Transfer: Section

D DRIVELINE/AXLE
B
SECTION
TRANSFER C
TF
E
CONTENTS
PRECAUTIONS .......................................................... 4 INDICATIONS OF 4WD WARNING LAMP .......... 29 F
Precautions for Supplemental Restraint System Trouble Diagnosis with CONSULT-II ...................... 30
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- CONSULT-II FUNCTION ..................................... 30
SIONER” .................................................................. 4 SELF-DIAGNOSIS .............................................. 30 G
Precautions for Transfer Assembly and Transfer SELF-DIAGNOSTIC ITEMS ................................ 31
Control Unit Replacement ........................................ 4 DATA MONITOR ................................................. 33
METHOD FOR POSITION ADJUSTMENT ........... 4 DATA MONITOR ITEMS ..................................... 34
H
Precautions .............................................................. 4 REFERENCE VALUE IN DATA MONITOR MODE
Service Notice .......................................................... 5 ... 37
Wiring Diagrams and Trouble Diagnosis .................. 5 WORK SUPPORT ............................................... 40
PREPARATION ........................................................... 6 CLUTCH FORCE RELEASE LIMIT ADJUST- I
Special Service Tools ............................................... 6 MENT .................................................................. 41
Commercial Service Tools ........................................ 9 TROUBLE DIAGNOSIS — INTRODUCTION ........... 43
ALL-MODE 4WