mode depending on operation condition. Refer to DLN-23, "4WD SYSTEM : System
Description". DLN
Does the 4WD indicator stop to blink?
NO >> GO TO 2. E
2.CHECK 4WD INDICATOR LAMP
Check 4WD indicator function. Refer to DLN-100, "Component Function Check". F
YES >> GO TO 3.
NO >> Proceed to diagnosis procedure. Refer to DLN-100, "Diagnosis Procedure". G
With CONSULT
H
I
NO >> Transfer assembly is mechanical malfunction. Replace transfer assembly. Refer to DLN-125,
"Removal and Installation".
J

4WD WARNING LAMP BLINKS SLOWLY
4WD WARNING LAMP BLINKS SLOWLY
4WD warning lamp blinks at approximately 2 seconds intervals while driving.

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.TERMINAL INSPECTION
Check intermittent incident. Refer to GI-47, "Intermittent Incident".

ATP WARNING LAMP DOES NOT TURN ON
ATP WARNING LAMP DOES NOT TURN ON
A
ATP warning lamp does not turn ON when 4WD shift switch from 4H to 4LO or 4LO to 4H with A/T selector B
lever in P position.
C
With CONSULT
1. Turn the ignition switch ON. DLN
YES >> Check DTC detected item. Refer to DLN-35, "DTC Index". E
NO >> GO TO 2.
2.CHECK COMBINATION METER F
G
NO >> Repair or replace the error-detected parts. H

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000011257028
Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If nec-
essary, repair or replace these parts.
Front oil seal: DLN-110, "Exploded View"

Rear oil seal: DLN-112, "Exploded View"
DLN-107, "Inspection"
—
Reference
TRANSFER FLUID (Level too high)

TRANSFER FLUID (Level low)
TRANSFER CASE (Damaged)

BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
LIQUID GASKET (Damaged)
TRANSFER FLUID (Wrong)
GEAR (Worn or damaged)

SUSPECTED PARTS
(Possible cause)
Noise 1 2 3 3 3
Symptom
Transfer fluid leakage 4 1 2 2 3
NOTE:
When transfer inner parts are malfunction, replace transfer assembly.

TRANSFER FLUID
< PERIODIC MAINTENANCE > [TRANSFER: TX91A]
PERIODIC MAINTENANCE A
TRANSFER FLUID
Inspection INFOID:0000000011257051
B
FLUID LEAKAGE
Check transfer surrounding area (oil seal, drain plug, and filler plug etc.) for fluid leakage. C
FLUID LEVEL
1. Remove filler plug . Then check that fluid is filled up from
mounting hole for the filler plug. DLN
CAUTION:
Never start engine while checking fluid level.
2. Apply sealant to thread of filler plug, and install it on transfer and E
then tighten to the specified torque.
CAUTION:
Remove old sealant adhering to thread of filler plug. F
Specified torque : 20.5 N·m (2.1 kg-m, 15 ft-lb)

JSDIA6719ZZ
Sealant : Hylomar 102 silicone or equivalent G
Draining INFOID:0000000011257052
H
1. Stop the engine.
2. Remove the drain plug transfer fluid.
3. Apply sealant to thread of drain plug, and install it to transfer and I
tighten to the specified torque.
CAUTION:
Remove old sealant adhering to thread of drain plug.
J

Sealant : Hylomar 102 silicone or equivalent K
JSDIA6720ZZ
Refilling INFOID:0000000011257053
L
1. Remove filler plug . Fill up with new transfer fluid up to mount-

ing hole for the filler plug. M
Recommended fluid : Refer to MA-32, "Fluids and Lu-

and capacity bricants". N
CAUTION:
Carefully fill the fluid. (Fill up for approximately 3 minutes.)
2. Leave the vehicle for 3 minutes, and check the fluid level again. O
3. Apply sealant to thread of filler plug, and install it on transfer and
tighten to the specified torque. JSDIA6719ZZ
CAUTION: P
Remove old sealant adhering to thread of filler plug.

Sealant : Hylomar 102 silicone or equivalent

< REMOVAL AND INSTALLATION > [TRANSFER: TX91A]
REMOVAL AND INSTALLATION

Exploded View INFOID:0000000011274905
JSDIA6721GB

: Vehicle front
: N·m (kg-m, in-lb)
Removal and Installation INFOID:0000000011257060
REMOVAL
2. Disconnect negative battery terminal.
3. Remove glove box cover. Refer to IP-14, "Removal and Installation" (LHD models), IP-39, "Removal and
Installation" (RHD models).
5. Remove transfer control unit.
INSTALLATION
Install in the reverse order of removal.

4WD SHIFT SWITCH
4WD SHIFT SWITCH
A
REMOVAL B
1. Remove cluster lid C lower (4WD models). Refer to IP-14, "Removal and Installation" (LHD models), IP-
39, "Removal and Installation" (RHD models).
2. Disconnect the 4WD shift switch connector. C
3. Remove the 4WD shift switch.
INSTALLATION DLN
E
INSPECTION AFTER INSTALLATION
Check that the actual 4WD mode and the indication of the 4WD indicator mutually coincide when the 4WD
shift switch is switched to each position. F

FRONT OIL SEAL
FRONT OIL SEAL
JSDIA6731GB
O-ring Front companion flange Front oil seal

Transfer assembly
: Always replace after every disassembly.
: N·m (kg-m, ft-lb)
: Apply transfer fluid.
REMOVAL
1. Remove the drain plug to drain the transfer fluid. Refer to DLN-107, "Draining".
2. Remove the front propeller shaft. Refer to DLN-133, "Removal and Installation".
3. Remove self-lock nut of companion flange with a flange wrench (commercial service tool).
4. Remove the O-ring.
5. Put a matching mark on top of the front drive shaft in line with
the mark on the front companion flange.
CAUTION:
Use paint to make the matching mark on the front drive
companion. Never damage the front drive shaft.
6. Remove the front companion flange, using suitable tool.
7. Remove front oil seal.
CAUTION:
Never damage the front case.
SDIA2779E
INSTALLATION

FRONT OIL SEAL
1. Install front oil seal with a drift (commercial service tool) until the
end face of front case. A
CAUTION:
• Never reuse front oil seal.
• Apply transfer fluid onto circumference of oil seal.
B
JSDIA6763ZZ
DLN
2. Align the matching mark of the front drive shaft with the match-
ing mark of the front companion flange, then install the front
companion flange. E
CAUTION:
Never damage the front oil seal lip.
3. Install the O-ring to gap between front companion flange and F
front drive shaft.
CAUTION:
• Never reuse the O-ring.
• Never damage the O-ring. G
4. Tighten the self-lock nut to specified torque. SDIA2779E
CAUTION:
Never reuse self-lock nut. H
5. Install front propeller shaft. Refer to DLN-133, "Removal and Installation".
6. Fill with new transfer fluid, check fluid level and for fluid leakage. Refer to DLN-107, "Inspection".
I
INSPECTION AFTER INSTALLATION J

Check fluid leakage and the fluid level. Refer to DLN-107, "Inspection".

REAR OIL SEAL
REAR OIL SEAL
JSDIA6734ZZ
Transfer assembly Rear oil seal

: Apply transfer fluid.
REMOVAL
1. Remove the drain plug to drain the transfer fluid. Refer to DLN-107, "Draining".
2. Remove the rear propeller shaft. Refer to DLN-155, "Removal and Installation".
3. Remove the rear oil seal.
CAUTION:
Never damage extension case and main shaft.
INSTALLATION
1. Install front oil seal with a drift (SST: KV40104710) until the end
face of front case.
CAUTION:
• Never reuse rear oil seal.
• Apply transfer fluid onto circumference of oil seal.
2. Install the rear propeller shaft. Refer to DLN-155, "Removal and
Installation".
JSDIA6764ZZ


TRANSFER ROTARY POSITION SENSOR
TRANSFER ROTARY POSITION SENSOR
A
DLN
G
JSDIA6725GB
Transfer assembly Transfer rotary position sensor

H

I
REMOVAL
1. Turn the ignition switch OFF. J
3. Disconnect the transfer rotary position sensor connector.
4. Remove the transfer rotary position sensor. K
INSTALLATION
Installation is in the reverse order of removal.
CAUTION: L
Never damage the O-ring of transfer rotary position sensor.
Inspection and Adjustment INFOID:0000000011257059
M

N
ADJUSTMENT AFTER INSTALLATION
When replacing transfer rotary position sensor, clear the transfer rotary position sensor learning value stored
in transfer control unit. Refer to DLN-50, "Description". O

TRANSFER MOTOR
TRANSFER MOTOR
JSDIA6722GB
Transfer assembly Transfer motor

REMOVAL
3. Disconnect the transfer motor connector.
4. Remove the transfer motor.
INSTALLATION
Note the following, and install in the reverse order of removal.
• When installing transfer motor, if there is misalignment between transfer motor axis and actuator shaft, rotate
the transfer motor axis by hand.
• Never damage the O-ring of transfer motor when install transfer motor.


MODE SENSOR
MODE SENSOR
A
DLN
G
JSDIA6723GB
Mode sensor Transfer assembly

H

I
REMOVAL
1. Turn the ignition switch OFF. J
3. Separate the front propeller shaft assembly and transfer assembly. Refer to DLN-133, "Removal and
Installation". K
4. Separate the rear propeller shaft assembly and transfer assembly. Refer to DLN-155, "Removal and
Installation".
5. Support transfer assembly and transmission assembly with a jack. L
6. To tilt the transfer assembly and transmission assembly downward, remove parts interrupting the work.
7. Lower jack to the position where the mode sensor can be removed.
8. Disconnect the mode sensor connector. M
9. Remove the mode sensor.
INSTALLATION N
CAUTION:
Never damage the O-ring of mode sensor.
O
INSPECTION AFTER INSTALLATION P


RANGE SENSOR
RANGE SENSOR
JSDIA6724GB
Transfer assembly Range sensor

REMOVAL
3. Separate the front propeller shaft assembly and transfer assembly. Refer to DLN-133, "Removal and
Installation".
4. Separate the rear propeller shaft assembly and transfer assembly. Refer to DLN-155, "Removal and
Installation".
5. Support transfer assembly and transmission assembly with a jack.
6. To tilt the transfer assembly and transmission assembly downward, remove parts interrupting the work.
7. Lower jack to the position where the range sensor can be removed.
8. Disconnect the range sensor connector.
9. Remove the range sensor.
INSTALLATION
CAUTION:
Never damage the O-ring of range sensor.


FRONT REVOLUTION SENSOR
FRONT REVOLUTION SENSOR
A
DLN
JSDIA7260GB
Transfer assembly Front revolution sensor G

H
REMOVAL I
3. Disconnect front revolution sensor connector. J
4. Remove front revolution sensor.
INSTALLATION
K
CAUTION:
Never damage the O-ring of front revolution sensor.
L
INSPECTION AFTER INSTALLATION M


VEHICLE SPEED SENSOR
VEHICLE SPEED SENSOR
NOTE:
The vehicle speed sensor is equipped for models without ABS.
JSDIA7479GB
Transfer assembly Vehicle speed sensor

: N·m (kg-m, it-lb)
NOTE:
REMOVAL
1. Disconnect vehicle speed sensor harness connector.
2. Remove vehicle speed sensor.
INSTALLATION
CAUTION:
Never damage the O-ring of vehicle speed sensor.
NOTE:

AIR BREATHER
AIR BREATHER
A
YD25DDTi
YD25DDTi : Exploded View INFOID:0000000012032412
B
M/T models
DLN
JSDIA6736GB
H
Air breather hose A Hose clip Hose connector
Bracket Air breather hose B Transfer assembly
To breather tube I
A/T models J
O
JSDIA7502ZZ
Air breather hose A Hose connector Hose clip P

Air breather hose B Transfer assembly
To breather tube
YD25DDTi : Removal and Installation INFOID:0000000012032413
REMOVAL

AIR BREATHER
Refer to the exploded view for air breather hose removal information.
INSTALLATION
M/T Models
• Set air breather hose with the paint mark facing upward.
• Be sure to insert air breather hose to air breather tube until hose
end reaches the tube bend R portion.
JSDIA6767ZZ
JSDIA6768ZZ
• Set air breather hose with the paint mark facing backward.
: Vehicle front
end reaches the end of tube.
JSDIA6769ZZ
• When inserting air breather hose A and air breather hose B to

hose connector , be sure to insert it fully until its reaches the
stop.
CAUTION:
Align paint marks on each air breather hose.
JSDIA6823ZZ
A/T Models

AIR BREATHER
• Be sure to insert air breather hose to air breather tube until hose A
end reaches the tube bend R portion.
JSDIA6711ZZ
DLN
G
JSDIA6712ZZ
H
• Set air breather hose with the paint mark facing backward.
: Vehicle front
I
end reaches the end of tube.
J
K
JSDIA6713ZZ

L
stop.
CAUTION:
Align paint marks on each air breather hose. M
JSDIA6823ZZ
O
YS23DDT, YS23DDTT

AIR BREATHER
YS23DDT, YS23DDTT : Exploded View INFOID:0000000012032419
M/T models
JSDIA6736GB
Air breather hose A Hose clip Hose connector

Bracket Air breather hose B Transfer assembly
To breather tube
A/T models
JSDIA7502ZZ
Air breather hose A Hose connector Hose clip

Air breather hose B Transfer assembly
To breather tube
YS23DDT, YS23DDTT : Removal and Installation INFOID:0000000012032420
REMOVAL
Refer to the exploded view for air breather hose removal information.
INSTALLATION
M/T Models

AIR BREATHER
• Be sure to insert air breather hose to breather tube (transmis- A
sion side) until hose end reaches the spool part of tube.
- Set air breather hose with the paint mark facing upward.
B
JSDIA7452ZZ DLN
• Set air breather hose to hose clips with the paint mark fac-
ing upward. E
JSDIA7453ZZ
H
• Be sure to insert air breather hose to air breather tube (transfer
side) until hose end reaches the end of tube.
- Set air breather hose with the paint mark facing backward. I
: Vehicle front
J
K
JSDIA6769ZZ
• When inserting air breather hose A and air breather hose B to L

stop.
CAUTION: M
JSDIA6823ZZ
O
A/T Models
P

AIR BREATHER
• Be sure to insert air breather hose to breather tube (transmis-
sion side) until hose end reaches the spool part of tube.
- Set air breather hose with the paint mark facing upward.
JSDIA7454ZZ
• Set air breather hose to clip part with the paint mark facing
upward.
JSDIA7455ZZ
• Be sure to insert air breather hose to air breather tube (transfer

side) until hose end reaches the end of tube.
- Set air breather hose with the paint mark facing backward.
: Vehicle front
JSDIA6713ZZ

stop.
CAUTION:
JSDIA6823ZZ

TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: TX91A]
UNIT REMOVAL AND INSTALLATION A

TRANSFER ASSEMBLY
B
DLN
JSDIA6737GB
H
Transfer assembly
I
REMOVAL J
1. Remove rear propeller shaft. Refer to DLN-155, "Removal and Installation".

2. Remove front propeller shaft. Refer to DLN-133, "Removal and Installation". K
3. Disconnect transfer motor, transfer rotary position sensor, mode sensor, and range sensor harness con-
nectors and separate harnesses from transfer assembly.
4. Disconnect front revolution sensor and vehicle speed sensor harness connectors and separate harnesses L
from transfer assembly. (Without ABS)
5. Remove transfer breather hose. Refer to DLN-119, "YD25DDTi : Removal and Installation" (YD25DDTi),
DLN-122, "YS23DDT, YS23DDTT : Removal and Installation" (YS23DDT/YS23DDTT).
M
6. Remove exhaust front tube. (YD25DDTi) Refer to EX-16, "Removal and Installation".
7. Remove bracket of DPF rear side. (YS23DDT/YS23DDTT) Refer to EM-171, "Removal and installation".
8. Remove main muffler. Refer to EX-16, "Removal and Installation" (YD25DDTi), EX-10, "Removal and N
Installation" (YS23DDT/YS23DDTT).
9. Support transfer assembly and transmission assembly with a jack.
CAUTION: O
Secure transfer assembly and transmission assembly to a jack.
10. Remove transmission cross member and engine mounting insulator (rear). Refer to EM-384, "Removal
and Installation" (YD25DDTi), EM-212, "Removal and Installation" (YS23DDT/YS23DDTT).
P
11. Lower jack to the position where the top transfer mounting bolts can be removed.
12. Remove transfer mounting bolts and separate transfer from transmission.
CAUTION:
Secure transfer assembly and transmission assembly to a jack.
INSTALLATION

TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: TX91A]
• When installing the transfer to the transmission, install the mount-
ing bolts following the standard below, tighten bolts to the specified
torque.
Bolt symbol
Insertion direction Transfer to transmission Transmission to transfer
JSDIA6766ZZ
Inspection and Adjustment INFOID:0000000011310707

ADJUSTMENT AFTER INSTALLATION
When replacing transfer assembly, clear the transfer rotary position sensor learning value stored in transfer
control unit. Refer to DLN-50, "Description".

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [TRANSFER: TX91A]
SERVICE DATA AND SPECIFICATIONS (SDS) A

General Specifications INFOID:0000000011257131
B
Axle 4WD
C
Applied model Engine YD25DDTi YS23DDT/YS23DDTT
Transmission M/T A/T M/T A/T
Transfer model TX91A DLN
4H 1.000
Gear ratio
4LO 2.717
E
Fluid capacity Refer to MA-32, "Fluids and Lubricants".

PRECAUTIONS
< PRECAUTION > [FRONT PROPELLER SHAFT: 2F1310]
PRECAUTION
PRECAUTIONS


SEF289H
NOTE:
NOTE:
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON
NOTE:
NOTE:
The removal of 12V battery may cause a DTC detection error.
Service Notice or Precautions for Propeller Shaft INFOID:0000000011105135
• Replace the propeller shaft if there is a breakage or deflection on tube.

• Never hit the tube or apply an impact on it during repair service. Never damage the tube as well.

< SYSTEM DESCRIPTION > [FRONT PROPELLER SHAFT: 2F1310]
B
PART OF JOINT
Universal Type (Solid Type) C
DLN
JSDIA4709ZZ
F

Symptom
Reference
×: Applicable
Revision: 2015 March

< SYMPTOM DIAGNOSIS >
Noise
Shake
Vibration
Possible cause and SUSPECTED PARTS
NVH Troubleshooting Chart
SYMPTOM DIAGNOSIS
Uneven rotating torque DLN-131, "Inspection"
×
×
Center bearing improper installation —
×
×
×
Excessive center bearing axial end play —
×
×
Center bearing mounting (insulator) cracks, damage or deterioration —
×
×
DLN-130
Excessive joint angle DLN-131, "Inspection"
×
×
×
Rotation imbalance DLN-131, "Inspection"
×
×
Excessive runout DLN-131, "Inspection"
×
×
DIFFERENTIAL NVH of FRONT and 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.
×
×
×
[FRONT PROPELLER SHAFT: 2F1310]
INFOID:0000000011105137
D23
FRONT PROPELLER SHAFT
< PERIODIC MAINTENANCE > [FRONT PROPELLER SHAFT: 2F1310]
B
LOOSENESS OF CONNECTED PART

Check each fixing bolt and nut for looseness using torque wrench. For each tightening torque, refer to DLN- C
132, "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 extremely. If the joint has a malfunction, remove
propeller shaft and perform inspection.
E
MAA0555D G
APPEARANCE AND NOISE
Check propeller shaft tube surface for dents or cracks. If malfunction is detected, replace propeller shaft
assembly. H
VIBRATION
If vibration is present at high speed, adjust the propeller shaft phase first.
I
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 companion flange and propeller J
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-136, "Inspec-
tion".
K

< REMOVAL AND INSTALLATION > [FRONT PROPELLER SHAFT: 2F1310]

REMOVAL
JSDIA6648GB
Propeller shaft assembly
: Vehicle front
DISASSEMBLY
JSDIA6649ZZ
Snap ring Journal bearing Journal

Flange yoke Propeller shaft tube
: Select with proper thickness.

: Apply multi-purpose grease.
NOTE:

Replace , , and as a set.
A
REMOVAL B
1. Shift transmission to the neutral position, and then release parking brake.
2. Put matching marks on propeller shaft flange yoke and trans-
fer companion flange. C
CAUTION:
For matching mark, use paint. Never damage propeller shaft
flange yoke and transfer companion flange.
DLN
JSDIA6659ZZ
F
3. Put matching marks on propeller shaft flange yoke and final
drive companion flange.
CAUTION:
For matching mark, use paint. Never damage propeller shaft G
flange yoke and final drive companion flange.
4. Remove propeller shaft assembly fixing bolts and nuts, and sep-
arate propeller shaft assembly from transfer companion flange H
and final drive companion flange.
5. Remove propeller shaft assembly.
6. Perform inspection after removal. Refer to DLN-136, "Inspec- I
JSDIA6660ZZ
tion".
INSTALLATION
J
• For non-reusable parts, refer to DLN-132, "Exploded View".
• For each tightening torque, refer to DLN-132, "Exploded View".
• After tightening the bolts and nuts to the specification torque, K
check that the bolts on propeller shaft flange yoke are tight-
ened as shown in the figure.
L
JSDIA6650ZZ
N
• Align matching marks to install propeller shaft flange yoke and

final drive companion flange. O
JSDIA6660ZZ

• Align matching marks to install propeller shaft flange yoke and
transfer companion flange.
JSDIA6659ZZ
• If propeller shaft or final drive has been replaced, connect them as follows:
- Install propeller shaft while aligning matching mark of propel-
ler shaft with matching mark of final drive on the joint as close
as possible.
NOTE:
Matching mark is has been painted in either position.
• Perform inspection after installation. Refer to DLN-136, "Inspec-
tion".
JSDIA6651ZZ
Disassembly and Assembly INFOID:0000000011117350
DISASSEMBLY
1. Put matching marks on propeller shaft tube and flange yoke as
shown.
CAUTION:
For matching mark, use paint. Never damage the surface.
SPD128
2. Remove snap rings .
JSDIA6658ZZ

3. Push out and remove journal bearings by lightly tapping the bot-
tom of yoke with a copper hammer. A
CAUTION:
Never damage journal and yoke hole.
4. Disassemble journal and flange yoke from propeller shaft tube. B
PDA0034D
DLN
ASSEMBLY
1. Set journal into yoke.
CAUTION:
E
• Never reuse journal.
• Always replace journal, journal bearing, and snap rings as a set.
2. Install journal bearings using a vise.
CAUTION: F
• Never reuse journal bearing.
• Always replace journal, journal bearing, and snap rings as
a set. G
• Apply multi-purpose grease to journal bearing.
• Never damage journal bearing and yoke part.
• During assembly, use caution so that the bearings never
H
fall down.
JSDIA0370ZZ
I
3. Install snap rings .
CAUTION:
• Never reuse snap ring. J
a set.
4. Measure journal axial play. If necessary, select the appropriate K
snap rings and replace them.
a. While pushing with 98 N·m (10 kg-m, 72 ft-lb), check the play in
an axial direction of the journal. L
JSDIA6658ZZ
Journal axial play : Refer to DLN-138, "Journal".
b. If journal axial play is outside the specification, use thicker/thinner snap rings to adjust. M
CAUTION:
Select snap rings with a difference in thickness at both sides within 0.02 mm (0.0008 in). For
selecting snap ring, refer to the latest parts information. N
5. Check that the journal moves smoothly and is below the joint
flex torque specification.
O
Joint flex torque : Refer to DLN-138, "Journal".
NOTE:
The joint flex torque may not be satisfied soon after the assem-
P
bly.
SDIA0856J

INSPECTION AFTER REMOVAL

Appearance
assembly.
Propeller Shaft Runout
Check propeller shaft runout at several points with a dial indicator. If
runout exceeds specifications, replace propeller shaft assembly.
Propeller shaft runout : Refer to DLN-138, "Propeller

Shaft Tube".
SPD106
• Propeller shaft runout measuring point

- Measuring points are in the range .
: Front side
Dimension
A : 125 mm (4.92 in)
JSDIA6661ZZ
Journal Axial Play

As shown in the figure, while fixing yoke on one side, check axial
play of joint. If the journal axial play exceeds the specification, repair
or replace the journal parts.
PDA0005D
Joint Flex Torque

Check that the journal moves smoothly and is below the joint flex
torque specification. If the joint flex torque exceeds the specification,
repair or replace the journal parts.
SDIA0856J

After assembly, perform a driving test to check propeller shaft vibration. If vibration occurred, separate propel-
ler shaft from final drive. Reinstall companion flange by changing the phase between companion flange and A
propeller shaft by the one bolt hole at a time. Then perform driving test and check propeller shaft vibration
again at each point.
B
DLN

< SERVICE DATA AND SPECIFICATIONS (SDS) [FRONT PROPELLER SHAFT: 2F1310]

YD25DDTi MODELS
Axle 4WD
Applied model
Transaxle M/T A/T
Propeller shaft model 2F1310
Number of joints 2
1st joint Universal (Solid type)
Joint type
2nd joint Universal (Solid type)
Transfer side Flange type
Coupling method
Front final drive side Flange type
Shaft length (Spider to spider) 708.1 mm (27.88 in)
Shaft outer diameter 63.5 mm (2.500 in)
YS23DDT AND YS23DDTT MODELS
Axle 4WD
Applied model
Transaxle M/T A/T
Propeller shaft model 2F1310
Number of joints 2
Joint type
Transfer side Flange type
Coupling method
Front final drive side Flange type
Shaft length (Spider to spider) 708.1 mm (27.88 in) 662.1 mm (26.07 in)
Propeller Shaft Tube INFOID:0000000011105143
Item Standard
Propeller shaft runout 0.6 mm (0.024 in) or less
Journal INFOID:0000000011105144
Item Standard
Journal axial play 0.02 mm (0.0008 in) or less
Joint flex torque 2.26 N·m (0.23 kg-m, 20 in-lb) or less

PRECAUTIONS
< PRECAUTION > [REAR PROPELLER SHAFT: 3S1330]
PRECAUTION A
PRECAUTIONS
B
• Never disconnect battery terminal while engine is running. C
• For vehicles with the engine listed below, remove the battery termi- DLN

E
F
SEF289H
G
NOTE:
H
NOTE:
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF. I
- Driving for 30 minutes or more on a steep slope. J
NOTE:
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon- K
NOTE: L
M
N

< SYSTEM DESCRIPTION > [REAR PROPELLER SHAFT: 3S1330]
SYSTEM DESCRIPTION
PART OF JOINT
Universal Type (Solid Type)
JSDIA4709ZZ

Symptom
Reference
×: Applicable

Noise
Shake
Vibration
SYMPTOM DIAGNOSIS
×
×
Center bearing improper installation DLN-143, "Exploded View"
×
×
×
Excessive center bearing axial end play DLN-142, "Inspection"
×
×
Center bearing mounting (insulator) cracks, damage or deterioration DLN-146, "Inspection"
×
×
DLN-141
×
×
×
×
×
×
×
DIFFERENTIAL NVH of REAR FINAL DRIVE in this section.
×
×
×
×
×
×
×
×
×
DRIVE SHAFT NVH in RAX section.
×
×
×
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
×
×
×
×
×
[REAR PROPELLER SHAFT: 3S1330]
INFOID:0000000010587341
D23
I
L
F
P
K
E
B
A
N
H
C
O
G
M
DLN
REAR PROPELLER SHAFT
< PERIODIC MAINTENANCE > [REAR PROPELLER SHAFT: 3S1330]
PERIODIC MAINTENANCE

Check each fixing bolt and nut for looseness using torque wrench. For each tightening torque, refer to DLN-
Move the joint of propeller shaft up and down and from side to side
MAA0555D
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
bearing has no backlash. If the bearing has a malfunction, remove
MAA0005D

• Check propeller shaft tube surface for dents or cracks. If malfunction is detected, replace propeller shaft
assembly.
• If center bearing is noisy or damaged, replace propeller shaft assembly.
VIBRATION
shaft at final drive companion flange; then change the phase between companion flange and propeller
tion".

< REMOVAL AND INSTALLATION > [REAR PROPELLER SHAFT: 3S1330]
REMOVAL AND INSTALLATION A

B
REMOVAL
C
DLN
JSDIA5789GB
H
: Vehicle front
I
J
DISASSEMBLY
JSDIA7261ZZ

Propeller shaft (1st shaft) Snap ring Journal bearing

Sleeve yoke (A/T) Journal Propeller shaft (2nd shaft)
Flange yoke Sleeve yoke (M/T)
: Vehicle front
REMOVAL
1. Shift the transmission to the neutral position, and then release the parking brake.
2. Put matching mark on rear propeller shaft flange yoke and
final drive companion flange.
CAUTION:
flange and final drive companion flange.
JPDID0207ZZ
3. Remove center bearing mounting bracket fixing nuts ( ).

4. Remove propeller shaft assembly fixing bolts.
5. Remove propeller shaft assembly from vehicle.
CAUTION:
Never damage rear oil seal of transmission.
6. Perform inspection after removal. Refer to DLN-146, "Inspec-
tion".
JSDIA5793ZZ
INSTALLATION
• Never damage the rear oil seal lip when installing rear propeller shaft to transmission assembly.
• Align matching mark to install propeller shaft flange yoke and
JPDID0207ZZ
• If propeller shaft assembly or final drive assembly has been replaced, connect them as follows:

1. Install propeller shaft while aligning its matching mark of
propeller shaft with the matching mark of final drive on the A
joint as close as possible.
2. Tighten the fixing bolts and nuts to the specified torque.
B
JSDIA5792ZZ
DLN
• Perform inspection after installation. Refer to DLN-146, "Inspection".
E
DISASSEMBLY
1. Put a matching mark between propeller shaft and flange yoke
and remove snap rings . F
CAUTION:
G
JSDIA0369ZZ
I
2. Lightly tap bottom of yoke using a copper hammer and remove
journal bearing.
CAUTION: J
Never damage the yoke.
L
PDA0034D
ASSEMBLY M
1. Install journal bearing to journal.
CAUTION:
• Never reuse journal and journal bearing.
N
2. Install bearing using a vise.
CAUTION: O
Never damage bearing or flange yoke.
JSDIA0370ZZ

3. Install journal to propeller shaft.
JSDIA6783ZZ
4. Install snap ring .

CAUTION:
• Never reuse snap ring.
a set.
JPDID0374ZZ

NOTE:
The joint flex torque may not be satisfied soon after the assem-
bly.
6. Check the journal axial play. Refer to DLN-146, "Inspection".
SDIA0856J

Appearance
assembly.
Propeller Shaft Runout
Propeller shaft runout : Refer to DLN-149, "Pro-

peller Shaft Tube".
JSDIA0193ZZ
Journal Axial Play

As shown in the figure, while fixing yoke on one side, check axial
play of joint. If the journal axial play exceeds the specification, repair A
Journal axial play : Refer to DLN-149, "Journal". B
PDA0005D
DLN
Joint Flex Torque
repair or replace the journal parts. E

F
G
SDIA0856J
Center Bearing H
Check center bearing for noise and damage. If malfunction is detected, replace propeller shaft assembly.
CAUTION:
Never disassemble center bearing.
I
ler shaft from final drive. Reinstall companion flange by changing the phase between companion flange and J
K

< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR PROPELLER SHAFT: 3S1330]

General Specification INFOID:0000000010588270
QR25DE MODELS
Axle 2WD
Applied model
Transmission M/T A/T
Propeller shaft model 3S1330
Number of joints 3
Joint type 2nd joint Universal (Solid type)
3rd joint Universal (Solid type)
Transmission side Sleeve type
Coupling method
Rear final drive side Flange type
1st shaft (Spider to spider) 788.9 mm (31.06 in) 829.9 mm (32.67 in)
Shaft length
2nd shaft (Spider to spider) 880.8 mm (34.68 in)
1st shaft 76.2 mm (3.000 in)
Shaft outer diameter
2nd shaft 76.2 mm (3.000 in)
YD25DDTi MODELS
Axle 2WD
Applied model
Number of joints 3
Coupling method
1st shaft (Spider to spider) 788.9 mm (31.06 in) 829.9 mm (32.67 in)
Shaft length
1st shaft 76.2 mm (3.000 in)
2nd shaft 76.2 mm (3.000 in)
Axle 2WD
Applied model
Number of joints 3
Coupling method

Axle 2WD
Applied model A
1st shaft (Spider to spider) 788.9 mm (31.06 in) 888.9 mm (35.00 in) B
Shaft length
1st shaft 76.2 mm (3.000 in)
2nd shaft 76.2 mm (3.000 in) C
DLN
Unit: mm (in)
Item Standard
Propeller shaft runout 0.6 (0.024) or less E
F
Item Standard
Journal axial play 0.02 mm (0.0008 in) or less
G
Propeller shaft joint flex effort 2.26 N·m (0.23 kg-m, 20 in-lb) or less

PRECAUTIONS
< PRECAUTION > [REAR PROPELLER SHAFT: 2S1330]
PRECAUTION
PRECAUTIONS


SEF289H
NOTE:
NOTE:
NOTE:
NOTE:


< SYSTEM DESCRIPTION > [REAR PROPELLER SHAFT: 2S1330]
B
PART OF JOINT
Universal Type (Solid Type) C
DLN
JSDIA4709ZZ
F

Symptom
Reference
×: Applicable

Noise
Shake
Vibration
SYMPTOM DIAGNOSIS
×
×
Center bearing improper installation —
×
×
×
Excessive center bearing axial end play —
×
×
Center bearing mounting (insulator) cracks, damage or deterioration —
×
×
DLN-152
×
×
×
×
×
×
×
DIFFERENTIAL NVH of FRONT and REAR FINAL DRIVE in this section.
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
[REAR PROPELLER SHAFT: 2S1330]
INFOID:0000000010588298
D23
< PERIODIC MAINTENANCE > [REAR PROPELLER SHAFT: 2S1330]
B

Check each fixing bolt and nut for looseness using torque wrench. For each tightening torque, refer to DLN- C
Move the joint of propeller shaft up and down and from side to side DLN
E
MAA0555D G
assembly. H
VIBRATION
I
shaft at final drive companion flange; then change the phase between companion flange and propeller J
tion".
K


REMOVAL
JSDIA5795GB
: Vehicle front

DISASSEMBLY
JSDIA7262ZZ

Propeller shaft tube Snap ring Journal bearing A

Sleeve yoke Journal Flange yoke
: Vehicle front B
C
REMOVAL DLN
1. Shift the transmission to the neutral position, and then release the parking brake.
2. Put matching mark on rear propeller shaft flange yoke and
final drive companion flange. E
CAUTION:
flange and final drive companion flange. F
3. Remove propeller shaft assembly fixing bolts.
4. Remove propeller shaft assembly from vehicle.
CAUTION: G
Never damage rear oil seal of transmission.
5. Perform inspection after removal. Refer to DLN-157, "Inspec-
JPDID0207ZZ
tion". H
INSTALLATION
• For non-reusable parts, refer to DLN-154, "Exploded View". I
• Never damage the rear oil seal lip when install rear propeller shaft to transfer assembly.
• Align matching mark to install propeller shaft flange yoke and J
JPDID0207ZZ
M
• If propeller shaft assembly or final drive assembly has been replaced, connect them as follows:
1. Install propeller shaft while aligning its matching mark of N
propeller shaft with the matching mark of final drive on the
joint as close as possible.
2. Tighten bolts and nuts to the specified torque. O
tion".
P
JSDIA5792ZZ
DISASSEMBLY

1. Put a matching mark between propeller shaft and flange yoke
and remove snap rings .
CAUTION:
JSDIA0369ZZ
2. Lightly tap bottom of yoke using a copper hammer and remove

journal bearing.
CAUTION:
Never damage the yoke.
PDA0034D
ASSEMBLY
1. Install journal bearing to journal.
CAUTION:
• Never reuse journal and journal bearing.
2. Install bearing using a vise.
CAUTION:
Never damage bearing or flange yoke.
JSDIA0370ZZ
3. Install journal to propeller shaft.
JSDIA6783ZZ

4. Install snap ring .
CAUTION: A
• Never reuse snap ring.
a set.
B
JPDID0374ZZ
DLN
E
NOTE:
The joint flex torque may not be satisfied soon after the assem- F
bly.
6. Check the journal axial play. Refer to DLN-157, "Inspection".
G
SDIA0856J
H
Appearance I
assembly.
Propeller Shaft Runout J
K
Propeller shaft runout : Refer to DLN-159, "Pro-
peller Shaft Tube".
L
M
JSDIA0083ZZ
Journal Axial Play

As shown in the figure, while fixing yoke on one side, check axial N
play of joint. If the journal axial play exceeds the specification, repair
O
PDA0005D
Joint Flex Torque

repair or replace the journal parts.
SDIA0856J

ler shaft from final drive. Reinstall companion flange by changing the phase between companion flange and


General Specification INFOID:0000000010588303
B
YD25DDTi MODELS
C
Axle 4WD
Applied model
Propeller shaft model 2S1330 DLN
Number of joints 2
Joint type E
Transfer side Sleeve type
Coupling method
Rear final drive side Flange type F
Shaft length (Spider to spider) 1289.0 mm (50.75 in)
G
Axle 4WD
Applied model H
Number of joints 2 I
Joint type
J
Transfer side Sleeve type
Coupling method
Shaft length (Spider to spider) 1313.0 mm (51.69 in) 1348.0 mm (53.07 in) K

L
Unit: mm (in)
Item Standard
M
Propeller shaft runout 1.02 (0.0402) or less
N
Item Standard
Journal axial play 0.02 mm (0.0008 in) or less O
Propeller shaft joint flex effort 2.26 N·m (0.23 kg-m, 20 in-lb) or less

PRECAUTIONS
< PRECAUTION > [FRONT FINAL DRIVE: R180A]
PRECAUTION
PRECAUTIONS


SEF289H
NOTE:
NOTE:
NOTE:
NOTE:
Service Notice or Precautions for Front Final Drive INFOID:0000000011105146
• Use recommended gear oil only, refer to MA-32, "Fluids and Lubricants".
certain they never interfere with the function of the parts when applied.
• Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
• Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of
the unit, preventing them from entering into the unit during disassembly or assembly.
with a new ones if necessary.
• Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
ening sequence is specified, observe it.
• When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
• Always use shop paper for cleaning the inside of components.
• Never use cotton gloves or shop rags to prevent entering of lint.

PRECAUTIONS
< PRECAUTION > [FRONT FINAL DRIVE: R180A]
• 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. A
DLN

PREPARATION
< PREPARATION > [FRONT FINAL DRIVE: R180A]
PREPARATION
PREPARATION
Tool number
Description
Tool name
KV10111100 Removing carrier cover
Seal cutter
S-NT046
ST30720000 • Installing side oil seal

Drift • Installing front oil seal
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ZZA0811D
ST27863000 • Installing side oil seal

Drift • Installing front oil seal
a: 74.5 mm (2.933 in) dia.
b: 62.5 mm (2.461 in) dia.
ZZA1003D
ST33200000 • Removing and installing mounting insulator

Drift • Installing pinion front bearing inner race
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
ZZA1002D
ST33051001 Removing side bearing inner race

Puller
PDIA0747J
ST33061000 Removing and installing side bearing inner

Base race
a: 28.5 mm (1.122 in) dia.
b: 38 mm (1.50 in) dia.
ZZA0969D

PREPARATION
Tool number
Description
Tool name A
KV10112100 Tightening the drive gear mounting bolt
Angle wrench
B
C
ZZA0120D
ST33230000 Installing side bearing inner race

Drift DLN
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28 mm (1.10 in) dia.
E
ZZA1046D
F
ST3127S000 Measuring pinion bearing preload and total
Preload gauge preload
H
ZZA0806D
KV38100200 Installing pinion front bearing outer race

Drift
a: 65 mm (2.56 in) dia. I
b: 49 mm (1.93 in) dia.
ZZA1143D
ST30613000 Installing pinion rear bearing outer race K

Drift
a: 72 mm (2.83 in) dia.
b: 48 mm (1.89 in) dia.
L
ZZA1000D M
ST30611000 Installing pinion rear bearing outer race
Drift bar (Use with ST30613000)
N
O
S-NT090

PREPARATION
Tool number
Description
Tool name
ST30901000 Installing pinion rear bearing inner race
Drift
a: 79 mm (3.11 in) dia.
b: 45 mm (1.77 in) dia.
c: 35.2 mm (1.386 in) dia.
ZZA0978D
KV381054S0 Removing front oil seal

Puller
ZZA0601D

Oil seal remover • Removing side oil seal
• Removing front oil seal
JSDIA4998ZZ
Sliding hammer Removing differential assembly
NT125
Pin punch Removing and installing lock pin

a: 4.5 mm (0.177 in) dia.
NT410
Flange wrench Removing and installing drive pinion lock nut
NT035

PREPARATION
A
Puller Removing companion flange
C
ZZA0119D
Separator Removing pinion rear bearing inner race
DLN
ZZA0700D
Sealant or/and Lubricant INFOID:0000000011105149 F
Item Use G
Genuine Liquid Gasket
Application to mating surface of carrier cover
(Three Bond 1217 or equivalent)
Genuine High Strength Thread Locking Sealant
Application into the thread hole of drive gear
H
(Loctite 270 or equivalent)
Red lead or equivalent Checking tooth contact
I

< SYSTEM DESCRIPTION > [FRONT FINAL DRIVE: R180A]
SYSTEM DESCRIPTION
PDIA0695E
Side shaft Side shaft bearing Side gear

Drive gear Pinion mate shaft Differential case
Side bearing Pinion mate gear Drive pinion
Collapsible spacer Companion flange Pinion front bearing
Pinion rear bearing Housing spacer

Symptom
Reference
×: Applicable

Noise
SYMPTOM DIAGNOSIS
Gear tooth rough DLN-192, "Inspection", DLN-200, "Inspection"
×
Gear contact improper DLN-188, "Adjustment"
DLN-167
Tooth surfaces worn DLN-192, "Inspection", DLN-200, "Inspection"
×
Backlash incorrect DLN-188, "Adjustment"
×
Companion flange excessive runout DLN-199, "Adjustment"
×
Gear oil improper DLN-168, "Inspection"
×
PROPELLER SHAFT NVH of FRONT and REAR PROPELLER SHAFT in this section.
×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections.
×
×
×
×
×
× STEERING NVH in ST section.
[FRONT FINAL DRIVE: R180A]
INFOID:0000000011105152
D23
I
L
F
P
K
E
B
A
N
H
C
O
G
M
DLN
FRONT DIFFERENTIAL GEAR OIL
< PERIODIC MAINTENANCE > [FRONT FINAL DRIVE: R180A]
FRONT DIFFERENTIAL GEAR OIL
OIL LEAKAGE
Make sure that oil is not leaking from final drive assembly or around it.
OIL LEVEL
1. Check oil level from filler plug mounting hole as shown in the fig-
ure after removing filler plug and gasket from final drive
assembly.
CAUTION:
Turn the ignition switch OFF while checking oil level.
• Oil level should be level with bottom of filler plug mounting
hole. Add gear oil if necessary. Refer to DLN-168, "Refilling".
2. Set a gasket on filler plug and install it on final drive assembly.
CAUTION:
Never reuse gasket.
3. Tighten filler plug to the specified torque. Refer to DLN-182, JSDIA6672ZZ
"Exploded View".

2. Remove drain plug and gasket.
3. Drain gear oil.
4. Set a gasket on drain plug and install it to final drive assembly.
CAUTION:
Never reuse gasket.
5. Tighten drain plug to the specified torque. Refer to DLN-182,
"Exploded View".
JSDIA6671ZZ
1. Remove filler plug and gasket. Then fill with new gear oil until
oil level reaches the specified level near filler plug mounting
hole.
Recommended : Refer to MA-32, "Fluids and Lubri-

oil and capacity cants".
2. Set a gasket on filler plug, and install it to final drive assembly.
CAUTION:
Never reuse gasket.
3. Tighten filler plug to the specified torque. Refer to DLN-182, JSDIA6672ZZ
"Exploded View".

FRONT OIL SEAL
< REMOVAL AND INSTALLATION > [FRONT FINAL DRIVE: R180A]

FRONT OIL SEAL
B
DLN
JSDIA6684GB
G
Drive pinion lock nut Companion flange Front oil seal

H
Front final drive assembly
Oil seal lip
: N·m (kg-m, ft-lb) I

: Apply gear oil.
J
*: Apply anti-corrosion oil.
K
REMOVAL L
CAUTION:
Verify identification stamp of replacement frequency put in the lower part of gear carrier to determine
replacement for collapsible spacer when replacing front oil seal. Refer to “Identification stamp of
replacement frequency of front oil seal”. If collapsible spacer replacement is necessary, remove final M
drive assembly and disassemble it to replace front oil seal and collapsible spacer. Refer to DLN-194,
"Disassembly and Assembly".
NOTE: N
The reuse of collapsible spacer is prohibited in principle. However, it is reusable on a one-time basis
only in cases when replacing front oil seal.
Identification stamp of replacement frequency of front oil seal O

FRONT OIL SEAL
• The diagonally shaded area in the figure shows stamping point for
replacement frequency of front oil seal.
• The following table shows if collapsible spacer replacement is
needed before replacing front oil seal.
When collapsible spacer replacement is required, disassemble
final drive assembly to replace collapsible spacer and front oil seal.
Refer to DLN-194, "Disassembly and Assembly".
Stamp Collapsible spacer replacement

No stamp Not required
PDIA1001E
“0” or “0” on the far right of stamp Required
“01” or “1” on the far right of stamp Not required
CAUTION:
Make a stamping after replacing front oil seal.
• After replacing front oil seal, make a stamping on the stamping point in accordance with the table below in
order to identify replacement frequency.
CAUTION:
Make a stamping from left to right.
Stamp before stamping Stamping on the far right Stamping

No stamp 0 0
“0”
1 01
(Front oil seal was replaced once.)
“01”
0 010
(Collapsible spacer and front oil seal were replaced last time.)
“0” is on the far right.
1 ...01
(Only front oil seal was replaced last time.)
0 ...010
1. Make a judgment if a collapsible spacer replacement is required.
2. Drain gear oil. Refer to DLN-168, "Draining".
3. Remove both front drive shafts. Refer to FAX-25, "Removal and Installation".
4. Remove front propeller shaft. Refer to DLN-133, "Removal and Installation".
5. Measure the total preload with the preload gauge (A) (SST:
ST3127S000).
NOTE:
Record the total preload torque measurement.
PDIA1002E

FRONT OIL SEAL
6. While holding companion flange with the flange wrench (com-
mercial service tool), remove drive pinion lock nut. A
PDIA1004E
DLN
7. Put matching mark on the end of the drive pinion. The match-
ing mark should be in line with the matching mark on com-
panion flange . E
CAUTION:
For matching mark, use paint. Never damage companion
flange and drive pinion.
F
G
JSDIA0038ZZ
8. Remove companion flange using puller (commercial service

H
tool).
LDIA0171E
K
9. Remove front oil seal using puller (A) (SST: KV381054S0).
N
JSDIA6692ZZ
INSTALLATION O

FRONT OIL SEAL
1. Drive the front oil seal in evenly using drifts (A and B).
A : Drift (SST: ST30720000)

B : Drift (SST: ST27863000)
CAUTION:
• Never reuse oil seal.
• Never incline oil seal when installing.
• Apply multi-purpose grease onto oil seal lips and gear oil
onto the circumference of oil seal.
JSDIA6693ZZ
2. Align the matching mark of drive pinion with the matching

mark of companion flange , then install the companion
flange.
3. Apply anti-corrosion oil to the thread and seat of new drive pin-
ion lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
Never reuse drive pinion lock nut.
JSDIA0038ZZ

mercial service tool), tighten drive pinion lock nut within the lim-
its of specified torque so as to keep the bearing preload within a
standard values, using preload gauge (A) (SST: ST3127S000).
Total preload torque : A value that add 0.1 – 0.4 N·m

(0.01 – 0.04 kg-m, 1 – 3 in-lb) to
the measured value before re-
moving.
Drive pinion lock nut : Refer to DLN-169, "Exploded
tightening torque View".
CAUTION:
• Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first.
• If the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Never
loosen drive pinion lock nut to adjust the preload torque.
5. Make a stamping for identification of front oil seal replacement
frequency. Refer to “Identification stamp of replacement fre-
quency of front oil seal”.
CAUTION:
Make a stamping after replacing front oil seal. PDIA1003E
6. Install front propeller shaft. Refer to DLN-133, "Removal and

Installation".
7. Install both front drive shafts. Refer to FAX-25, "Removal and Installation".
8. Refill gear oil to the final drive. Refer to DLN-168, "Refilling".
9. Perform inspection after installation. Refer to DLN-172, "Inspection".

Check oil level and final drive for oil leakage. Refer to DLN-168, "Inspection".

SIDE OIL SEAL
SIDE OIL SEAL
A
DLN
JSDIA6685ZZ
G
Side oil seal Front final drive assembly
Oil seal lip
: Always replace after every disassembly. H

: Apply gear oil.
I
REMOVAL J
2. Remove both front drive shafts from front final drive assembly. Refer to FAX-25, "Removal and Installa-
tion". K
3. Remove side oil seal, using oil seal remover (commercial ser-
vice tool).
CAUTION: L
Never damage gear carrier.
N
LDIA0173E
INSTALLATION O

SIDE OIL SEAL
1. Using the drifts (A and B), drive side oil seal until it becomes
flush with the gear carrier end.

CAUTION:
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lip, and gear oil
JSDIA6694ZZ
2. Install both front drive shafts. Refer to FAX-25, "Removal and
Installation".


AIR BREATHER
AIR BREATHER
A
DLN
G
JSDIA6697ZZ
Air breather hose A Clip A Clip B

H
Hose connector Air breather hose B Hose clamp
Front final drive assembly
: Always replace after every disassembly. I
J
REMOVAL
1. Loosen hose clamp, and remove air breather hose B from final drive assembly.
2. Remove clip B from bracket of body frame. K
JSDIA6698ZZ N
3. Remove clip A from bracket of hoodledge.

4. Remove air breather hose assembly. O
5. Separate each component part.
JSDIA6699ZZ
INSTALLATION

AIR BREATHER
• When inserting air breather hose to hose connector , be sure to
insert it fully until its end reaches the stop.
CAUTION:
JSDIA6823ZZ
• When inserting air breather hose B to final drive assembly, be sure to insert it fully until its end reaches the
stop.
CAUTION:
• Install air breather hose B so that the paint mark on it
and tab of hose clamp faced forward of the vehicle.
: Vehicle front
JSDIA6700ZZ
• Set hose clamp at the end of air breather hose with

dimension (A) from the hose edge.
Dimension (A) : 5 – 7 mm (0.20 – 0.28 in)

• When installing air breather hose, make sure there are no pinched
or restricted areas on air breather hose caused by bending or
winding.
JSDIA2531ZZ

FRONT FINAL DRIVE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [FRONT FINAL DRIVE: R180A]

B
DLN
JSDIA6701GB
M
Flame assembly Front final drive assembly Front cross member assembly
: Vehicle front N
Removal and Installation INFOID:0000000011105168 O
REMOVAL
1. Remove both front drive shafts. Refer to FAX-25, "Removal and Installation". P
CAUTION:
Oil may leak from the opening. Use cap and/or plug to prevent leakage.

< UNIT REMOVAL AND INSTALLATION > [FRONT FINAL DRIVE: R180A]
2. Remove front cross member assembly .
: Vehicle front
3. Remove front propeller shaft from front final drive. Refer to DLN-
133, "Removal and Installation".
4. Remove air breather hose from front final drive. Refer to DLN-
175, "Removal and Installation".
5. Set a suitable jack to front final drive assembly.
JSDIA6705ZZ
6. Remove front final drive assembly mounting bolts and nuts, then
remove front final drive assembly.
CAUTION:
Secure front final drive assembly to suitable jack while
removing it.
WDIA0145E
INSTALLATION
Note the following, install in the reverse order of removal.
• Perform inspection after installation. Refer to DLN-178, "Inspection".

When oil leaks while removing/installing final drive assembly, check oil level after the installation. Refer to
DLN-168, "Inspection".

SIDE SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [FRONT FINAL DRIVE: R180A]
UNIT DISASSEMBLY AND ASSEMBLY A

SIDE SHAFT
B
DLN
JSDIA6708GB J

Pinion front bearing Collapsible spacer Mounting insulator K
Breather connector Side oil seal Drain plug
Gasket Gear carrier Pinion rear bearing
L
Pinion height adjusting washer Drive pinion Drive gear
Differential case Side bearing Side bearing adjusting washer
Spacer Side shaft Side shaft bearing M
Snap ring Snap ring Side oil seal
Side gear thrust washer Side gear Pinion mate thrust washer
Pinion mate gear Pinion mate shaft Lock pin
N
Bearing cap Carrier cover Filler plug

Oil seal lip Screw hole Comply with the assembly proce-
O
dure when tightening. Refer to DLN-
183, "Disassembly and Assembly".
P
: Apply gear oil.

: Apply multi purpose grease.

SIDE SHAFT
: Apply Genuine Liquid Gasket, Three Bond 1217 or equivalent.

: Apply Genuine High Strength Thread Locking Sealant, Loctite 270 or equivalent.
DISASSEMBLY
1. Remove the carrier cover bolts.
2. Remove carrier cover to insert the seal cutter (A) (SST:
KV10111100) between gear carrier and carrier cover.
CAUTION:
• Never damage the mating surface.
• Never insert flat-bladed screwdriver, this will damage the
mating surface.
JSDIA6853ZZ
3. Remove side oil seal with oil seal remover (commercial service
tool).
CAUTION:
Never damage gear carrier.
PDIA0713E
4. Remove snap ring (hole side) with a snap ring pliers.
PDIA0714E
5. Remove differential side shaft assembly out of gear carrier with

a suitable tool.
NOTE:
Tap on side shaft assembly from side gear side.
6. Remove snap ring (side shaft side).
PDIA0715E

SIDE SHAFT
7. Press side shaft out of side shaft bearing .
CAUTION: A
Never drop side shaft.
8. Perform inspection after disassembly. Refer to DLN-181,
"Inspection". B
JSDIA6854ZZ
DLN
ASSEMBLY
1. Press side shaft bearing to side shaft .
CAUTION: E
Never reuse side shaft bearing.
2. Install snap ring (side shaft side).
3. Install side shaft assembly into gear carrier. F
4. Install snap ring (hole side).
JSDIA6855ZZ
H
5. Install side oil seal until it becomes flush with the gear carrier,
with the drifts (A and B).
A : Drift (SST: ST30720000) I

CAUTION:
• Never reuse oil seal. J
• Apply multi-purpose grease onto oil seal lips, and gear oil
onto the circumference of oil seal. K
JSDIA6856ZZ
L
INSPECTION AFTER DISASSEMBLY
Side Shaft
• If it is chipped (by friction), cracked, damaged, or unusually worn, replace. M
Bearing
• Clean up the disassembled parts.
N
• If any chipped (by friction), pitted, worn, rusted or scratched marks, or unusual noise from the bearing is
observed, replace as a bearing assembly (as a new set).
Oil Seal
O
• Whenever disassembled, replace.
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace.

DIFFERENTIAL ASSEMBLY
JSDIA6708GB

Pinion front bearing Collapsible spacer Mounting insulator
Differential case Side bearing Side bearing adjusting washer
Spacer Side shaft Side shaft bearing
Bearing cap Carrier cover Filler plug
: Apply gear oil.


A
DISASSEMBLY
1. Remove mounting insulators with drift (SST: ST33200000) if necessary.
B
2. Remove side shaft assembly. Refer to DLN-180, "Disassembly and Assembly".
3. Remove side oil seal from gear carrier with a oil seal remover (commercial service tool).
4. For proper reinstallation, paint matching marks on one side of C
bearing cap.
CAUTION:
• For matching marks, use paint. Never damage bearing
caps and carrier case. DLN
• Bearing caps are manufactured as integral molding. Use
the matching marks to them in their original positions.
E
JSDIA6857ZZ
F
5. Remove bearing caps.
PDIA0701E
6. Lift the differential assembly out of the gear carrier with sliding J
hammer (commercial service tool).
PDIA0547E
M
7. Remove differential assembly together with side bearing outer

races and side bearing adjusting washers. N
CAUTION:
• Never drop the side bearing outer race.
• Identify the assembled position of the side bearing outer
race in advance. O
• Mark side bearing adjusting washers so that the original
mounting positions (right/left) can be identified later.
8. Remove spacer. P
SPD527

9. Remove side bearing inner races, using puller (A) and the base
(B).
A : Puller (SST: ST33051001)

B : Base (SST: ST33061000)
CAUTION:
• To prevent damage to the side bearing and drive gear,
place copper plates between these parts and vise.
• To prevent damage to bearing, engage puller jaws in
groove ( ).
• It is not necessary to remove side bearing inner race
except when it is replaced.
PDIA0758J
10. For proper reinstallation, paint matching marks on one differ-

ential assembly and drive gear.
CAUTION:
For matching marks, use paint. Never damage differential
assembly and drive gear.
11. Remove drive gear mounting bolts and then remove drive gear
from differential assembly.
JSDIA5285ZZ
12. Remove lock pin of pinion mate shaft, using the pin punch (com-
mercial service tool).
PDIA0759J
13. Remove pinion mate shaft.
SDIA0031J

14. Remove pinion mate gears, pinion mate thrust washers, side
gears, side gear thrust washers from differential case. A
"Inspection".
B
SDIA0032J
DLN
ASSEMBLY
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly or reinstall the old ones on
E
the side gears.
2. Install side gears and side gear thrust washers into differential
case.
F
SDIA0193J
H
3. Align 2 pinion mate gears in diagonally opposite positions, then
rotate and install them into differential case after installing thrust
washer to pinion mate gear.
I
K
SDIA0194J
4. Align the lock pin holes on differential case with pinion mate
shaft, and install pinion mate shaft. L
SDIA0195J
O
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers.

a. Place differential assembly straight up so that side gear to be
measured comes upward.
JPDID0205GB
b. Using feeler gauge, measure the clearance between side gear

back and differential case at 3 different points, while rotating
side gear. Average the 3 readings, and then measure the clear-
ance of the other side as well.
Side gear backlash : Refer to DLN-202, "Differ-

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

is large
When the back clearance : Use a thinner thrust washer.
is small
CAUTION:
Select a side gear thrust washer for right and left individu-
PDIA0576E
ally.
6. Drive a lock pin into pinion mate shaft, using the pin punch
(commercial service tool).
CAUTION:
Never reuse lock pin.
PDIA0759J
7. Apply thread locking sealant into the thread hole of drive gear.
• For applying thread locking sealant, refer to DLN-182,
"Exploded View".
CAUTION:
Clean and degrees drive gear back and threaded holes suf-
ficiently.
8. Install the drive gear to differential assembly.
CAUTION:
Align the matching mark of differential assembly and drive
gear.
SDIA2594E

9. Tighten the drive gear mounting bolts with the following procedure.
A
a. Tighten the bolts in a crisscross fashion to the specified torque.
Drive gear mounting : 58.8 N•m (6.0 kg-m, 43 ft-lb)

bolt tightening torque B
DLN
SDIA0247J
b. Tighten the bolts additionally to the specified angle using the

angle wrench (A) (SST: KV10112100). E
Drive gear mounting : 34 to 39 degree

bolt tightening angle
F
CAUTION:
Check the tightening angle using the angle wrench. Never
make judgment by visual inspection.
G
JSDIA6776ZZ
H
10. Press side bearing inner races to differential assembly, using the
drift (A) and the base (B).
A : Drift (SST: ST33230000) I

B : Base (SST: ST33061000)
CAUTION:
J
• Never reuse side bearing inner race.
• Apply gear oil to side bearing.
11. Install spacer.
K
PDIA0810J
12. Install the differential case assembly with the side bearing outer
races into the gear carrier. L
CAUTION:
• Never reuse side bearing outer race when replacing side
bearing inner race (replace as a set). M
• Apply differential gear oil to the side bearings.
SPD527
O

13. Insert left and right original side bearing adjusting washers in
place between side bearings and gear carrier.
SPD558
14. Install the side bearing caps with the matching marks aligned
and tighten the side bearing cap bolts to the specified torque.
CAUTION:
Align matching marks on bearing cap with that on gear car-
rier.
JSDIA6857ZZ
15. Install side oil seal until it becomes flush with the gear carrier
with the drift (A and B).

CAUTION:
• Never reuse side oil seal.
JSDIA6858ZZ
16. Check and adjust drive gear runout, tooth contact, backlash, and
total preload torque. Refer to DLN-188, "Adjustment".
17. Apply liquid gasket to mating surface of rear cover.
• For applying liquid gasket, refer to DLN-182, "Exploded View".
CAUTION:
• Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adher-
ing to the mounting surfaces.
• The width of sealant bead is approximately 3 mm (0.12 in).
Apply sealant evenly.
18. Install the carrier cover to the gear carrier. Tighten the bolts to
the specified torque.
• For tightening torque, refer to DLN-182, "Exploded View". PDIA0712E
19. Install side shaft assembly. Refer to DLN-180, "Disassembly and

Assembly".
20. Install mounting insulators with drift (SST: ST33200000).
Adjustment INFOID:0000000011378337
TOTAL PRELOAD TORQUE

1. Remove side shaft. Refer to DLN-180, "Disassembly and Assembly".
2. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
3. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.

4. Measure total preload with the preload gauge (A) (SST:
ST3127S000). A
Total preload torque : Refer to DLN-201, "Preload

Torque". B
NOTE:
Total preload torque = Pinion bearing preload torque + Side
bearing preload torque C
• 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. JSDIA6859ZZ
Adjust the pinion bearing preload first, then adjust the side DLN
bearing preload.
When the preload torque is large E

On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same amount to
each side. For selecting adjusting washer, refer to the latest parts in- F
formation.
When the preload is small G

On pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Tighten side bearing adjusting nut. H
Use thicker side bearing adjusting washers by the same amount to
each side. For selecting adjusting washer, refer to the latest parts in-
formation.
I
CAUTION:
Select a side bearing adjusting washer for right and left individually.
DRIVE GEAR RUNOUT J
1. Remove carrier cover. Refer to DLN-183, "Disassembly and Assembly".
2. Fit a dial indicator to the drive gear back face.
K
3. Rotate the drive gear to measure runout.
Drive gear back : Refer to DLN-201, "Drive Gear

face runout Runout". L
• 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 M
gear may be deformed, etc.
CAUTION:
Replace drive gear and drive pinion gear as a set. N
SPD886
TOOTH CONTACT
1. Remove carrier cover. Refer to DLN-183, "Disassembly and Assembly". O

2. Apply red lead or equivalent to drive gear.
CAUTION:
Apply red lead or equivalent to both the faces of 3 to 4
gears at 4 locations evenly spaced on drive gear.
SPD357
3. 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.
SDIA0570E
Tooth Contact Judgment Guide
SDIA2549E

4. If tooth contact is improperly adjusted, follow the procedure
below to adjust the pinion height (dimension X). A
SDIA0517E
DLN
• If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken pinion height adjusting washer to
move drive pinion closer to drive gear. E
For selecting adjusting washer, refer to the latest parts infor-
mation.
F
G
PDIA0440E
• If the tooth contact is near the flank (flank contact), or near the H
toe (toe contact), thin pinion height adjusting washer to move
drive pinion farther from drive gear.
For selecting adjusting washer, refer to the latest parts infor- I
mation.
K
PDIA0441E
BACKLASH
1. Remove carrier cover. Refer to DLN-183, "Disassembly and Assembly". L
2. Fit a dial indicator to the drive gear face to measure the back-
lash.
M
Backlash : Refer to DLN-202, "Backlash".
• If the backlash is outside of the specified value, adjust with the
side bearing adjusting nut. N
When the backlash is large:

Make drive gear back side adjusting washer thicker, O
and drive gear tooth side adjusting washer thinner by SPD513
the same amount. For selecting adjusting washer, re-
fer to the latest parts information. P
When the backlash is small:
Make drive gear back side adjusting washer thinner,
and drive gear tooth side adjusting washer thicker by
the same amount. For selecting adjusting washer, re-
fer to the latest parts information.
CAUTION:

Never change the total amount of washers as it changes the bearing preload.

Drive Gear and Drive Pinion
• If the gear teeth never mesh or line-up correctly, determine the cause and adjust or replace as necessary.
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive
gear and drive pinion as a set.
Bearing
Oil Seal
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace them.
Differential Assembly
DIFFERENTIAL CASE
• If any wear or crack on the contact sides of the differential case is found, replace.
SIDE GEAR AND PINION MATE GEAR
• If any cracks or damage on the surface of the tooth is found, replace.
• If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
SIDE GEAR THRUST WASHER AND PINION MATE THRUST WASHER
• If it is chipped (by friction), damaged, or unusually worn, replace.

DRIVE PINION
DRIVE PINION
A
DLN
I
JSDIA6708GB
Drive pinion lock nut Companion flange Front oil seal J

Pinion front bearing Collapsible spacer Mounting insulator
K
Differential case Side bearing Side bearing adjusting washer L
Spacer Side shaft Side shaft bearing
M
Bearing cap Carrier cover Filler plug N
O
: Select with proper thickness. P
: Apply gear oil.


DRIVE PINION
DISASSEMBLY
1. Remove side shaft assembly. Refer to DLN-180, "Disassembly and Assembly".
2. Remove differential assembly. Refer to DLN-183, "Disassembly and Assembly".
3. While holding companion flange with the flange wrench (A)
(commercial service tool), remove drive pinion lock nut.
JSDIA6860ZZ
4. Put matching mark on the end of drive pinion. The matching

mark should be in line with the matching mark on companion
flange .
CAUTION:
NOTE:
The matching mark on the final drive companion flange indicates
the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary. PDIA0799J
5. Remove companion flange using the suitable puller (commercial

service tool).
PDIA0703E
6. Press drive pinion assembly and remove it.

CAUTION:
Never drop drive pinion assembly.
JSDIA6861ZZ

DRIVE PINION
7. Remove front oil seal, using oil seal remover (commercial ser-
vice tool). A
CAUTION:
Never damage carrier case.
8. Remove pinion front bearing inner race. B
9. Remove collapsible spacer.
PDIA0716E
DLN
10. Remove pinion rear bearing inner race and pinion height adjust-
ing washer with the separator (A) (commercial service tool).
E
G
PDIA0801J
11. Tap pinion front bearing outer race and rear bearing outer H
race uniformly using a brass rod or equivalent to remove
them.
CAUTION:
Never damage carrier case. I
"Inspection".
J
JSDIA6862ZZ
K
ASSEMBLY
1. Install pinion front bearing outer race using drift (A) (SST:
KV38100200). L
CAUTION:
• At first, using a hammer, tap bearing outer race until it
becomes flat to carrier case. M
• Never reuse pinion front bearing outer race.
JSDIA6863ZZ
O

DRIVE PINION
2. Install pinion rear bearing outer race using drift (A) and drift
bar (B).

B : Drift bar (SST: ST30611000)
CAUTION:
becomes flat to carrier case.
• Never reuse pinion rear bearing outer race.
JSDIA6864ZZ
3. Temporarily install pinion height adjusting washer .

CAUTION:
Pay attention to the direction of pinion height adjusting
washer. (Assemble as shown in the figure.)
When hypoid gear set has been replaced
• Select pinion height adjusting washer. Refer to DLN-199,
"Adjustment".
When hypoid gear set has been reused
• Temporarily install the removed pinion height adjusting washer
or same thickness washer to drive pinion. JSDIA0760ZZ
4. Install pinion rear bearing inner race to drive pinion with the
drift (A) (SST: ST30901000).
CAUTION:
Never reuse pinion rear bearing inner race.
5. Check and adjust the tooth contact and backlash of drive gear
and drive pinion following the procedure below.
a. Assemble drive pinion into carrier case.
CAUTION:
• Never assemble collapsible spacer.
• Apply gear oil to pinion rear bearing.
JSDIA0761ZZ
b. Assemble pinion front bearing inner race to drive pinion assem-
bly.
CAUTION:
• Never reuse pinion front bearing inner race.
• Apply gear oil to pinion front bearing.
c. Using drift (A) (SST: ST33200000), press the pinion front bear-
ing inner race to drive pinion as far as drive pinion lock nut can
be tightened.
JSDIA6868ZZ
d. Install companion flange.

CAUTION:
Never assemble front oil seal.
NOTE:

DRIVE PINION
When reusing drive pinion, align the matching mark of drive
pinion with the matching mark of companion flange, and then A
install companion flange .
e. Temporarily tighten removed drive pinion lock nut to drive pinion.
NOTE: B
Use removed drive pinion lock nut only for the preload measure-
ment.
f. Rotate drive pinion more than 20 times to adjust bearing. C
PDIA0799J
DLN
g. Tighten to drive pinion lock nut holding companion flange with
the flange wrench (A) (commercial service tool), while adjusting
pinion bearing preload torque using preload gauge (B) (SST:
E
ST3127S000).
Pinion bearing preload : 1.08 - 1.66 N·m (0.11 – 0.16 kg-

(without oil seal) m, 10 – 14 in-lb) F
CAUTION:
Drive pinion lock nut is tightened with no collapsible
spacer. Be careful not to overtighten it. While measuring the G
preload, tighten it by 5° to 10°.
h. Assemble removed side bearing adjusting washer or same
thickness of it and install differential assembly. Refer to DLN- H
CAUTION:
Apply differential gear oil to the side bearings. I
i. Install bearing caps.
j. Check and adjust tooth contact, drive gear to drive pinion back-
lash. Refer to DLN-188, "Adjustment". J
k. Remove bearing caps and differential assembly.
l. Remove companion flange.
WDIA0382E
m. Remove drive pinion assembly from gear carrier. K
n. Remove pinion front bearing inner race.
6. Assemble collapsible spacer to drive pinion .
CAUTION: L
Never reuse collapsible spacer.
7. Assemble drive pinion into carrier case.
CAUTION: M
Apply gear oil to pinion rear bearing.
8. Assemble pinion front bearing inner race to drive pinion assem-
bly. N
CAUTION:
• Apply gear oil to pinion front bearing. JSDIA6869ZZ
O

DRIVE PINION
9. Using drift (A) (SST: ST33200000), press the pinion front bear-
ing inner race to drive pinion as far as drive pinion nut can be
tightened.
JSDIA6868ZZ
10. Install front oil seal until it becomes flush with the carrier case
end, using the drifts (A and B) as shown in figure.

CAUTION:
JSDIA6870ZZ
11. Install companion flange.

NOTE:
pinion with the matching mark of companion flange, and then
12. Apply anti-corrosion oil to the thread and seat of drive pinion
lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
PDIA0799J

DRIVE PINION
(commercial service tool), tighten drive pinion lock nut within the A
limits of specified torque so as to keep the pinion bearing pre-
load within a standard values, using preload gauge (B) (SST:
ST3127S000).
B
Pinion bearing preload : Refer to DLN-201, "Pre-
load Torque".
C
CAUTION:
ening torque first.
• If the preload torque exceeds the specified value, replace DLN
• After adjustment, rotate drive pinion back and forth 2 to 3 E
times to check for unusual noise, rotation malfunction,
and other malfunctions.
14. Install differential assembly. Refer to DLN-183, "Disassembly F
and Assembly".
CAUTION:
Never install carrier cover yet.
15. Check and adjust drive gear runout, tooth contact, and drive G
WDIA0382E
gear to drive pinion backlash. Refer to DLN-188, "Adjustment".
16. Check companion flange runout. Refer to DLN-199, "Adjustment".
H
17. Check total preload torque. Refer to DLN-188, "Adjustment".
18. Install side shaft assembly. Refer to DLN-180, "Disassembly and Assembly".
19. Install carrier cover. Refer to DLN-183, "Disassembly and Assembly". I
PINION GEAR HEIGHT J

If the hypoid gear set has been replaced, select the pinion height adjusting washer.
1. Use the formula below to calculate pinion height adjusting
washer thickness. K
Washer selection equation:

T = T0 + (t1− t2) L
T: Correct washer thickness
T0: Removed washer thickness
Old drive pinion head letter “H × 0.01” M
t1:
(“H”: machined tolerance 1/100 mm × 100)
New drive pinion head letter “H × 0.01”
t2:
(“H”: machined tolerance 1/100 mm × 100) SDIA0249J
N
Example:
T = 3.21 + [(2 × 0.01) − (−1 × 0.01)] = 3.24 O
T0: 3.21
t1: +2
t2: −1 P
2. Select the proper pinion height adjusting washer. For selecting adjusting washer, refer to the latest parts
information.
CAUTION:
If unable to find a washer of desired thickness, use a washer with thickness closest to the calcu-
lated value.

DRIVE PINION
Example:
Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm
COMPANION FLANGE RUNOUT

1. Fit a dial indicator onto the companion flange face (inner side of
the propeller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.
Companion flange face : Refer to DLN-202,

runout "Companion Flange
Runout".
3. Fit a test indicator to the inner side of companion flange (socket
diameter).
4. Rotate companion flange to check for runout. JSDIA0116ZZ
Inner side of the companion : Refer to DLN-202,

flange runout "Companion Flange
Runout".
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, possible cause will be an
assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for
these items and repair if necessary.
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.

Bearing
Oil Seal
Companion Flange
• If any chipped mark [about 0.1 mm, (0.004 in)] or other damage on the contact sides of the lips of the com-
panion flange is found, replace.
Carrier Case
• If any wear or crack on the sliding surface of the carrier case is found, replace.

< SERVICE DATA AND SPECIFICATIONS (SDS) [FRONT FINAL DRIVE: R180A]

B
YD25DDTi MODELS
C
Axle 4WD
Applied model
Transmission M/T
Final drive model R180A DLN
Gear ratio 3.357 3.538 3.692 4.363
Number of teeth (Drive gear/Drive pinion) 47/14 46/13 48/13 48/11
E
Number of pinion gears 2
Drive pinion adjustment spacer type Collapsible
Oil capacity Refer to MA-32, "Fluids and Lubricants". F
Axle 4WD
Applied model
Transmission A/T G
Final drive model R180A
Gear ratio 3.357 3.916
H
Number of teeth (Drive gear/Drive pinion) 47/14 47/12
Drive pinion adjustment spacer type Collapsible I
Oil capacity Refer to MA-32, "Fluids and Lubricants".
YS23DDT AND YS23DDTT MODELS J
Axle 4WD
Applied model
Transmission M/T A/T K
Final drive model R180A
Gear ratio 3.357 3.538 3.692 3.357
L
Drive pinion adjustment spacer type Collapsible M
Preload Torque INFOID:0000000011105180

N
Unit: N·m (kg-m, in-lb)
Item Standard
O
Pinion bearing (P1) 1.08 – 1.66 (0.11 – 0.16, 10 – 14)
Side bearing (P2) 0.588 – 1.078 (0.06 – 0.10, 6 – 9)
Side bearing to pinion bearing (Total preload) P
1.668 – 2.738 (0.17 – 0.27, 15 – 24)
(Total preload = P1 + P2)
Drive Gear Runout INFOID:0000000011105181
Unit: mm (in)
Item Standard
Drive gear back face runout 0.08 (0.0031) or less

< SERVICE DATA AND SPECIFICATIONS (SDS) [FRONT FINAL DRIVE: R180A]
Backlash INFOID:0000000011105182
Unit: mm (in)
Item Standard
Drive gear to drive pinion gear 0.10 – 0.15 (0.0039 – 0.0059)
Companion Flange Runout INFOID:0000000011188774
Unit: mm (in)
Item Standard
Companion flange face runout 0.10 (0.004) or less
Inner side of the companion flange runout 0.10 (0.004) or less
Differential Side Gear Clearance INFOID:0000000011105183
Unit: mm (in)
Item Standard
0.10 (0.004) or less
Side gear backlash (Clearance between side gear and differential
(Each gear should rotate smoothly without excessive resistance
case)
during differential motion.)

PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: H215]
PRECAUTION A
PRECAUTIONS
B
• Never disconnect battery terminal while engine is running. C
• For vehicles with the engine listed below, remove the battery termi- DLN

E
F
SEF289H
G
NOTE:
H
NOTE:
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF. I
- Driving for 30 minutes or more on a steep slope. J
NOTE:
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon- K
NOTE: L
Service Notice or Precautions for Rear Final Drive INFOID:0000000011274792
M
• Overhaul should be done in a clean work area, it is preferable to work in dustproof area. N
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them O
P

PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: H215]
purpose grease as specified for each vehicle, if necessary.

PREPARATION
< PREPARATION > [REAR FINAL DRIVE: H215]
PREPARATION A
PREPARATION
B
Tool number
Description C
Tool name
KV10109900 Removing and installing side bearing adjust-
Wrench ing nut
DLN
E
S-NT035
KV10112100 Tightening drive gear mounting bolt

Angle wrench F
ZZA0120D
H
Drift
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia. I
J
ZZA0814D
KV40105330 Installing side bearing inner race

Drift
K
a: 62.5 mm (2.461 in) dia.
b: 55 mm (2.17 in) dia.
c: 15 mm (0.59 in)
L
ZZA1133D
ST3127S000 Measuring pinion bearing preload and total M

ZZA0503D O
ST22360002 Removing drive pinion
Drift
a: 29 mm (1.14 in) dia. P
b: 23 mm (0.91 in) dia.
ZZA0534D

PREPARATION
Tool number
Description
Tool name
KV38100500 Installing front bearing outer race
Drift
a: 80 mm (3.15 in) dia.
b: 60 mm (2.36 in) dia.
SDIA1264J
KV40105710 Installing pinion front bearing inner race

Press stand
a: 50 mm (1.97 in) dia.
b: 40 mm (1.57 in) dia.
S-NT509
KV40101840 Installing front oil seal

Drift
a: 85 mm (3.35 in) dia.
b: 67 mm (2.64 in) dia.
c: 77 mm (3.03 in) dia.
JSDIA6038ZZ
ST30720000 Installing front oil seal

Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
SDIA1264J

Puller • Removing side bearing inner race
• Removing companion flange
ZZA0119D
Adaptor Removing side bearing inner race

a: 48 – 54 mm (1.89 – 2.13 in) dia.
JSDIA6815ZZ

PREPARATION
A
Pin punch Removing and installing lock pin
a: 5 mm (0.20 in) dia.
C
NT410
DLN
NT035
Oil seal remover Removing front oil seal F
JSDIA4998ZZ
H
Separator Removing pinion rear bearing inner race
J
ZZA0700D
Drift Installing rear bearing outer race

a: 104 – 106 mm (4.09 – 4.17 in) dia. K
S-NT109
Drift Installing pinion rear bearing inner race M

a: 52 mm (2.05 in) dia.
b: 46 mm (1.81 in) dia.
N
S-NT661
O
P
Item Use
Application to threads of drain plug and filler plug
Application into the thread hole of drive gear

< SYSTEM DESCRIPTION > [REAR FINAL DRIVE: H215]
SYSTEM DESCRIPTION
JSDIA6717ZZ
Companion flange Pinion front bearing Collapsible spacer

Pinion rear bearing Drive gear Side gear
Pinion mate gear Pinion mate shaft Differential case
Side bearing adjusting nut Side bearing Drive pinion

Symptom
Reference
×: Applicable
*: 4WD models only

Noise
SYMPTOM DIAGNOSIS
×
DLN-209
×
×
×
×
PROPELLER SHAFT NVH of FRONT* and REAR PROPELLER SHAFT in this section.
×
×
×
×
DRIVE SHAFT NVH in FAX* and RAX section.
×
×
×
[REAR FINAL DRIVE: H215]
INFOID:0000000011274865
D23
I
L
F
P
K
E
B
A
N
H
C
O
G
M
DLN
REAR DIFFERENTIAL GEAR OIL
< PERIODIC MAINTENANCE > [REAR FINAL DRIVE: H215]
OIL LEAKAGE
• Check that oil is not leaking from final drive assembly or around it.
• When oil leaking, drain all gear oil, and then fill with specified amount of gear oil. Refer to DLN-210, "Refill-
ing".
NOTE:
Oil is not refilled up to filler plug mounting hole.
CAUTION:
Oil volume cannot checked by oil level height.
1. Stop engine.
2. Remove drain plug and drain gear oil.
3. Set a gasket on drain plug and install it to final drive assembly
and tighten to the specified torque. Refer to DLN-216, "Exploded
View".
CAUTION:
Never reuse gasket.
JSDIA5679ZZ
1. Drain all gear oil. Refer to DLN-210, "Draining".

CAUTION:
Drain gear oil until gear oil start to drip.
2. Remove filler plug .
3. Fill with specified amount of gear oil.

NOTE:
CAUTION:
4. Apply sealant to filler plug, then install it to final drive assembly. JSDIA6813ZZ
Refer to DLN-216, "Exploded View".

FRONT OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: H215]

FRONT OIL SEAL
B
DLN
JSDIA5758GB
H
Rear final drive assembly Front oil seal Companion flange
Drive pinion lock nut
I
Oil seal lip

: Always replace after every disassembly. J
: Apply multi purpose grease
*: Apply anti-corrosive oil. K
L
REMOVAL
1. Remove rear propeller shaft. Refer to DLN-144, "Removal and Installation" (3S1330), DLN-155, "Removal
and Installation" (2S1330). M
panion flange . N
CAUTION:
O
P
JSDIA0038ZZ

FRONT OIL SEAL
3. Remove drive pinion lock nut using the flange wrench (commer-
cial service tool).
JSDIA5759ZZ
4. Remove companion flange using pullers (commercial service

tool).
5. Remove front oil seal using oil seal remover.
CAUTION:
MDIB0048E
INSTALLATION
1. Apply multi-purpose grease to front oil seal lips.
2. Install front oil seal until it becomes flush with the case end,
using the drift (A and B) as shown in figure.
(A) : Drift (SST: ST30720000)

(B) : Drift (SST: KV40101840)
CAUTION:
• Never incline oil seal when installing.
3. Remove rear axle shaft from final drive. Refer to RAX-8,
"Removal and Installation".
JPDID0036ZZ

mark of companion flange , and then install the companion
flange.
JSDIA0038ZZ

FRONT OIL SEAL
5. Temporarily tighten drive pinion lock nut to drive pinion, using
flange wrench (commercial service tool). A
CAUTION:
• Never reuse drive pinion lock nut.
• Apply anti-corrosion oil to the thread and seat of new
B
drive pinion lock nut.
6. Tighten drive pinion lock nut within the limits of specified torque
so as to keep the pinion bearing preload within a standard val-
ues, using preload gauge (SST: ST3127S000). C
Pinion bearing torque : Refer to DLN-240, "Preload JSDIA5759ZZ
Torque". DLN
CAUTION:
• Adjust to the lower limit of the drive pinion lock nut tightening torque first.
• If the preload torque exceeds the specified value, replace collapsible spacer and tighten it again E
to adjust. Never loosen drive pinion lock nut to adjust the preload torque.
7. Check for companion flange runout as follows: F

• For companion flange face, fit a dial indicator onto the com-
panion flange face (inner side of the propeller shaft mounting
bolt holes).
• For inner side of the companion flange, fit a test indicator to G
the inner side of companion flange (socket diameter).
• Rotate companion flange to check for runout.
H
Companion flange : Refer to DLN-242, "Com-
runout panion Flange Runout".
• If the runout value is outside the runout limit, follow the proce- I
dure below to adjust. JSDIA0116ZZ
- Check for runout while changing the phase between compan-

ion flange and drive pinion by 90° step, and search for the position where the runout is the minimum. J
- If the runout value is still outside of the limit after the phase has been changed, replace companion
flange.
- 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. K
8. Install rear axle shaft from final drive. Refer to RAX-8, "Removal and Installation".
9. Install rear propeller shaft. Refer to DLN-144, "Removal and Installation" (3S1330), DLN-155, "Removal
and Installation" (2S1330). L
M

Check oil level and final drive for oil leakage. Refer to DLN-210, "Inspection". N

AIR BREATHER
AIR BREATHER
JSDIA7215GB
Rear axle housing Breather hose connector Hose clamp

Air Breather hose assembly

REMOVAL
1. Remove the hose clamp and separate air breather hose
from breather connector .
JSDIA5767ZZ
2. Remove mounting bolt ( ) and then separate the air breather

hose assembly from vehicle frame.
3. Remove the air breather hose assembly.
CAUTION:
Never remove breather hose connector from rear axle hous-
ing.
JSDIA5768ZZ
INSTALLATION

AIR BREATHER
• While installing new rear axle housing, tighten the breather hose connector to the end of thread cutting por- A
tion with specified tightening torque. Refer to DLN-214, "Exploded View".
CAUTION:
Never reuse breather hose connector.
B
• Set air breather hose assembly to breather hose connector
with paint mark facing rear direction of vehicle.
• Install hose clamp such that tab facing rear direction of vehicle
C
: Vehicle front
CAUTION: DLN
Never reuse hose clamp.
winding. E
JSDIA5769ZZ
I

J

REAR FINAL DRIVE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: H215]
UNIT REMOVAL AND INSTALLATION

JSDIA6811GB
Filler plug Gasket Rear final drive assembly

Gasket Drain plug Rear axle housing

*
: Apply anti-corrosive oil.
REMOVAL
1. Remove rear propeller shaft.
• 3S1330: Refer to DLN-144, "Removal and Installation".
• 2S1330: Refer to DLN-155, "Removal and Installation".
3. Remove rear axle shaft from final drive. Refer to RAX-8, "Removal and Installation".
4. Set a suitable jack to rear final drive assembly.
5. Remove final drive mounting bolts and remove final drive assembly from the vehicle.
CAUTION:
Never damage drive gear, differential case and carrier case.
6. Remove gasket.
7. When removing axle housing, follow the procedure below.
a. Remove sensor spring of load sensing valve. Refer to BR-37, "Removal and Installation" (LHD models),
BR-113, "Removal and Installation" (RHD models).
b. Disconnect wheel sensor harness connector and remove wheel sensor harness from rear axle housing.
(Models with ABS and VDC) Refer to BRC-118, "REAR WHEEL SENSOR : Removal and Installation"
(without VDC), BRC-292, "REAR WHEEL SENSOR : Removal and Installation" (with VDC).
c. Remove brake hose and tube from rear axle housing. Refer to BR-34, "REAR : Removal and Installation"
(LHD models), BR-110, "REAR : Removal and Installation" (RHD models).

< UNIT REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: H215]
d. Remove air breather hose assembly from rear axle housing. Refer to DLN-214, "Removal and Installa-
tion". A
e. Remove parking brake cable from rear axle housing. Refer to PB-8, "Removal and Installation" (LHD
modesl), PB-18, "Removal and Installation" (RHD models).
f. Set a suitable jack to rear axle housing. B
g. Remove spring for rear suspension. Refer to RSU-9, "Removal and Installation" (Leaf rigid type suspen-
sion), RSU-23, "Removal and Installation" (5 link suspension).
h. Remove rear axle housing. C
INSTALLATION
Note the following, and installation is in the reverse order of removal.
• Install the gasket in the direction shown in the figure. DLN
: Final drive side

: Axle housing side E
CAUTION:
• Never reuse gasket.
• Remove any moisture, oil, or foreign material adhering to F
application and mounting surfaces.
JPDID0053ZZ
G
• Tighten final drive mounting bolts of two standard holes ( ) first,

H
and then tighten other bolts at opposite angle.
• After installing the final drive assembly, refill with gear oil to the
final drive. Refer to DLN-210, "Refilling".
• Perform inspection after installation. Refer to DLN-217, "Inspec- I
tion".
JSDIA5772ZZ
K
INSPECTION AFTER INSTALLATION L


< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: H215]
UNIT DISASSEMBLY AND ASSEMBLY

JSDIA6744GB

Pinion front bearing Carrier case Collapsible spacer
Pinion rear bearing Pinion height adjusting washer Drive pinion
Drive gear Differential case* Side bearing
Side bearing adjusting nut Bearing cap Lock finger
Side gear thrust washer* Side gear* Pinion mate thrust washer*
Pinion mate gear* Pinion mate shaft* Lock pin*

: Apply gear oil.

*: These may be assembled parts. For supply unit, refer to the latest parts information.

A
DISASSEMBLY
1. Secure final drive assembly onto a suitable attachment (A).
B
DLN
JPDID0039ZZ
E
2. For proper reinstallation, paint matching marks on one side of
bearing cap.
CAUTION: F
caps and carrier case.
G
H
JSDIA6770ZZ
3. Remove lock finger . I
MDIB0099E L
4. Remove side bearing adjusting nuts using wrench (A) (SST:

KV10109900).
M
CAUTION:
Identify the assembled position of the side bearing adjust-
ing nuts in advance.
N
JPDID0061ZZ

JSDIA6771ZZ
6. Insert a suitable bar in between differential assembly and carrier

case, and then separate differential assembly from carrier case.
JSDIA6772ZZ
7. Remove differential assembly together with the side bearing

outer race.
CAUTION:
• Never drop the side bearing outer race.
race in advance.
SPD011
8. Remove side bearing inner races, using adaptor (A) and puller
(B).
A : Adaptor (commercial service tool)

B : Puller (commercial service tool)
CAUTION:
place copper plates between these parts and vise.
• To prevent damage to bearing, engage puller jaws in
groove ( ).
JSDIA6773ZZ

9. For proper reinstallation, paint matching marks on differential
assembly and drive gear. A
CAUTION:
assembly and drive gear.
B
JSDIA6774ZZ
DLN
E
G
JSDIA6775ZZ
11. When disassembling differential assembly, refer to the following procedure. H

NOTE:
For supply unit, refer to the latest parts information.
a. Remove lock pin of pinion mate shaft, using the pin punch (com-
mercial service tool). I
PDIA0759J
L
b. Remove pinion mate shaft.
O
SDIA0031J

c. Remove pinion mate gears, pinion mate thrust washers, side
gears, side gear thrust washers from differential case.
"Inspection".
SDIA0032J
ASSEMBLY
1. When assembling differential assembly, refer to the following procedure.
NOTE:
For supply unit, refer to the latest parts information.
a. 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.
b. Install side gears and side gear thrust washers into differential
case.
SDIA0193J
c. Align 2 pinion mate gears in diagonally opposite positions, then

rotate and install them into differential case after installing thrust
washer to pinion mate gear.
SDIA0194J
d. Align the lock pin holes on differential case with pinion mate
shaft, and install pinion mate shaft.
SDIA0195J
e. Measure side gear end play. If necessary, select the appropriate side gear thrust washers.

i. Place differential assembly straight up so that side gear to be
measured comes upward. A
JPDID0205GB
DLN
ii. Using feeler gauge, measure the clearance between side gear
back and differential case at 3 different points, while rotating
side gear. Average the 3 readings, and then measure the clear-
E
ance of the other side as well.
Side gear backlash : Refer to DLN-242, "Differ-

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

is large
When the back clearance : Use a thinner thrust washer.
is small J
CAUTION:
Select a side gear thrust washer for right and left individu-
PDIA0576E
ally. K
f. Drive a lock pin into pinion mate shaft, using the pin punch
(commercial service tool).
CAUTION: L
Never reuse lock pin.
PDIA0759J
2. Apply thread locking sealant into the thread hole of drive gear. O
"Exploded View".
CAUTION: P
ficiently.
CAUTION:
gear.
SDIA2594E


bolt tightening torque
SDIA0247J

angle wrench (A) (SST: KV10112100).

bolt tightening angle
CAUTION:
make judgment by visual inspection.
JSDIA6776ZZ

drift (A) and the adaptor (B).

B : Drift (SST: KV40105330)
CAUTION:
6. Assemble side bearing outer races to inner races.
CAUTION:
JPDID0049ZZ
• Never reuse side bearing outer race.
7. Install differential assembly to carrier case.
MDIB0095E

8. Align the alignment marks on bearing cap and carrier case,
and then tighten the mounting bolts to the specified torque. A
• For tightening torque, refer to DLN-218, "Exploded View".
JPDID0255ZZ
DLN
9. Install side bearing adjusting nuts to the carrier case using
wrench (A) (SST: KV10109900), and then tighten so that the
total preload and the backlash are within the standard. Refer to
E
DLN-225, "Adjustment".
10. Check the drive gear runout, tooth contact, backlash and total
preload. Refer to DLN-225, "Adjustment".
F
G
JPDID0061ZZ
11. Install the lock finger . H

MDIB0099E
K
TOTAL PRELOAD TORQUE L

2. Rotate drive pinion back and forth 2 to 3 times to check for
unusual noise and rotation malfunction. M
3. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
N
O
JPDID0039ZZ

4. While rotate drive pinion at 30 rpm or 60 rpm, measure total pre-
load with the preload gauge (A) (SST: ST3127S000).

Torque".
NOTE:
bearing preload torque
and side bearing preload. JPDID0102ZZ
Adjust the pinion bearing preload first, then adjust the side
bearing preload.
When the preload torque is large

On side bearings: Loosen side bearing adjusting nut.
When the preload is small

On side bearings: Tighten side bearing adjusting nut.
CAUTION:
Retighten or loosen the left and right side bearing nuts evenly so that they are within the stan-
dard.
DRIVE GEAR RUNOUT
JPDID0039ZZ

face runout Runout".
drive gear and differential case, or differential case or drive
CAUTION:
Replace drive gear and drive pinion gear as a set.
SDIA1279J
TOOTH CONTACT

A
JPDID0039ZZ
DLN
CAUTION:
E
G
PDE0045D
H
ion gear to drive gear tooth contact.
CAUTION:
I
SDIA0570E
K

SDIA0207E
4. If tooth contact is improperly adjusted, follow the procedure

below to adjust the pinion height (dimension X).
SDIA0517E
move drive pinion closer to drive gear.
mation.
PDIA0440E

• If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin pinion height adjusting washer to move A
mation.
B
PDIA0441E
DLN
BACKLASH
E
JPDID0039ZZ
H
lash.
Backlash : Refer to DLN-242, "Backlash". I

side bearing adjusting nut.
J
Tighten side bearing adjusting nut on the differential
case side, and then tighten side adjusting nut on the K
SDIA1278J
drive gear side.
L
Tighten side bearing adjusting nut on the drive gear
side, and then tighten side adjusting nut on the differ-
ential case side.
M
CAUTION:
If it is outside the standard, retighten or loosen the left and right side bearing adjusting nuts
evenly so that they are within the standard.
N
INSPECTION AFTER DISASSEMBLY O

• If the gear teeth never mesh or line-up correctly, determine the cause and adjust or replace as necessary. P
Bearing

DIFFERENTIAL CASE
SIDE GEAR AND PINION MATE GEAR
• If any cracks or damage on the surface of the tooth is found, replace.
• If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
SIDE GEAR THRUST WASHER AND PINION MATE THRUST WASHER
• If it is chipped (by friction), damaged, or unusually worn, replace.

DRIVE PINION
DRIVE PINION
A
DLN
I
JSDIA6744GB
Drive pinion lock nut Companion flange Front oil seal J

Pinion front bearing Carrier case Collapsible spacer
K
Drive gear Differential case* Side bearing
Side gear thrust washer* Side gear* Pinion mate thrust washer* L
Pinion mate gear* Pinion mate shaft* Lock pin*
dure when tightening. Refer to DLN- M

: N·m (kg-m, ft-lb) N

O
: Apply gear oil.

P
*: These may be assembled parts. For supply unit, refer to the latest parts information.
DISASSEMBLY

DRIVE PINION
JSDIA6777ZZ

mark should be in line with the matching mark on companion
flange .
CAUTION:
NOTE:
sary. PDIA0799J

service tool).
MDIB0075E
5. Remove drive pinion, using the drift (A) (SST: ST22360002).

CAUTION:
vice tool).
CAUTION:
7. Remove pinion front bearing inner race.
JPDID0104ZZ

DRIVE PINION
ing washer with the separator (commercial service tool). A
JPDID0055ZZ
DLN
10. Tap pinion front bearing outer race and rear bearing outer
them. E
CAUTION:
"Inspection". F
G
JSDIA6790ZZ
ASSEMBLY
H
1. Install front bearing outer race using drift (A) (SST:
KV38100500).
CAUTION:
• At first, using a hammer, tap bearing outer race until it I
J
K
JSDIA6791ZZ
2. Install rear bearing outer race using drift (A) (commercial ser- L
vice tool).
CAUTION:
becomes flat to carrier case. M
JSDIA6792ZZ O

DRIVE PINION
CAUTION:
When hypoid gear set has been replaced
"Adjustment".
drift (A) (commercial service tool).
CAUTION:
JSDIA0761ZZ
5. Check and adjust the tooth contact and backlash of drive gear and drive pinion following the procedure
below.
CAUTION:
• Never assemble collapsible spacer.
bly.
CAUTION:
c. Install companion flange.
CAUTION: JPDID0105ZZ

NOTE:
PDIA0799J

DRIVE PINION
d. Tap the companion flange with a plastic hammer as far as the
drive pinion lock nut can be tightened. A
CAUTION:
e. Temporarily tighten removed drive pinion lock nut to drive pinion. B
NOTE:
Use removed drive pinion nut only for the preload measurement.
f. Rotate drive pinion more than 20 times to adjust bearing.
C
SPD697
DLN
the flange wrench (commercial service tool), while adjusting pin-
ion bearing preload torque using preload gauge (A) (SST:
E
ST3127S000).
Pinion bearing preload : 1.0 - 1.3 N·m (0.11 – 0.13 kg-m,

(without oil seal) 9 – 11 in-lb) F
CAUTION:
spacer. Be careful not to overtighten it. While measuring the G
preload, tighten it by 5° to 10°. JPDID0102ZZ
h. Install differential assembly. Refer to DLN-219, "Disassembly and Assembly".

i. Check and adjust tooth contact, drive gear to drive pinion backlash. Refer to DLN-225, "Adjustment". H
j. Remove differential assembly.
k. Remove companion flange.
I
l. Remove drive pinion assembly from carrier case.
m. Remove pinion front bearing inner race.
6. Assemble collapsible spacer. J
CAUTION:
7. Assemble drive pinion into carrier case. K
CAUTION:
L
bly.
CAUTION:
• Apply gear oil to pinion front bearing. M
JPDID0105ZZ
N
9. Using press stand (A) (SST: KV40105710), press the pinion
front bearing inner race to drive pinion as far as drive pinion
nut can be tightened. O
JSDIA6796ZZ

DRIVE PINION
end, using the drifts (A and B) as shown in figure.

CAUTION:
JSDIA6802ZZ

NOTE:
pinion.
CAUTION:
PDIA0799J
(commercial service tool), tighten drive pinion lock nut within the
ST3127S000).

load Torque".
CAUTION:
ening torque first.
• After adjustment, rotate drive pinion back and forth 2 to 3
14. Install differential assembly. Refer to DLN-219, "Disassembly
and Assembly".
CAUTION:
Never install lock finger yet.
15. Check and adjust drive gear runout, tooth contact, and drive JSDIA6803ZZ
17. Check total preload torque. Refer to DLN-225, "Adjustment".

DRIVE PINION
18. Install the lock finger .
• For tightening torque, refer to DLN-218, "Exploded View". A
MDIB0099E
DLN
PINION GEAR HEIGHT E

washer thickness.
F
T = T0 + (t1− t2)
T: Correct washer thickness G
Old drive pinion head letter “H × 0.01”
t1: H
t2:
I
Example:
T = 3.21 + [(2 × 0.01) − (−1 × 0.01)] = 3.24
T0: 3.21 J
t1: +2
t2: −1
K
information.
CAUTION:
If unable to find a washer of desired thickness, use a washer with thickness closest to the calcu- L
lated value.
Example: M
N
1. Fit a dial indicator to the outer side of companion flange (socket
diameter).
O
Outer side of the companion : Refer to DLN-242, P

Runout".
3. If the runout value is outside the runout limit, follow the proce-
dure below to adjust.
a. Check for runout while changing the phase between companion JSDIA6824ZZ
flange and drive pinion by 90° step, and search for the position
where the runout is the minimum.

DRIVE PINION
assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for

Bearing
Oil Seal
Companion Flange
panion flange is found, replace.
Carrier Case

< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR FINAL DRIVE: H215]

B
M/T MODELS
QR25DE Models C
Axle 2WD
Applied model
Engine QR25DE DLN
Final drive model H215
Gear ratio 3.916 4.083 4.363
E
Number of teeth (Drive gear/Drive pinion) 47/12 49/12 48/11
Drive pinion adjustment spacer type Collapsible F
YD25DDTi Models
G
Axle 2WD
Applied model
Engine YD25DDTi H
Gear ratio 3.357 3.538 3.692 3.916 4.083
Number of teeth (Drive gear/Drive pinion) 47/14 46/13 48/13 47/12 49/12 I
J
Axle 4WD K
Applied model
Engine YD25DDTi
Gear ratio 3.357 3.538 3.692 4.363
L
M
YS23DDT AND YS23DDTT Models N
Axle 2WD
Applied model O
Engine YS23DDT/YS23DDTT
Gear ratio 3.357 3.538 3.692 P

Axle 4WD
Applied model
Gear ratio 3.357 3.538 3.692
A/T MODELS
QR25DE Models
Axle 2WD
Applied model
Engine QR25DE
Gear ratio 3.538
Number of teeth (Drive gear/Drive pinion) 46/13
YD25DDTi Models
Axle 2WD 4WD

Applied model
Engine YD25DDTi
Gear ratio 3.357 3.916 3.357 3.916
YS23DDT AND YS23DDTT Models
Axle 2WD 4WD

Applied model
Gear ratio 3.357
GEAR RATIO: 3.357 TYPE

NOTE:
Gear ratio is stamped on side surface of drive gear.

Item Standard A
Rotating speed: 30 rpm 1.07 – 1.46 (0.11 – 0.14, 10 – 12)
Pinion bearing (P1)
B
Total preload (Side bearing to pinion bearing) Rotating speed: 30 rpm 1.362 – 2.053 (0.14 – 0.20, 12 – 18)
NOTE:
P1: Pinion bearing preload Rotating speed: 60 rpm 1.173 – 1.844 (0.12 – 0.18, 11 – 16) C
P2: Side bearing preload

NOTE: DLN
Item Standard E
Pinion bearing (P1)
F
NOTE:
P1: Pinion bearing preload Rotating speed: 60 rpm 1.159 – 1.814 (0.12 – 0.18, 11 – 16) G

H
NOTE:
Item Standard
I

Pinion bearing (P1)
Rotating speed: 60 rpm 0.89 – 1.26 (0.09 – 0.12, 8 – 11) J
NOTE:
P1: Pinion bearing preload Rotating speed: 60 rpm 1.147 – 1.791 (0.12 – 0.18, 11 – 15) K
GEAR RATIO: 3.916 TYPE L

NOTE:
M
Item Standard
Pinion bearing (P1)
Rotating speed: 60 rpm 0.89 – 1.26 (0.09 – 0.12, 8 – 11) N
NOTE:
P1: Pinion bearing preload Rotating speed: 60 rpm 1.133 – 1.761 (0.12 – 0.17, 10 – 15) O
GEAR RATIO: 4.083 TYPE P

NOTE:
Item Standard
Pinion bearing (P1)

Item Standard
NOTE:
P1: Pinion bearing preload Rotating speed: 60 rpm 1.123 – 1.740 (0.12 – 0.17, 10 – 15)

NOTE:
Item Standard
Pinion bearing (P1)
NOTE:
Unit: mm (in)
Item Standard
Drive gear back face runout 0.05 (0.0020) or less
Unit: mm (in)
Item Standard
Drive gear to drive pinion gear 0.10 – 0.15 (0.0039 – 0.0059)
Unit: mm (in)
Item Standard
Outer side of the companion flange runout 0.08 (0.0031) or less
Differential Side Gear Clearance INFOID:0000000011274788
Unit: mm (in)
Item Standard
0.10 (0.004) or less
Side gear backlash (Clearance between side gear and differential
(Each gear should rotate smoothly without excessive resistance
case)
during differential motion.)

PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: H215 (DL)]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000011786392
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING: DLN
• 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 E
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
F
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors. G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING: H
• 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 I
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. J
When disconnecting the battery terminal, pay attention to the following. K

L
M
K9K engine : 4 minutes ZD30DDTi : 60 seconds N
SEF289H
V9X engine : 4 minutes O
NOTE:
ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal P
NOTE:

PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: H215 (DL)]
NOTE:
NOTE:
Service Notice or Precautions for Rear Final Drive INFOID:0000000011862891
• Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
purpose grease as specified for each vehicle, if necessary.

PREPARATION
< PREPARATION > [REAR FINAL DRIVE: H215 (DL)]
PREPARATION A
PREPARATION
B
Tool number
Description C
Tool name
KV10109900 Removing and installing side bearing adjust-
Wrench ing nut
DLN
E
S-NT035
KV10112100 Tightening drive gear mounting bolt

Angle wrench F
ZZA0120D
H
Drift
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia. I
J
ZZA0814D
KV40105330 Installing side bearing inner race

Drift
K
a: 62.5 mm (2.461 in) dia.
b: 55 mm (2.17 in) dia.
c: 15 mm (0.59 in)
L
ZZA1133D
ST3127S000 Measuring pinion bearing preload and total M

ZZA0503D O
ST22360002 Removing drive pinion
Drift
a: 29 mm (1.14 in) dia. P
b: 23 mm (0.91 in) dia.
ZZA0534D

PREPARATION
Tool number
Description
Tool name
KV38100500 Installing front bearing outer race
Drift
a: 80 mm (3.15 in) dia.
b: 60 mm (2.36 in) dia.
SDIA1264J
KV40105710 Installing pinion front bearing inner race

Press stand
a: 50 mm (1.97 in) dia.
b: 40 mm (1.57 in) dia.
S-NT509
KV40101840 Installing front oil seal

Drift
a: 85 mm (3.35 in) dia.
b: 67 mm (2.64 in) dia.
c: 77 mm (3.03 in) dia.
JSDIA6038ZZ
ST30720000 Installing front oil seal

Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
SDIA1264J

Puller • Removing side bearing inner race
• Removing companion flange
ZZA0119D
Adaptor Removing side bearing inner race

a: 48 – 54 mm (1.89 – 2.13 in) dia.
JSDIA6815ZZ

PREPARATION
A
C
NT035
Oil seal remover Removing front oil seal
DLN
JSDIA4998ZZ
Separator Removing pinion rear bearing inner race F
ZZA0700D
H
Drift Installing rear bearing outer race
a: 104 – 106 mm (4.09 – 4.17 in) dia.
J
S-NT109
Drift Installing pinion rear bearing inner race

a: 52 mm (2.05 in) dia. K
b: 46 mm (1.81 in) dia.
S-NT661
M
Item Use N
Application to threads of drain plug and filler plug
O
Application to threads of differential lock position switch
Application into the thread hole of drive gear P

COMPONENT PARTS
< SYSTEM DESCRIPTION > [REAR FINAL DRIVE: H215 (DL)]
SYSTEM DESCRIPTION
COMPONENT PARTS
Component Parts Location INFOID:0000000011786296
LHD MODELS
JSDIA7264ZZ
Rear final drive

Differential lock control unit Refer to DLN-250, "Differential Lock Control Unit".
Mainly transmits the following signal to differential lock control unit via CAN communica-
tion.
• 4WD mode signal
For detailed installation location, refer to DLN-11, "Component Parts Location".
tion.
For detailed installation location, refer to EC-422, "Component Parts Location"
(YD25DDTi), EC-762, "YS23DDTT : Component Parts Location" (YS23DDTT).
Mainly transmits the following signals to differential lock control unit via CAN communica-
tion.
ABS actuator and electric unit • ABS operation signal
(control unit) • VDC operation signal
• ABS malfunction signal
• VDC malfunction signal
For detailed installation location, refer to BRC-126, "Component Parts Location".

COMPONENT PARTS
A
Mainly receives the following signal from differential lock control unit via CAN communica-
tion.
Combination meter • Differential lock indicator lamp signal
For detailed installation location, refer to MWI-8, "METER SYSTEM : Component Parts Lo- B
cation".
Differential lock mode switch Refer to DLN-251, "Differential Lock Mode Switch".
Differential lock solenoid Refer to DLN-250, "Differential Lock Solenoid". C
Differential lock position switch Refer to DLN-250, "Differential Lock Position Switch".
RHD MODELS DLN
JSDIA7265ZZ M
Rear final drive
N
tion. O
For detailed installation location, refer to EC-422, "Component Parts Location"
(YD25DDTi), EC-762, "YS23DDTT : Component Parts Location" (YS23DDTT).
P
Mainly transmits the following signals to differential lock control unit via CAN communica-
tion.
ABS actuator and electric unit • ABS operation signal
(control unit) • VDC operation signal
For detailed installation location, refer to BRC-126, "Component Parts Location".

COMPONENT PARTS
Differential lock control unit Refer to DLN-250, "Differential Lock Control Unit".
Differential lock mode switch Refer to DLN-251, "Differential Lock Mode Switch".
tion.
• 4WD mode signal
For detailed installation location, refer to DLN-11, "Component Parts Location".
Mainly receives the following signal from differential lock control unit via CAN communica-
tion.
Combination meter • Differential lock indicator lamp signal
For detailed installation location, refer to MWI-8, "METER SYSTEM : Component Parts Lo-
cation".
Differential lock solenoid Refer to DLN-250, "Differential Lock Solenoid".
Differential lock position switch Refer to DLN-250, "Differential Lock Position Switch".
Differential Lock Control Unit INFOID:0000000011786298
• Differential lock control unit, according to signal from differential

lock mode switch, controls differential lock solenoid and switches
status of rear differential (lock/unlock).
• Fail-safe mode is available if malfunction is detected in differential
lock system. For fail-safe, refer to DLN-262, "Fail-Safe".
JSDIA7245ZZ
Differential Lock Solenoid INFOID:0000000011786299
Differential lock solenoid controls pressure plate according to signal

from differential lock control unit.
JSDIA7246ZZ
Differential Lock Position Switch INFOID:0000000011786300
Differential lock position switch detects status of rear differential

(lock/unlock) according to the position of pressure plate and trans-
mits signal to differential lock control unit.
JSDIA7247ZZ

COMPONENT PARTS
Differential Lock Mode Switch INFOID:0000000011786301
A
Differential lock mode switch activates or deactivates differential lock
system according to switch position.
B
DLN
JSDIA7248ZZ

JSDIA7240ZZ
Companion flange Pinion front bearing Collapsible spacer

Pinion rear bearing Drive gear Pinion mate shaft
Side bearing adjusting nut Side bearing Side gear
Pinion mate gear Return spring Differential case
Differential lock solenoid Cam ring Differential lock position switch
Pressure plate Drive pinion

Differential Lock Mechanism INFOID:0000000011786303
A
CONTROL DIAGRAM
DLN
SDIA2498E
G
OPERATION PRINCIPLE
UNLOCK MODE
Cam ring (drive) and side gear (driven) are not engaged by spring force of return spring. H
LOCK MODE
1. Differential lock solenoid operates pressure plate.
2. Pressure plate presses cam ring. I
3. Engage cam ring (drive) and side gear (driven), and the differential is locked.
J

SYSTEM
SYSTEM
DIFFERENTIAL LOCK SYSTEM
DIFFERENTIAL LOCK SYSTEM : System Description INFOID:0000000011786305
• Differential lock system is a device that locks differential function and facilitates emergency escaping of the
vehicle when being stuck on a rough road, muddy road, deep snowy road, or when driving is impossible due
to one-sided wheel spin.
• Lock/unlock of rear differential is switched according to operation of differential lock mode switch.
• Fail-safe function deactivates differential lock system when the system is malfunctioning. Refer to DLN-262,
"Fail-Safe".
SYSTEM DIAGRAM
JSDIA7249GB
Signal with Communication Line

Major signal transmission between each unit via CAN communication lines are shown in the following table.

Mainly receives the following signal from differential lock control unit via CAN commu-
Combination meter nication.
• Differential lock indicator lamp signal
Mainly transmits the following signals to differential lock control unit via CAN communi-
cation.
ABS actuator and electric unit (control unit) • ABS operation signal
• VDC operation signal
Mainly transmits the following signal to differential lock control unit via CAN communi-
ECM cation.
Mainly transmits the following signal to differential lock control unit via CAN communi-
Transfer control unit cation.
• 4WD mode signal
CONDITION FOR OPERATE DIFFERENTIAL LOCK

SYSTEM
Differential lock mode Differential lock opera- A

4WD mode ABS or VDC operation Vehicle speed
switch tion
2WD — — OFF
4H — — OFF B
ON
7 km/h (4 MPH) or more OFF
4L OFF*
7 km/h (4 MPH) or less ON
C
*: VDC function is not operate when 4WD mode is “4L”.
DLN

SYSTEM
DIFFERENTIAL LOCK SYSTEM : Circuit Diagram INFOID:0000000011863227
JSDIA7472GB
DIFFERENTIAL LOCK SYSTEM : Fail-Safe INFOID:0000000011863223
If any malfunction occurs in differential lock system, and control unit detects the malfunction, differential lock
control unit controls becomes the fail-safe mode depending on DTC.

SYSTEM
DTC Vehicle condition A

Except the following DTC Rear differential lock is disengaged.
•P1856
No impact to vehicle behavior. (Differential lock system can operate.)
•P18D0 B
WARNING/INDICATOR/CHIME LIST
WARNING/INDICATOR/CHIME LIST : Warning Lamp/Indicator Lamp INFOID:0000000011863225 C
Name Design Layout/Function DLN

Differential lock indicator lamp For function: Refer to MWI-37, "WARNING LAMPS/INDICATOR LAMPS : Differen-
tial Lock Indicator Lamp". E

DIAGNOSIS SYSTEM (DIFFERENTIAL LOCK CONTROL UNIT)
CONSULT Function INFOID:0000000011786307
APPLICATION ITEMS
CONSULT can display each diagnostic item using the diagnostic test modes as follows.
Diagnostic test mode Function

ECU Identification Differential lock 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 differential lock control unit can be read.
*: The following diagnosis information is erased by erasing.
• DTC
• Freeze frame data (FFD)
ECU IDENTIFICATION
Differential lock control unit part number can be read.
SELF DIAGNOSTIC RESULT
Refer to DLN-262, "DTC Index".
When “PRSNT” is displayed on self-diagnosis result.
• The system is presently malfunctioning.
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)
The following vehicle status is recorded when DTC is detected and is displayed on CONSULT.
Item name Display item

The number of times that ignition switch is turned ON after the DTC is detected is displayed.
• When “0” is displayed: It indicates that the system is presently malfunctioning.
• When except “0” is displayed: It indicates that system malfunction in the past is detected, but the system is pres-
IGN COUNTER ently normal.
(0 – 39) NOTE:
Each time when ignition switch is turned OFF to ON, numerical number increases in 1→2→3...38→39.
When the operation number of times exceeds 39, the number do not increase and “39” is displayed until self-
diagnosis is erased.
DATA MONITOR
NOTE:

CONT MODUL VOLT (V) Power supply voltage for differential lock control unit is displayed.
SOLENOID VOLT (V) Power supply voltage for differential lock solenoid is displayed.
4WD MODE (2H/4H/4Lo) 4WD shift switch status is displayed.
INDICATOR (On/Off/FLASH) Control status of differential lock indicator lamp is displayed.
D-LOCK SW SIG (On/Off) Differential lock mode switch position is displayed.
D-LOCK PERMIT SIGNAL (On/Off) Differential lock operation permission by differential lock control unit is displayed.
D-LOCK POS SW (On/Off) Condition of differential lock position switch is displayed.
BUZ SIG (On/Off) Buzzer is not equipped, but it is displayed.
SOLENOID DRIVE MONITOR (On/Off) Monitored driving status of differential lock solenoid is displayed.
FAIL-SAFE RELAY SIGNAL (On/Off) Signal state for operating the fail-safe relay is displayed.
WHEEL SPD SEN RR (km/h or mph) Wheel speed calculated by rear RH wheel sensor signal is displayed.

A
WHEEL SPD SEN RL (km/h or mph) Wheel speed calculated by rear LH wheel sensor signal is displayed.
VHCL/S SEN-RR (km/h or mph) Average of rear wheel sensors (left and right is displayed.
DLN

DIFFERENTIAL LOCK CONTROL UNIT
< ECU DIAGNOSIS INFORMATION > [REAR FINAL DRIVE: H215 (DL)]
ECU DIAGNOSIS INFORMATION

Reference Value INFOID:0000000011786308
VALUES ON THE DIAGNOSIS TOOL

NOTE:

CONT MODUL VOLT Ignition switch: ON 9 – 16 V
SOLENOID VOLT Ignition switch: ON 9 – 16 V
4WD shift switch: 2H 2H
4WD MODE 4WD shift switch: 4H 4H
4WD shift switch: 4L 4L
Differential lock indicator lamp: ON On
INDICATOR Differential lock indicator lamp: OFF Off
Differential lock indicator lamp: Flash FLASH
Differential lock mode switch: ON On
D-LOCK SW SIG
Differential lock mode switch: OFF Off
4WD shift switch: Except 4L Off
D-LOCK PERMIT SIGNAL • 4WD shift switch: 4L

Differential lock mode Off
• Vehicle speed above 7 km/h (4 MPH)
switch: ON
• 4WD shift switch: 4L
On
• Vehicle speed below 7 km/h (4 MPH)
Differential lock system: Lock mode On
D-LOCK POS SW Differential lock system: Unlock mode Off
Differential lock standby condition Off
BUZ SIG Always Off
4WD shift switch: Except 4L Off
SOLENOID DRIVE MONITOR • 4WD shift switch: 4L

Differential lock mode Off
• Vehicle speed above 7 km/h (4 MPH)
switch: ON
• 4WD shift switch: 4L
On
• Vehicle speed below 7 km/h (4 MPH)
Differential lock system: In fail-safe mode On
FAIL-SAFE RELAY SIGNAL
Differential lock system: Not malfunction Off
WHEEL SPD SEN RR Vehicle running (in straight-ahead driving)

Nearly matches the speed
CAUTION:
meter display (±10% or less)
Check air pressure of tire under standard condition.
WHEEL SPD SEN RL Vehicle running (in straight-ahead driving)

CAUTION:
meter display (±10%)

A
VHCL/S SEN-RR Vehicle running

CAUTION:
meter display (±10%) B
TERMINAL LAYOUT
C
DLN
JSDIA0057ZZ
PHYSICAL VALUES F
Terminal No.
Description
(Wire color)
Condition Value (Approx.) G
Input/
+ - Signal name
Output
1 Differential lock so- Differential lock mode switch: ON 9 – 16 V H

Ground Output Ignition switch: ON
(Y) lenoid (+) Differential lock mode switch: OFF 0V
2 Differential lock so- Differential lock mode switch: ON 0V

Ground Input Ignition switch: ON I
(V) lenoid (-) Differential lock mode switch: OFF 9 – 16 V
5 Differential lock mode switch: ON 9 – 16 V
Differential lock
(LG)*1 Ground Input Ignition switch: ON
mode switch (ON) Differential lock mode switch: OFF 0V J
(G)*2
7 Ignition switch: ON 9 – 16 V
Ground Ignition signal Input
(SB) Ignition switch: OFF 0V K
8 Input/
— CAN-H — —
(L) Output
9 L
Power supply for
(GR)*1 Ground Input Always 9 – 16 V
solenoid
(R)*2
10 M
(B)
11
(B) N
Differential lock system: Lock mode
0V
(Differential lock indicator lamp: ON)
12 Differential lock po- Differential lock system: Unlock mode O
Ground Input Ignition switch: ON 9 – 16 V
(L) sition switch (Differential lock indicator lamp: OFF)
Differential lock standby condition
9 – 16 V
(Differential lock indicator lamp: Flash)
P
14 Differential lock Differential lock mode switch: ON 0V
Ground Input Ignition switch: ON
(BG) mode switch (OFF) Differential lock mode switch: OFF 9 – 16 V

Terminal No.
Description
(Wire color)
Input/
+ - Signal name
Output
Power supply for
15
Ground control unit (back- Input Always 9 – 16 V
(G)
up)
16 Input/
— CAN-L — —
(P) Output
*1: LHD models
*2: RHD models
CAUTION:
When using circuit tester to measure voltage for inspection, be sure not to extend forcibly any con-
nector terminals.
Fail-Safe INFOID:0000000011786309
If any malfunction occurs in differential lock system, and control unit detects the malfunction, differential lock
control unit controls becomes the fail-safe mode depending on DTC.

Except the following DTC Rear differential lock is disengaged.
•P1856
•P18D0
DTC Inspection Priority Chart INFOID:0000000011786310
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
Priority Detected items (DTC)

• U1000 CAN COMM CIRCUIT
1
• U1010 CONTROL UNIT (CAN)
2 Other than the above
DTC Index INFOID:0000000011786311
DTC Display Item Reference

P1836 CONTROL UNIT 3 DLN-273, "DTC Description"
P1838 ON SW DLN-274, "DTC Description"
P1839 POSI SW ON DLN-277, "DTC Description"
P1844 RELAY DLN-280, "DTC Description"
P1848 SOL DISCONNECT DLN-281, "DTC Description"
P1849 SOL SHORT DLN-285, "DTC Description"
P1850 SOL CURRENT DLN-289, "DTC Description"
P1856 VDC SYSTEM DLN-291, "DTC Description"
P18CB SOLENOID POWER SUPPLY DLN-292, "DTC Description"
P18CC WHEEL SPEED SIGNAL DLN-295, "DTC Description"
P18CD INCOMPLETE SELF SHUTDOWN DLN-296, "DTC Description"
P18CE DIFF LOCK POSITION SWITCH DLN-298, "DTC Description"
P18D0 ABS SYSTEM DLN-301, "DTC Description"

DTC Display Item Reference
A
U1000 CAN COMM CIRCUIT DLN-302, "DTC Description"
U1010 CONTROL UNIT (CAN) DLN-303, "DTC Description"
NOTE: B
If some DTCs are displayed at the same time, refer to DLN-262, "DTC Inspection Priority Chart".
DLN

< WIRING DIAGRAM > [REAR FINAL DRIVE: H215 (DL)]
WIRING DIAGRAM
Wiring Diagram INFOID:0000000011786312
JRDWC5213GB

DLN
JRDWC5214GB

JRDWC5215GB

DLN
JRDWC5216GB

JRDWC5217GB

DLN
JRDWC5218GB

DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [REAR FINAL DRIVE: H215 (DL)]
BASIC INSPECTION
Work Flow INFOID:0000000011786313
DETAILED FLOW
1.INTERVIEW FROM THE CUSTOMER
Clarify customer complaints before inspection. First of all, perform an interview utilizing DLN-271, "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.
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 SYMPTOM
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 fail-safe function. Refer to DLN-262,
"Fail-Safe".
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.
>> GO TO 3.
3.PERFORM SELF-DIAGNOSIS
With CONSULT
Perform self-diagnosis for “DIFF LOCK”.
YES >> Record or print self-diagnosis results. GO TO 4.
NO >> GO TO 6.
4.RECHECK SYMPTOM
With CONSULT
1. Erase self-diagnostic results for “DIFF LOCK”.
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-
262, "DTC Inspection Priority Chart".
YES >> GO TO 5.
5.REPAIR OR REPLACE ERROR-DETECTED PARTS
• Repair or replace error-detected parts.
• Reconnect part or connector after repairing or replacing.
• When DTC is detected, erase self-diagnostic results for “DIFF LOCK”.
>> 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?

YES >> GO TO 7.
NO >> Check harness and connectors based on the information obtained by interview. Refer to GI-47, A
7.FINAL CHECK
B
With CONSULT
1. Check the reference value for differential lock control unit.
2. Recheck the symptom and check that symptom is not reproduced on the same conditions.
Is the symptom reproduced? C
YES >> GO TO 3.
DLN
Diagnostic Work Sheet INFOID:0000000011786314
Description E
• 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. F
Interview sheet sample

G
Interview sheet
Registration Initial year
Customer number registration
MR/MS H
name
Vehicle type VIN
Storage date Engine Mileage km ( Mile)
Differential lock indicator lamp does not turn ON with differential lock mode switch ON. I
Differential lock indicator lamp flashes while driving.
Symptom Noise Vibration
J
Others
( )
First occurrence Recently Others ( )
K
Frequency of occurrence Always Under a certain conditions of Sometimes (time(s)/day)
Irrelevant
Climate con- Weather Fine Cloud Rain Snow Others ( ) L

ditions Temperature Hot Warm Cool Cold Temperature [Approx. °C( °F)]
Relative humidity High Moderate Low
M
Urban area Suburb area High way
Road conditions
Mounting road (uphill or down hill) Rough road
Irrelevant
When engine starts During idling
N
Operation conditions, etc.
During driving During acceleration At constant speed driving
During deceleration During cornering (right curve or left curve)
O

Interview sheet
Registration Initial year
Customer number registration
MR/MS
name
Vehicle type VIN
Storage date Engine Mileage km ( Mile)
Other conditions
Memo

P1836 DIFFERENTIAL LOCK CONTROL UNIT
< DTC/CIRCUIT DIAGNOSIS > [REAR FINAL DRIVE: H215 (DL)]
DTC/CIRCUIT DIAGNOSIS A
B
DTC DETECTION LOGIC

Malfunction is detected in the memory (EEPROM) system of differential lock control unit. C

DTC No. DTC detecting condition
DLN
Diagnosis condition Ignition switch: ON
CONTROL UNIT 3 Signal —

P1836
(Control unit 3) Threshold — E
Diagnosis delay time —
POSSIBLE CAUSE F
Internal malfunction of differential lock control unit.
FAIL-SAFE
When differential lock system is malfunctioning, fail-safe status activates and rear differential lock is disen- G
gaged.
H
1.PRECONDITIONING
wait at least 10 seconds before conducting the next test. I
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE J
With CONSULT
K
2. Perform self-diagnosis for “DIFF LOCK”.
YES >> Proceed to diagnosis procedure. Refer to DLN-273, "Diagnosis Procedure". L
M
With CONSULT N
After erasing the DTC, perform DTC confirmation procedure again. Refer to DLN-273, "DTC Description".
YES >> Replace differential lock control unit. Refer DLN-312, "Removal and Installation". O
NO >> Check differential lock control unit pin terminals for damage or loose connection with harness con-
nector. If any items are damaged, repair or replace error-detected parts.
P

P1838 DIFFERENTIAL LOCK MODE SWITCH
DTC DETECTION LOGIC

More than two switch inputs are simultaneously detected due to short circuit of differential lock mode switch.

ON SW Signal (terminal) Differential lock mode switch (terminal #5 and #14)

P1838
(Differential lock ON switch) Threshold —
POSSIBLE CAUSE
• Malfunction of differential lock mode switch
• Malfunction of differential lock mode switch circuit
• Internal malfunction of differential lock control unit
FAIL-SAFE
When differential lock system is malfunctioning, fail-safe status activates and rear differential lock is disen-
gaged.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
CAUTION:
Stop the vehicle.
2. Operate differential lock mode switch to each position.
1.CHECK DIFFERENTIAL LOCK MODE SWITCH

Check differential lock mode switch. Refer to DLN-276, "Component Inspection".
YES >> GO TO 2.
NO >> Replace differential lock mode switch. Refer to DLN-313, "Removal and Installation".
2.CHECK IGNITION VOLTAGE FOR DIFFERENTIAL LOCK MODE SWITCH
2. Disconnect differential lock mode switch harness connector.
3. Check the voltage between differential lock mode switch harness connector and ground.

Differential lock mode switch A

— Voltage (Approx.)
Connector Terminal
M79 1 Ground 0V
B
CAUTION:
5. Check the voltage between differential lock mode switch harness connector and ground. C
Differential lock mode switch

— Voltage DLN
Connector Terminal
M79 1 Ground 9 – 16 V
Is the inspection result normal? E
YES >> GO TO 4.
NO >> GO TO 3.
3.CHECK IGNITION SIGNAL CIRCUIT FOR DIFFERENTIAL LOCK MODE SWITCH F

G
4. Check the continuity between differential lock mode switch harness connector and fuse block (J/B) har-
ness connector.
H
Differential lock mode
Fuse block (J/B)
switch Continuity
Connector Terminal Connector Terminal I
M79 1 M36 10C Existed
5. Check the continuity between differential lock mode switch harness connector and the ground. J

— Continuity
Connector Terminal K
L
M
4.CHECK DIFFERENTIAL LOCK MODE SWITCH SIGNAL
2. Connect differential lock mode switch harness connector. N
3. Disconnect differential lock control unit harness connector.
CAUTION:
Never start the engine. O
5. Check the voltage between differential lock control unit harness connector and ground.
Differential lock control unit P

— Condition Voltage (Approx.)
Connector Terminal
Differential lock mode switch: ON 9 – 16 V
5
Differential lock mode switch: OFF 0V
M80 Ground
Differential lock mode switch: ON 0V
14
Differential lock mode switch: OFF 9 – 16 V

YES >> GO TO 5.
NO >> GO TO 6.
5.CHECK DIFFERENTIAL LOCK MODE SWITCH SIGNAL CIRCUIT
2. Disconnect differential lock mode switch harness connector.
3. Check the continuity between differential lock control unit harness connector and differential lock mode
switch harness connector.
Differential lock mode

Differential lock control unit
switch Continuity
2 Existed
5
7 Not existed
M80 M79
2 Not existed
14
7 Existed
4. Check the continuity between differential lock control unit harness connector and ground.

— Continuity
Connector Terminal
5
M80 Ground Not existed
14
YES >> GO TO 6.
NO >> Repair or replace damaged parts.
6.CHECK TERMINALS AND HARNESS CONNECTORS
• Check differential lock control unit pin terminals for damage or loose connection with harness connector.
• Check differential lock mode switch pin terminals for damage or loose connection with harness connector.
YES >> Replace differential lock control unit. Refer to DLN-312, "Removal and Installation".

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

Terminal
Differential lock mode switch: ON Existed
2
Differential lock mode switch: OFF Not existed
1
Differential lock mode switch: ON Not existed
7
Differential lock mode switch: OFF Existed
NO >> Replace differential lock mode switch. Refer to DLN-313, "Removal and Installation".

P1839 DIFFERENTIAL LOCK POSITION SWITCH
A

When differential lock position switch is ON, rotation difference occurs in wheel speed (rear wheel right and
left).
C
Diagnosis condition Engine running and vehicle running
DLN
POSI SW ON Signal (terminal) Differential lock position switch (terminal #12)
P1839 (Differential lock position
switch ON) Threshold —
Diagnosis delay time — E
POSSIBLE CAUSE
• Malfunction of differential lock position switch F
• Malfunction of differential lock position switch circuit
FAIL-SAFE G
gaged.
DTC CONFIRMATION PROCEDURE H
1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and I
>> GO TO 2. J
With CONSULT
K
2. Turn the differential lock mode switch ON.
3. Drive at 20km/h (12 MPH) or less for approx. 1 minute on the curved road.
4. Perform self-diagnosis for “DIFF LOCK”. L
NO-1 >> To check malfunction symptom before repair: Refer to GI-47, "Intermittent Incident". M
N
1.CHECK DIFFERENTIAL LOCK POSITION SWITCH GROUND CIRCUIT
Check the continuity between differential lock position switch harness connector and ground.
O
2. Disconnect differential lock position switch harness connector.
3. Check the continuity between differential lock position switch harness connector and ground.
P
Differential lock position switch
— Continuity
Connector Terminal
C10 3 Ground Existed
YES >> GO TO 2.

2.CHECK DIFFERENTIAL LOCK POSITION SWITCH SIGNAL CIRCUIT
2. Check the continuity between differential lock control unit harness connector and differential lock position
Differential lock position

switch Continuity
M80 12 C10 1 Existed

— Continuity
Connector Terminal
YES >> GO TO 3.
3.CHECK DIFFERENTIAL LOCK POSITION SWITCH SIGNAL
1. Connect differential lock control unit harness connector.
CAUTION:
3. Check the voltage between differential lock position switch harness connector and ground.

— Voltage
Connector Terminal
C10 1 Ground 9 – 16 V
YES >> GO TO 4.
4.CHECK DIFFERENTIAL LOCK POSITION SWITCH
Check differential lock position switch. Refer to DLN-278, "Component Inspection".
YES >> GO TO 5.
NO >> Replace differential lock position switch. Refer to DLN-324, "Disassembly and Assembly".
• Check differential lock position switch pin terminals for damage or loose connection with harness connector.

2. Remove differential lock position switch. Refer to DLN-324, "Disassembly and Assembly".

3. Check the continuity between differential lock position switch
connector terminals. A
Differential lock
position switch Condition Continuity B
Terminal
While pulling rod of differential lock posi-

tion switch Existed C
(Differential system is locked state.)
1 3
While pushing rod of differential lock posi- JSDIA7253ZZ
tion switch Not existed DLN

(Differential system is unlocked state.)
YES >> INSPECTION END E

P1844 RELAY
P1844 RELAY
DTC DETECTION LOGIC

Differential lock control unit detects as irregular by comparing target value with monitor value.

RELAY Signal —
P1844
(Relay) Threshold —
POSSIBLE CAUSE
Internal malfunction of differential lock control unit
FAIL-SAFE
gaged.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1.CHECK POWER SUPPLY AND GROUND CIRCUIT

Perform the trouble diagnosis of the power supply and ground circuit. Refer to DLN-304, "Diagnosis Proce-
dure".
YES >> GO TO 2.
Check differential lock control unit pin terminals for damage or loose connection with harness connector.

P1848 DIFFERENTIAL LOCK SOLENOID
A

An open was detected in the differential lock solenoid or circuit.
CONSULT screen terms C

When all of the following conditions are satisfied:
Diagnosis condition • Ignition switch: ON
• Differential lock mode switch: ON
DLN
SOL DISCONNECT
P1848 Signal (terminal) Differential lock solenoid (terminal #1 and #2)
(Solenoid disconnect)
Threshold — E
POSSIBLE CAUSE
F
• Internal malfunction of differential lock solenoid
• Malfunction of differential lock solenoid circuit (open)
• Malfunction of differential lock solenoid command current
• Differential lock solenoid relay does not switch to ON position. G
FAIL-SAFE
gaged. H

1.PRECONDITIONING I
J
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE K
With CONSULT
CAUTION: L
M
NO-2 >> Confirmation after repair: INSPECTION END N
O
1.CHECK DIFFERENTIAL LOCK SOLENOID POWER SUPPLY VOLTAGE
2. Check the voltage between differential lock control unit harness connector and ground. P

— Voltage
Connector Terminal
M80 9 Ground 9 – 16 V
CAUTION:


— Voltage
Connector Terminal
M80 9 Ground 9 – 16 V
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK DIFFERENTIAL LOCK SOLENOID POWER SUPPLY CIRCUIT
4. Check the continuity between differential lock control unit harness connector and fuse block (J/B) harness
connector.
Differential lock control unit Fuse block (J/B)

Continuity
M80 9 M34 5A Existed
5. Check the continuity between differential lock control unit harness connector and the ground.

— Continuity
Connector Terminal
3.CHECK DIFFERENTIAL LOCK CONTROL UNIT GROUND

— Continuity
Connector Terminal
10
M80 Ground Existed
11
YES >> GO TO 4.
4.CHECK DIFFERENTIAL LOCK SOLENOID CIRCUIT
Check the resistance between differential lock control unit harness connector.

Connector Terminal
M80 1 2 2.9 Ω
YES >> GO TO 6.
NO >> GO TO 5.

5.CHECK HARNESS FOR DIFFERENTIAL LOCK SOLENOID CIRCUIT A

1. Remove differential lock solenoid harness connector.
2. Check the continuity between differential lock control unit harness connector and differential lock solenoid
harness connector.
B
Differential lock control unit Differential lock solenoid

Continuity
Connector Terminal Connector Terminal C
1 2
M80 C10 Existed
2 1
DLN

— Continuity E
Connector Terminal
1
M80 Ground Not existed
2 F
YES >> GO TO 6.
NO >> Repair or replace error-detected parts. G
6.CHECK DIFFERENTIAL LOCK SOLENOID

Check differential lock solenoid. Refer to DLN-283, "Component Inspection". H
YES >> GO TO 7.
NO >> Differential lock solenoid is malfunctioning. Replace differential assembly. Refer to DLN-324, "Dis- I
assembly and Assembly".
J
• Check differential lock solenoid pin terminals for damage or loose connection with harness connector.
K
YES >> After erasing the DTC, perform DTC confirmation procedure again. If DTC “P1848” is detected,
replace differential lock control unit. Refer to DLN-312, "Removal and Installation".
L
1.CHECK DIFFERENTIAL LOCK SOLENOID OPERATION M

2. Disconnect differential lock solenoid harness connector.
3. Apply 12 V to differential lock solenoid connector #1 (-) and #2 (+) terminals. N
CAUTION:
• Never make the terminals short.
• Connect the fuse between differential lock solenoid connector terminals.
Does differential lock solenoid operate? O
YES >> GO TO 2.
NO >> Differential lock solenoid is malfunctioning. Replace differential assembly. Refer to DLN-324, "Dis-
assembly and Assembly". P
2.CHECK DIFFERENTIAL LOCK SOLENOID RESISTANCE
2. Check the resistance between differential lock solenoid harness connector terminals.

Differential lock solenoid

Terminal
1 2 2.9 Ω

A

A short was detected in the differential lock solenoid internal circuit or in the harness.
CONSULT screen terms C

DLN
SOL SHORT
P1849 Signal Differential lock solenoid (terminal #1 and #2)
(Solenoid short)
Threshold — E
POSSIBLE CAUSE
F
• Internal malfunction of differential lock solenoid
• Malfunction of differential lock solenoid circuit (short)
FAIL-SAFE G
gaged.
DTC CONFIRMATION PROCEDURE H
1.PRECONDITIONING
I
>> GO TO 2. J
With CONSULT
1. Turn the ignition switch OFF to ON. K
CAUTION:
2. Turn the differential lock mode switch ON. L
YES >> Proceed to diagnosis procedure. Refer to DLN-285, "Diagnosis Procedure". M
Diagnosis Procedure INFOID:0000000011880170 N

1. Turn the ignition switch OFF. O
Differential lock control unit P

— Voltage
Connector Terminal
M80 9 Ground 9 – 16 V
CAUTION:


— Voltage
Connector Terminal
M80 9 Ground 9 – 16 V
YES >> GO TO 3.
NO >> GO TO 2.
connector.

Continuity

— Continuity
Connector Terminal

— Continuity
Connector Terminal
10
M80 Ground Existed
11
YES >> GO TO 4.
4.CHECK DIFFERENTIAL LOCK SOLENOID CIRCUIT
Check the resistance between differential lock control unit harness connector.

Connector Terminal
M80 1 2 2.9 Ω
YES >> GO TO 6.
NO >> GO TO 5.
5.CHECK HARNESS FOR DIFFERENTIAL LOCK SOLENOID CIRCUIT
1. Remove differential lock solenoid harness connector.

2. Check the continuity between differential lock control unit harness connector and differential lock solenoid
harness connector. A
Differential lock control unit Differential lock solenoid

Continuity
Connector Terminal Connector Terminal B
1 2
M80 C10 Existed
2 1
C
Differential lock control unit DLN

— Continuity
Connector Terminal
1
M80 Ground Not existed E
2
YES >> GO TO 6. F
6.CHECK DIFFERENTIAL LOCK SOLENOID
Check differential lock solenoid. Refer to DLN-287, "Component Inspection". G
YES >> GO TO 7.
H
7.CHECK TERMINALS AND HARNESS CONNECTORS I
• Check differential lock solenoid pin terminals for damage or loose connection with harness connector.
Is the inspection result normal? J
YES >> After erasing the DTC, perform DTC confirmation procedure again. If DTC “P1849” is detected,
replace differential lock control unit. Refer to DLN-312, "Removal and Installation".
NO >> Repair or replace error-detected parts. K
1.CHECK DIFFERENTIAL LOCK SOLENOID OPERATION L

2. Disconnect differential lock solenoid harness connector.
3. Apply 12 V to differential lock solenoid connector #1 (-) and #2 (+) terminals. M
CAUTION:
• Never make the terminals short.
• Connect the fuse between differential lock solenoid connector terminals. N
Does differential lock solenoid operate?
YES >> GO TO 2.
NO >> Differential lock solenoid is malfunctioning. Replace differential assembly. Refer to DLN-324, "Dis- O
2.CHECK DIFFERENTIAL LOCK SOLENOID RESISTANCE
1. Turn the ignition switch OFF. P
2. Check the resistance between differential lock solenoid harness connector terminals.
Differential lock solenoid

Terminal
1 2 2.9 Ω


A

When differential lock mode switch is ON and difference between request current and actual current more
than threshold.
C
DLN
SOL CURRENT
P1850 Signal —
(Solenoid current)
E
Threshold —
POSSIBLE CAUSE F
• Malfunction of differential lock solenoid circuit
G
FAIL-SAFE
gaged.
H
1.PRECONDITIONING
I
J
>> GO TO 2.
With CONSULT K
CAUTION:
Never start the engine. L
Is DTC “P1850” detected? M
N
1.CHECK DIFFERENTIAL LOCK SOLENOID CIRCUIT O

Check differential lock solenoid circuit. Refer to DLN-281, "Diagnosis Procedure".
YES >> GO TO 2. P
With CONSULT

YES >> Replace differential lock control unit. Refer DLN-312, "Removal and Installation".

P1856 VDC SYSTEM
P1856 VDC SYSTEM
A

Malfunction is detected in VDC system that is output from ABS actuator and electric unit (control unit) through
CAN communication.
C
DLN
VDC SYSTEM Signal VDC malfunction signal
P1856
(VDC system) Threshold —
POSSIBLE CAUSE
VDC system malfunction F
FAIL-SAFE
G
1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and H
>> GO TO 2. I
With CONSULT J
1. Drive at 30 km/h (19 MPH) or more for approximately 1 minute.
Is DTC “P1856” detected? K
NO-2 >> Confirmation after repair: INSPECTION END L
1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS M

With CONSULT
Perform self-diagnosis for “ABS”.
Is any DTC detected? N
YES >> Check the DTC. Refer to BRC-184, "DTC Index".
NO >> GO TO 2.
O
Is inspection result normal? P
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC “P1856”
is detected, replace differential lock control unit. Refer to DLN-312, "Removal and Installation".

P18CB DIFFERENTIAL LOCK SOLENOID POWER SUPPLY
DTC DETECTION LOGIC

When engine is running and differential lock solenoid power supply and ignition signal voltage is higher than 9
V and differential lock mode switch ON, differences between ignition signal voltage and differential lock sole-
noid power supply voltage higher than 4.6 V.

SOLENOID POWER SUP-
P18CB PLY • Ignition signal (terminal #7)
Signal (terminal)
(Solenoid power supply) • Solenoid power supply (terminal #9)
Threshold —
POSSIBLE CAUSE
• Malfunction of differential lock solenoid power supply or ignition signal voltage circuit (short)
FAIL-SAFE
gaged.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
CAUTION:
Is DTC “P18CB” detected?
1.CHECK IGNITION SIGNAL VOLTAGE


Connector Terminal
M80 7 Ground 0V

CAUTION: A
B
— Voltage
Connector Terminal
M80 7 Ground 9 – 16 V C
YES >> GO TO 3.
NO >> GO TO 2. DLN
2.CHECK IGNITION SIGNAL CIRCUIT

1. Turn the ignition switch OFF. E
F
connector.

Continuity G
5. Check the continuity between differential lock control unit harness connector and the ground. H

— Continuity I
Connector Terminal
Is the inspection result normal? J
NO >> Repair or replace error-detected parts. K
2. Check the voltage between differential lock control unit harness connector and ground. L

— Voltage M
Connector Terminal
M80 9 Ground 9 – 16 V
3. Turn the ignition switch ON. N
CAUTION:
O

— Voltage
Connector Terminal P
M80 9 Ground 9 – 16 V
YES >> GO TO 5.
NO >> GO TO 4.

connector.

Continuity

— Continuity
Connector Terminal

— Continuity
Connector Terminal
10
M80 Ground Existed
11
YES >> GO TO 6.
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P18CB” is detected, replace differential lock control unit. Refer to DLN-312, "Removal and Instal-
lation".

P18CC WHEEL SPEED SIGNAL
P18CC WHEEL SPEED SIGNAL
A

Malfunction is detected in wheel speed signal that is output from ABS actuator and electric unit (control unit)
through CAN communication.
C
DLN
WHEEL SPEED SIGNAL Signal Each wheel speed signal
P18CC
(Wheel speed signal) Threshold —
POSSIBLE CAUSE
ABS malfunction F
• Wheel speed signal error
FAIL-SAFE
When differential lock system is malfunctioning, fail-safe status activates and rear differential lock is disen- G
gaged.
H
1.PRECONDITIONING
wait at least 10 seconds before conducting the next test. I
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE J
With CONSULT
K
Is DTC “P18CC” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-295, "Diagnosis Procedure". L
M
1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS

With CONSULT N
YES >> Check the DTC. Refer to BRC-184, "DTC Index". O
NO >> GO TO 2.
P
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC “P18CC”

P18CD SELF SHUTDOWN
P18CD SELF SHUTDOWN
DTC DETECTION LOGIC

When ignition switch is ON, self-shut down of differential lock control unit was incomplete.

INCOMPLETE SELF SHUT- Signal (terminal) Power supply for control unit (back-up) (terminal #15)
P18CD DOWN
(Incomplete self shutdown) Threshold —
POSSIBLE CAUSE
• Malfunction of differential lock control unit power supply circuit (open or short)
• Battery power supply
FAIL-SAFE
gaged.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
Is DTC “P18CD” detected?
1.CHECK DIFFERENTIAL LOCK CONTROL UNIT POWER SUPPLY VOLTAGE


Connector Terminal
M80 15 Ground 9 – 16 V
CAUTION:

P18CD SELF SHUTDOWN
Differential lock control unit A

— Voltage
Connector Terminal
M80 15 Ground 9 – 16 V
B
YES >> GO TO 3.
NO >> GO TO 2. C
2.CHECK DIFFERENTIAL LOCK CONTROL UNIT POWER SUPPLY CIRCUIT
2. Check the 10A fuse (#4). DLN
connector. E

Continuity
Connector Terminal Connector Terminal F
G

— Continuity
Connector Terminal H
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-12, "Wiring Diagram - BAT- I
3.CHECK DIFFERENTIAL LOCK CONTROL UNIT GROUND J

K

— Continuity
Connector Terminal L
10
M80 Ground Existed
11
M
YES >> GO TO 4.
N
Is the inspection result normal? O
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC
“P18CD” is detected, replace differential lock control unit. Refer to DLN-312, "Removal and Instal-
lation". P

P18CE DIFFERENTIAL LOCK POSITION SWITCH
DTC DETECTION LOGIC

When differential lock position switch is OFF, rotation fixing occurs in wheel speed (rear wheel right and left).

DIFF LOCK POSITION
SWITCH Signal (terminal) Differential lock position switch (terminal #12)
P18CE
(Differential lock position Threshold —
switch)
POSSIBLE CAUSE
• Malfunction of differential lock position switch
• Malfunction of differential lock position switch circuit
FAIL-SAFE
gaged.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
2. Turn the differential lock mode switch OFF.
3. Drive at 20 km/h (12 MPH) or less for approx. 1 minute on the curved road.
Is DTC “P18CE” detected?
1.CHECK DIFFERENTIAL LOCK POSITION SWITCH GROUND CIRCUIT

Check the continuity between differential lock position switch harness connector and ground.
2. Disconnect differential lock position switch harness connector.
3. Check the continuity between differential lock position switch harness connector and ground.

— Continuity
Connector Terminal
C10 3 Ground Existed
YES >> GO TO 2.

2.CHECK DIFFERENTIAL LOCK POSITION SWITCH SIGNAL CIRCUIT A

2. Check the continuity between differential lock control unit harness connector and differential lock position
B
Differential lock position

switch Continuity
C
M80 12 C10 1 Existed
3. Check the continuity between differential lock control unit harness connector and ground. DLN

— Continuity E
Connector Terminal
Is the inspection result normal? F
YES >> GO TO 3.
3.CHECK DIFFERENTIAL LOCK POSITION SWITCH SIGNAL G
1. Connect differential lock control unit harness connector.
CAUTION: H
3. Check the voltage between differential lock position switch harness connector and ground.
I
— Voltage
Connector Terminal
C10 1 Ground 9 – 16 V J

YES >> GO TO 4. K
Check differential lock position switch. Refer to DLN-299, "Component Inspection". L
YES >> GO TO 5.
NO >> Replace differential lock position switch. Refer to DLN-324, "Disassembly and Assembly". M
• Check differential lock control unit pin terminals for damage or loose connection with harness connector. N
• Check differential lock position switch pin terminals for damage or loose connection with harness connector.
YES >> Replace differential lock control unit. Refer to DLN-312, "Removal and Installation". O
P
2. Remove differential lock position switch. Refer to DLN-324, "Disassembly and Assembly".

3. Check the continuity between differential lock position switch
connector terminals.
Differential lock
position switch Condition Continuity
Terminal
While pulling rod of differential lock posi-

tion switch Existed
(Differential system is locked state.)
1 3
While pushing rod of differential lock posi- JSDIA7253ZZ
tion switch Not existed

(Differential system is unlocked state.)

P18D0 ABS SYSTEM
P18D0 ABS SYSTEM
A

Malfunction is detected in ABS that is output from ABS actuator and electric unit (control unit) through CAN
communication.
C
DLN
ABS SYSTEM Signal ABS malfunction signal
P18D0
(ABS system) Threshold —
POSSIBLE CAUSE
ABS malfunction F
FAIL-SAFE
G
1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and H
>> GO TO 2. I
With CONSULT J
Is DTC “P18D0” detected? K
NO-2 >> Confirmation after repair: INSPECTION END L
1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS M

With CONSULT
Is any DTC detected? N
YES >> Check the DTC. Refer to BRC-184, "DTC Index".
NO >> GO TO 2.
O
Is inspection result normal? P
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC “P18D0”

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring.
DTC DETECTION LOGIC
Differential lock control unit is not transmitting/receiving CAN communication signal for 2 seconds or more.

CAN COMM CIRCUIT Signal CAN communication signal

U1000
(CAN communication circuit) Threshold —
Diagnosis delay time 2 seconds or more
POSSIBLE CAUSE
• CAN communication error
FAIL-SAFE
gaged.
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
Proceed to LAN-34, "Trouble Diagnosis Flow Chart".

A
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul- B
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring. C
DTC DETECTION LOGIC
DLN
Detecting error during the initial diagnosis of CAN controller of differential lock control unit.

(Trouble diagnosis content) E
CONTROL UNIT (CAN) Signal —

U1010 F
[Control unit (CAN)] Threshold —
POSSIBLE CAUSE G
Internal malfunction of differential lock control unit
FAIL-SAFE H
gaged.
DTC CONFIRMATION PROCEDURE I
1.PRECONDITIONING
J
>> GO TO 2. K
With CONSULT
1. Turn the ignition switch OFF to ON. L
YES >> Proceed to diagnosis procedure. Refer to DLN-303, "Diagnosis Procedure". M
N
1.PERFORM SELF-DIAGNOSIS O
With CONSULT
Is DTC “U1010” detected? P

1.CHECK IGNITION SIGNAL VOLTAGE


Connector Terminal
M80 7 Ground 0V
CAUTION:

— Voltage
Connector Terminal
M80 7 Ground 9 – 16 V
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK IGNITION SIGNAL CIRCUIT
connector.

Continuity

— Continuity
Connector Terminal
3.CHECK DIFFERENTIAL LOCK CONTROL UNIT POWER SUPPLY VOLTAGE

Connector Terminal
M80 15 Ground 9 – 16 V

CAUTION:
Never start the engine. A
Differential lock control unit B

— Voltage
Connector Terminal
M80 15 Ground 9 – 16 V
C
YES >> GO TO 5.
NO >> GO TO 4.
DLN
4.CHECK DIFFERENTIAL LOCK CONTROL UNIT POWER SUPPLY CIRCUIT
2. Check the 10A fuse (#4). E
connector.
F

Continuity
Connector Terminal Connector Terminal G
H
— Continuity
Connector Terminal
I
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-12, "Wiring Diagram - BAT- J
5.CHECK DIFFERENTIAL LOCK SOLENOID POWER SUPPLY VOLTAGE K
L

— Voltage
Connector Terminal
M
M80 9 Ground 9 – 16 V
CAUTION: N
O
— Voltage
Connector Terminal
M80 9 Ground 9 – 16 V P
YES >> GO TO 7.
NO >> GO TO 6.

connector.

Continuity

— Continuity
Connector Terminal

— Continuity
Connector Terminal
10
M80 Ground Existed
11

DIFFERENTIAL LOCK INDICATOR LAMP
DIFFERENTIAL LOCK INDICATOR LAMP
A
1.DIFFERENTIAL LOCK INDICATOR LAMP OPERATION CHECK B

Check that differential lock indicator lamp turns ON after the ignition switch is turned ON (engine stop) and
turns OFF after the engine is started.
NO >> Proceed to DLN-307, "Diagnosis Procedure".
DLN
1.PERFORM SELF-DIAGNOSIS E
With CONSULT
Is any DTC detected? F
YES >> Perform trouble diagnosis for detected DTC. Refer to DLN-262, "DTC Index".
NO >> GO TO 2.
2.CHECK DIFFERENTIAL LOCK MODE SWITCH G
Perform the trouble diagnosis for differential lock mode switch. Refer to DLN-274, "Diagnosis Procedure".
Is the inspection results normal? H
YES >> GO TO 3.
3.CHECK DIFFERENTIAL LOCK INDICATOR LAMP SIGNAL I
With CONSULT
CAUTION: J
Stop the vehicle.
2. Change 4WD shift switch to 4L.
3. Change differential lock mode switch to ON. K
4. Check “INDICATOR” in “DATA MONITOR” for “DIFF LOCK”.
Does the item on “DATA MONITOR” indicate “On” or “FLASH”?
YES >> Perform the trouble diagnosis for combination meter. Refer to MWI-91, "WITH COLOR INFOR- L
MATION DISPLAY : On Board Diagnosis Function" (With color information display), MWI-93,
"WITH MONOCHROME INFORMATION DISPLAY : On Board Diagnosis Function" (With mono-
chrome information display).
NO >> Replace differential lock control unit. Refer to DLN-312, "Removal and Installation". M

DIFFERENTIAL LOCK INDICATOR LAMP DOES NOT TURN ON
< SYMPTOM DIAGNOSIS > [REAR FINAL DRIVE: H215 (DL)]
SYMPTOM DIAGNOSIS
DIFFERENTIAL LOCK INDICATOR LAMP DOES NOT TURN ON
Differential lock indicator lamp does not turn ON when turning differential lock mode switch to “ON” after
engine start.
1.CHECK DIFFERENTIAL LOCK INDICATOR LAMP

Confirm the differential lock indicator lamp proves out when ignition switch is turned ON.
YES >> GO TO 2.
NO >> Refer to DLN-307, "Component Function Check".
2.CHECK SELF-DIAGNOSTIC RESULTS
With CONSULT
Is any DTC detected by self-diagnosis?
YES >> Check the malfunctioning system. Refer to DLN-262, "DTC Index".
NO >> GO TO 3.
3.CHECK DIFFERENTIAL LOCK MODE SWITCH OPERATION
Check differential lock mode switch circuit. Refer to DLN-274, "Diagnosis Procedure".
YES >> GO TO 4.
4.CHECK DIFFERENTIAL LOCK CONTROL UNIT POWER SUPPLY AND GROUND CIRCUIT
Check differential lock control unit power supply and ground circuit. Refer to DLN-304, "Diagnosis Procedure".
YES >> Replace the differential lock control unit. Refer to DLN-312, "Removal and Installation".

DIFFERENTIAL LOCK INDICATOR LAMP FLASHES WHILE DRIVING
< SYMPTOM DIAGNOSIS > [REAR FINAL DRIVE: H215 (DL)]
DIFFERENTIAL LOCK INDICATOR LAMP FLASHES WHILE DRIVING
A
The differential lock indicator lamp will flash once every 2 seconds when the differential lock system is in B
standby condition. Standby condition is the time between when the differential lock mode switch is turned ON
and when the differential lock control unit sees all conditions are met to engage the differential lock. The differ-
ential lock indicator lamp should be OFF if there has been a malfunction detected. For more information
regarding the differential lock system operation, refer to the Owners Manual. C
DLN
1.CHECK SELF-DIAGNOSTIC RESULTS
With CONSULT
Perform self-diagnosis for “DIFF LOCK”. E
Is any malfunction detected by self-diagnosis?
YES >> Check the malfunctioning system. Refer to DLN-262, "DTC Index".
NO >> GO TO 2. F
Perform trouble diagnosis for differential lock mode switch circuit. Refer to DLN-274, "Diagnosis Procedure".
G
YES >> Condition is intermittent. Refer to GI-47, "Intermittent Incident".
NO >> Repair or replace the error-detected parts. H

Symptom
Reference
×: Applicable

Noise
×
DLN-310
×
×
×
×
PROPELLER SHAFT NVH of FRONT and REAR PROPELLER SHAFT in this section.
×
×
×
×
×
× BRAKE NVH in BR section.

×
[REAR FINAL DRIVE: H215 (DL)]
INFOID:0000000011862996
D23
< PERIODIC MAINTENANCE > [REAR FINAL DRIVE: H215 (DL)]
B
OIL LEAKAGE
• Check that oil is not leaking from final drive assembly or around it. C
• When oil leaking, drain all gear oil, and then fill with specified amount of gear oil. Refer to DLN-311, "Refill-
ing".
NOTE:
Oil is not refilled up to filler plug mounting hole. DLN
CAUTION:
E
1. Stop engine.
F
2. Remove drain plug and drain gear oil.
3. Set a gasket on drain plug and install it to final drive assembly
and tighten to the specified torque. Refer to DLN-321, "Exploded
View". G
CAUTION:
Never reuse gasket.
H
I
JSDIA5679ZZ
J
1. Drain all gear oil. Refer to DLN-311, "Draining".
CAUTION:
Drain gear oil until gear oil start to drip. K
2. Remove filler plug .
3. Fill with specified amount of gear oil.
L
NOTE: M
CAUTION:
N
4. Apply sealant to filler plug, then install it to final drive assembly. JSDIA6813ZZ
Refer to DLN-321, "Exploded View".
O

< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: H215 (DL)]

JSDIA7211ZZ
: Vehicle front
REMOVAL
3. Remove glove box cover. Refer to IP-14, "Removal and Installation" (LHD models), IP-39, "Removal and
Installation" (RHD models).
5. Remove differential lock control unit mounting screw and remove differential lock control unit.
INSTALLATION

DIFFERENTIAL LOCK MODE SWITCH
DIFFERENTIAL LOCK MODE SWITCH
A
REMOVAL B
1. Remove cluster lid C lower. Refer to IP-14, "Removal and Installation" (LHD models), IP-39, "Removal
and Installation" (RHD models).
2. Remove differential lock mode switch from cluster lid C lower. C
INSTALLATION
DLN

FRONT OIL SEAL
FRONT OIL SEAL
JSDIA7213GB
Rear final drive assembly Front oil seal Companion flange

Drive pinion lock nut
Oil seal lip

: Apply gear oil.

REMOVAL
CAUTION:
Verify identification stamp of replacement frequency put in the lower part of carrier case to determine
replacement for collapsible spacer when replacing front oil seal. Refer to “Identification stamp of
replacement frequency of front oil seal”. If collapsible spacer replacement is necessary, remove final
drive assembly and disassemble it to replace front oil seal and collapsible spacer. Refer to DLN-337,
"Disassembly and Assembly".
NOTE:
The reuse of collapsible spacer is prohibited in principle. However, it is reusable on a one-time basis
only in cases when replacing front oil seal.
Identification stamp of replacement frequency of front oil seal

FRONT OIL SEAL
• The diagonally shaded area in the figure shows stamping point for
replacement frequency of front oil seal. A
• The following table shows if collapsible spacer replacement is
needed before replacing front oil seal.
When collapsible spacer replacement is required, disassemble
B
final drive assembly to replace collapsible spacer and front oil seal.
Refer to DLN-337, "Disassembly and Assembly".
C
Stamp Collapsible spacer replacement
No stamp Not required
JSDIA7214ZZ
“0” or “0” on the far right of stamp Required DLN
“01” or “1” on the far right of stamp Not required
CAUTION:
Make a stamping after replacing front oil seal. E
• After replacing front oil seal, make a stamping on the stamping point in accordance with the table below in
order to identify replacement frequency.
CAUTION: F
Make a stamping from left to right.
Stamp before stamping Stamping on the far right Stamping

G
No stamp 0 0
“0”
1 01
(Front oil seal was replaced once.)
H
“01”
0 010
1 ...01 I
(Only front oil seal was replaced last time.)
0 ...010
J
1. Make a judgment if a collapsible spacer replacement is required.
3. Remove rear propeller shaft. Refer to DLN-155, "Removal and Installation". K
5. Measure the total preload with the preload gauge (A) (SST:
ST3127S000). L
NOTE:
Record the total preload torque measurement.
M
JSDIA3495ZZ

FRONT OIL SEAL
panion flange .
CAUTION:
JSDIA0038ZZ

mercial service tool), remove drive pinion lock nut.
JSDIA5759ZZ
8. Remove companion flange using puller (commercial service

tool).
MDIB0048E
9. Remove front oil seal, using oil seal remover (A) (commercial
service tool).
CAUTION:
JSDIA3499ZZ
INSTALLATION

FRONT OIL SEAL
end, using the drifts (A and B) as shown in figure. A

B : Drift (SST: KV40101840) B
CAUTION:
• When installing, never incline oil seal. C
JSDIA3500ZZ
DLN
mark of companion flange , and then install the companion
flange. E
pinion.
CAUTION: F
G
JSDIA0038ZZ

H
ST3127S000). I
Total preload torque : A value that add 0.1 – 0.4 N·m

(0.01 – 0.04 kg-m, 1 – 3 in-lb) to J
the measured value before re-
moving.
Drive pinion lock nut : Refer to DLN-314, "Exploded K
tightening torque View".
CAUTION:
• Adjust to the lower limit of the drive pinion lock nut tight- L
ening torque first.
collapsible spacer and tighten it again to adjust. Never M
and other malfunctions. N
5. Make a stamping for identification of front oil seal replacement JSDIA3501ZZ
frequency. Refer to “Identification stamp of replacement fre-

quency of front oil seal”. O
CAUTION:
Make a stamping after replacing front oil seal.
6. Install rear axle shaft from final drive. Refer to RAX-8, "Removal and Installation". P
7. Install rear propeller shaft. Refer to DLN-155, "Removal and Installation".

FRONT OIL SEAL

AIR BREATHER
AIR BREATHER
A
DLN
G
JSDIA7215GB
Rear axle housing Breather hose connector Hose clamp

H
Air Breather hose assembly
: N·m (kg-m, ft-lb) I

Removal and Installation INFOID:0000000011803805 J
REMOVAL
1. Remove the hose clamp and separate air breather hose K
from breather connector .
N
JSDIA5767ZZ
2. Remove mounting bolt ( ) and then separate the air breather

hose assembly from vehicle frame. O
3. Remove the air breather hose assembly.
CAUTION:
Never remove breather hose connector from rear axle hous- P
ing.
JSDIA5768ZZ
INSTALLATION

AIR BREATHER
• While installing new rear axle housing, tighten the breather hose connector to the end of thread cutting por-
tion with specified tightening torque. Refer to DLN-319, "Exploded View".
CAUTION:
Never reuse breather hose connector.
• Set air breather hose assembly to breather hose connector
with paint mark facing rear direction of vehicle.
• Install hose clamp such that tab facing rear direction of vehicle
: Vehicle front
CAUTION:
Never reuse hose clamp.
winding.
JSDIA5769ZZ


< UNIT REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: H215 (DL)]

B
DLN
JSDIA6811GB
H
Filler plug Gasket Rear final drive assembly
Gasket Drain plug Rear axle housing
I
*
J
: Apply anti-corrosive oil.

K
REMOVAL L
1. Remove rear propeller shaft. Refer to DLN-155, "Removal and Installation".
3. Disconnect differential lock position switch harness connector and differential lock solenoid harness con- M
nector.
5. Set a suitable jack to rear final drive assembly. N
6. Remove final drive mounting bolts and remove final drive assembly from the vehicle.
CAUTION:
Never damage drive gear, differential case and carrier case. O
7. Remove gasket.
8. When removing axle housing, follow the procedure below.
a. Remove each electrical harness. P
b. Remove brake hose and tube from rear axle housing. Refer to BR-34, "REAR : Removal and Installation"
(LHD models), BR-110, "REAR : Removal and Installation" (RHD models).
c. Remove air breather hose assembly from rear axle housing. Refer to DLN-319, "Removal and Installa-
tion".
d. Remove parking brake cable from rear axle housing. Refer to PB-8, "Removal and Installation" (LHD
modesl), PB-18, "Removal and Installation" (RHD models).

< UNIT REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: H215 (DL)]
e. Set a suitable jack to rear axle housing.
f. Remove spring for rear suspension. Refer to RSU-9, "Removal and Installation" (Leaf rigid type suspen-
sion), RSU-23, "Removal and Installation" (5 link suspension).
g. Remove axle housing.
INSTALLATION
Note the following, and installation is in the reverse order of removal.
• Install the gasket in the direction shown in the figure.
: Final drive side

: Axle housing side
CAUTION:
• Never reuse gasket.
• Remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
JPDID0053ZZ
• Tighten final drive mounting bolts of two standard holes ( ) first,

and then tighten other bolts at opposite angle.
• After installing the final drive assembly, refill with gear oil to the
final drive. Refer to DLN-311, "Refilling".
tion".
JSDIA5772ZZ


< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: H215 (DL)]
UNIT DISASSEMBLY AND ASSEMBLY A

B
DLN
JSDIA7226GB K

Differential lock solenoid connector L
Pinion front bearing Carrier case
housing
Differential lock position switch Connector bracket Collapsible spacer
Pinion rear bearing Pinion height adjusting washer Drive pinion M
Drive gear Differential assembly Side bearing
N
O
: Always replace after every disassembly. P
: Apply gear oil.



DISASSEMBLY
1. Remove differential lock solenoid harness bracket mounting
bolt.
JSDIA7230ZZ
2. Remove differential lock solenoid connector housing .
JSDIA7229ZZ
JPDID0039ZZ
4. For proper reinstallation, paint matching marks on one side of

bearing cap.
CAUTION:
caps and carrier case.
JSDIA6770ZZ

5. Remove lock finger .
A
MDIB0099E
DLN
6. Remove side bearing adjusting nuts using wrench (A) (SST:
KV10109900).
CAUTION:
E
Identify the assembled position of the side bearing adjust-
ing nuts in advance.
G
JPDID0061ZZ

H
JSDIA6771ZZ
K
8. Insert a suitable bar in between differential assembly and carrier
case, and then separate differential assembly from carrier case.
CAUTION: L
Never damage differential lock position switch.
N
JSDIA6772ZZ
9. Remove differential assembly together with the side bearing O

outer race.
CAUTION:
• Never drop the side bearing outer race. P
race in advance.
SPD011

10. Remove connector bracket mounting bolts.
JSDIA7510ZZ
11. Remove differential lock position switch harness connector

from connector bracket .
12. Remove connector bracket.
JSDIA7227ZZ
13. Remove differential lock position switch harness clip from car-
rier case.
JSDIA7228ZZ
14. Remove differential lock position switch .
JSDIA7232ZZ

15. Remove side bearing inner races, using adaptor (A) and puller
(B). A
A : Adaptor (commercial service tool)

B : Puller (commercial service tool) B
CAUTION:
place copper plates between these parts and vise. C
DLN
G
JSDIA7234ZZ
16. For proper reinstallation, paint matching marks on differential

assembly and drive gear. H
CAUTION:
assembly and drive gear. I
JSDIA6774ZZ
K
18. Perform inspection after disassembly. Refer to DLN-335, L
"Inspection".
N
JSDIA6775ZZ
ASSEMBLY
O
1. Apply recommended sealant to threads of differential lock posi-
tion switch .
• For sealant to use, refer to DLN-323, "Exploded View".
CAUTION: P
Remove old sealant and oil adhering to threads of differen-
tial lock position switch.
JSDIA7224ZZ

2. Install differential lock position switch to carrier case and

tighten it to the specified torque.
CAUTION:
Remove old sealant and oil adhering to threads in carrier
case.
JSDIA7232ZZ
CAUTION:
Harness clip is non-reusable. When replace it, replace
differential lock position switch.
JSDIA7225ZZ
3. Apply thread locking sealant into the thread hole of drive gear.
"Exploded View".
CAUTION:
ficiently.
CAUTION:
gear.
SDIA2594E

bolt tightening torque
SDIA0247J

angle wrench (A) (SST: KV10112100). A

bolt tightening angle B
CAUTION:
make judgment by visual inspection. C
JSDIA6776ZZ
DLN
drift (A) and the adaptor (B).
E
CAUTION: F
7. Assemble side bearing outer races to inner races.
G
CAUTION:
JSDIA7235ZZ
• Never reuse side bearing outer race.
8. Install differential assembly to carrier case. H
JSDIA7236ZZ
K
9. Align the alignment marks on bearing cap and carrier case,

and then tighten the mounting bolts to the specified torque. L
JPDID0255ZZ

10. Install side bearing adjusting nuts to the carrier case using
wrench (A) (SST: KV10109900), and then tighten so that the
total preload and the backlash are within the standard. Refer to
DLN-331, "Adjustment".
JPDID0061ZZ

12. Check the drive gear runout, tooth contact, backlash and total
preload. Refer to DLN-331, "Adjustment".
MDIB0099E
13. Install connector bracket .

JSDIA7510ZZ
14. Install differential lock position switch harness clip to carrier

case and install harness connector to connector bracket .
JSDIA7238ZZ
15. Install differential lock solenoid harness bracket mounting bolt.

JSDIA7230ZZ

16. Install differential lock solenoid connector housing .

• For tightening torque, refer to DLN-323, "Exploded View". A
JSDIA7229ZZ
DLN
CAUTION:
O-ring is non-reusable. When replace it, replace differen-
tial lock solenoid connector housing. E
JSDIA7239ZZ
H
TOTAL PRELOAD TORQUE I

2. Rotate drive pinion back and forth 2 to 3 times to check for
unusual noise and rotation malfunction. J
3. Rotate drive pinion at least 20 times to check for smooth opera-
tion of the bearing.
K
L
JPDID0039ZZ
4. While rotate drive pinion at 30 rpm or 60 rpm, measure total pre- M

load with the preload gauge (A) (SST: ST3127S000).

N
Torque".
NOTE:
O
bearing preload torque
and side bearing preload. JPDID0102ZZ P
Adjust the pinion bearing preload first, then adjust the side
bearing preload.
When the preload torque is large

On side bearings: Loosen side bearing adjusting nut.

When the preload is small

On side bearings: Tighten side bearing adjusting nut.
CAUTION:
Retighten or loosen the left and right side bearing nuts evenly so that they are within the stan-
dard.
DRIVE GEAR RUNOUT
JPDID0039ZZ

face runout Runout".
drive gear and differential case, or differential case or drive
CAUTION:
Replace drive gear and drive pinion gear as a set.
SDIA1279J
TOOTH CONTACT
JPDID0039ZZ

CAUTION:
PDE0045D

ion gear to drive gear tooth contact. A
CAUTION:
B
SDIA0570E
DLN
SDIA0207E
4. If tooth contact is improperly adjusted, follow the procedure M

below to adjust the pinion height (dimension X).
SDIA0517E
P

move drive pinion closer to drive gear.
mation.
PDIA0440E
• If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin pinion height adjusting washer to move
mation.
PDIA0441E
BACKLASH
JPDID0039ZZ
lash.
Backlash : Refer to DLN-345, "Backlash".

side bearing adjusting nut.

back side, and then loosen side bearing adjusting nut SDIA1278J
on the drive gear tooth side.
tooth side, and then loosen side bearing adjusting nut
on the drive gear back side.
CAUTION:
If it is outside the standard, retighten or loosen the left and right side bearing adjusting nuts
evenly so that they are within the standard.

A
B
gear and drive pinion as a set. C
Bearing
• If any chipped (by friction), pitted, worn, rusted or scratched marks, or unusual noise from the bearing is DLN
• Clean up the disassembled parts. E
• If any cracks or damage on the surface of side gear and pinion mate gear tooth is found, replace.
• If it is chipped (by friction), damaged, or unusually worn, replace. F

DRIVE PINION
DRIVE PINION
JSDIA7226GB

Differential lock solenoid connector
Pinion front bearing Carrier case
housing
Differential lock position switch Connector bracket Collapsible spacer
Drive gear Differential assembly Side bearing

: Apply gear oil.


DRIVE PINION
A
DISASSEMBLY
B
DLN
E
JSDIA6777ZZ

mark should be in line with the matching mark on companion F
flange .
CAUTION:
For matching mark, use paint. Never damage companion G
NOTE:
H
sary. PDIA0799J
I
service tool).
J
L
MDIB0075E
5. Remove drive pinion, using the drift (A) (SST: ST22360002). M

CAUTION:
N
vice tool).
CAUTION:
7. Remove pinion front bearing inner race. O
JPDID0104ZZ P

DRIVE PINION
ing washer with the separator (commercial service tool).
JPDID0055ZZ
10. Tap pinion front bearing outer race and rear bearing outer
them.
CAUTION:
"Inspection".
JSDIA6790ZZ
ASSEMBLY
1. Install front bearing outer race using drift (A) (SST:
KV38100500).
CAUTION:
JSDIA6791ZZ
2. Install rear bearing outer race using drift (A) (commercial ser-
vice tool).
CAUTION:
JSDIA6792ZZ

DRIVE PINION
CAUTION: A
When hypoid gear set has been replaced B
"Adjustment".
C
DLN
drift (A) (commercial service tool).
CAUTION: E
G
JSDIA0761ZZ
5. Check and adjust the tooth contact and backlash of drive gear and drive pinion following the procedure
H
below.
CAUTION:
• Never assemble collapsible spacer. I
bly. J
CAUTION:
• Apply gear oil to pinion front bearing. K
c. Install companion flange.
CAUTION: JPDID0105ZZ

L
NOTE:
install companion flange . M
O
PDIA0799J

DRIVE PINION
d. Tap the companion flange with a plastic hammer as far as the
drive pinion lock nut can be tightened.
CAUTION:
e. Temporarily tighten removed drive pinion lock nut to drive pinion.
NOTE:
Use removed drive pinion nut only for the preload measurement.
f. Rotate drive pinion more than 20 times to adjust bearing.
SPD697

the flange wrench (commercial service tool), while adjusting pin-
ion bearing preload torque using preload gauge (A) (SST:
ST3127S000).
Pinion bearing preload : 1.0 - 1.3 N·m (0.11 – 0.13 kg-m,

(without oil seal) 9 – 11 in-lb)
CAUTION:
spacer. Be careful not to overtighten it. While measuring the
preload, tighten it by 5° to 10°. JPDID0102ZZ
h. Install differential assembly. Refer to DLN-324, "Disassembly and Assembly".

i. Check and adjust tooth contact, drive gear to drive pinion backlash. Refer to DLN-331, "Adjustment".
j. Remove differential assembly.
k. Remove companion flange.
l. Remove drive pinion assembly from carrier case.
m. Remove pinion front bearing inner race.
6. Assemble collapsible spacer.
CAUTION:
7. Assemble drive pinion into carrier case.
CAUTION:
bly.
CAUTION:
JPDID0105ZZ
9. Using press stand (A) (SST: KV40105710), press the pinion

front bearing inner race to drive pinion as far as drive pinion
nut can be tightened.
JSDIA6796ZZ

DRIVE PINION
end, using the drifts (A and B) as shown in figure. A

B : Drift (SST: KV40101840) B
CAUTION:
• When installing, never incline oil seal. C
JSDIA6802ZZ
DLN
NOTE:
When reusing drive pinion, align the matching mark of drive E
F
pinion.
CAUTION:
Never reuse drive pinion lock nut. G
PDIA0799J
H
limits of specified torque so as to keep the pinion bearing pre- I
ST3127S000).
J
load Torque".
CAUTION: K
ening torque first.
L
times to check for unusual noise, rotation malfunction, M
14. Install differential assembly. Refer to DLN-324, "Disassembly
and Assembly". N
CAUTION:
Never install lock finger yet.
15. Check and adjust drive gear runout, tooth contact, and drive JSDIA6803ZZ O
17. Check total preload torque. Refer to DLN-331, "Adjustment". P

DRIVE PINION
MDIB0099E
PINION GEAR HEIGHT

washer thickness.

T = T0 + (t1− t2)
T: Correct washer thickness
Old drive pinion head letter “H × 0.01”
t1:
t2:
Example:
T = 3.21 + [(2 × 0.01) − (−1 × 0.01)] = 3.24
T0: 3.21
t1: +2
t2: −1
information.
CAUTION:
If unable to find a washer of desired thickness, use a washer with thickness closest to the calcu-
lated value.
Example:

1. Fit a dial indicator to the outer side of companion flange (socket
diameter).
Outer side of the companion : Refer to DLN-345,

Runout".
3. If the runout value is outside the runout limit, follow the proce-
dure below to adjust.
a. Check for runout while changing the phase between companion JSDIA6824ZZ
flange and drive pinion by 90° step, and search for the position
where the runout is the minimum.

DRIVE PINION
assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for A
B

C
DLN
Bearing
E
F
Oil Seal
G
Companion Flange
panion flange is found, replace. H
Carrier Case
I

< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR FINAL DRIVE: H215 (DL)]

M/T MODELS
Axle 4WD
Applied model
Engine YD25DDTi YS23DDTT
Gear ratio 3.692
A/T MODELS
Axle 4WD
Applied model
Engine YD25DDTi YS23DDTT
Gear ratio 3.357 3.916 3.357

NOTE:
Item Standard
Pinion bearing (P1)
NOTE:

NOTE:
Item Standard
Pinion bearing (P1)

< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR FINAL DRIVE: H215 (DL)]
Item Standard
A
NOTE:
B

NOTE: C
Item Standard DLN

Pinion bearing (P1)
E
NOTE:
F
G
Unit: mm (in)
Item Standard
Drive gear back face runout 0.05 (0.0020) or less H
I
Unit: mm (in)
Item Standard
Drive gear to drive pinion gear 0.10 – 0.15 (0.0039 – 0.0059) J
Unit: mm (in)
K
Item Standard
Outer side of the companion flange runout 0.08 (0.0031) or less L

Driveline: Section

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TRANSMISSION & DRIVELINE

SECTION DLN DRIVELINE

Revision: 2015 March DLN-1 D23

P181B INCOMPLETE SELFSHUT .................... 76 HEAVY TIGHT-CORNER BRAKING SYMP-

Revision: 2015 March DLN-2 D23

REMOVAL AND INSTALLATION ............. 108 TRANSFER ASSEMBLY ................................ 125

RANGE SENSOR ............................................. 116 REMOVAL AND INSTALLATION ............. 132

Revision: 2015 March DLN-3 D23

SERVICE DATA AND SPECIFICATIONS SYMPTOM DIAGNOSIS ........................... 152

SERVICE DATA AND SPECIFICATIONS SYSTEM DESCRIPTION .......................... 166

Revision: 2015 March DLN-4 D23

REMOVAL AND INSTALLATION ............. 169 PREPARATION ......................................... 205

SIDE SHAFT ..................................................... 179 REMOVAL AND INSTALLATION ............. 211 I

Revision: 2015 March DLN-5 D23

DIAGNOSIS SYSTEM (DIFFERENTIAL P1856 VDC SYSTEM ....................................... 291

ECU DIAGNOSIS INFORMATION ............. 260 P18CB DIFFERENTIAL LOCK SOLENOID

Revision: 2015 March DLN-6 D23

Revision: 2015 March DLN-7 D23

When disconnecting the battery terminal, pay attention to the following.

D4D engine : 20 minutes YS23DDT : 4 minutes

Revision: 2015 March DLN-8 D23

• Never reuse transfer fluid, once it has been drained. DLN

Revision: 2015 March DLN-9 D23

Commercial Service Tools INFOID:0000000011257140

Tool name Description

Flange wrench Removing and installing self-lock nut

Sealant or/and Lubricant INFOID:0000000011376255

Revision: 2015 March DLN-10 D23

Revision: 2015 March DLN-11 D23

No. Component Function

Transfer control unit Refer to DLN-17, "Transfer Control Unit".

Transfer motor Refer to DLN-17, "Transfer Motor".

Mode sensor Refer to DLN-18, "Mode Sensor".

Revision: 2015 March DLN-12 D23

Revision: 2015 March DLN-13 D23

Range sensor Refer to DLN-18, "Range Sensor".

Transfer motor Refer to DLN-17, "Transfer Motor".

Mode sensor Refer to DLN-18, "Mode Sensor".

Revision: 2015 March DLN-14 D23

No. Component Function

Transfer motor Refer to DLN-17, "Transfer Motor".

Revision: 2015 March DLN-15 D23

No. Component Function

Revision: 2015 March DLN-16 D23

Range sensor Refer to DLN-18, "Range Sensor".

Transfer motor Refer to DLN-17, "Transfer Motor".

Transfer Rotary Position Sensor INFOID:0000000011256205

• Transfer rotary position sensor is installed to back side of transfer I

Transfer Motor INFOID:0000000011256206

Revision: 2015 March DLN-17 D23

• Mode sensor is installed to top of transfer assembly.

Range Sensor INFOID:0000000011106361

• Range sensor is installed to top of transfer assembly.

Front Revolution Sensor (Without ABS) INFOID:0000000011828113

• Front revolution sensor is installed to back side of transfer assem-

4WD Shift Switch INFOID:0000000011106362

• The 4WD shift switch is installed to cluster lid C lower.

Park/Neutral Position Switch (M/T Models) INFOID:0000000011370719

• Park/neutral position switch is installed to manual transmission assembly.

Revision: 2015 March DLN-18 D23

Seal guard Main shaft Extension case M

TORQUE DISTRIBUTION FLOW

Revision: 2015 March DLN-19 D23

Climate Weather Fine Cloud Rain Snow Others ( )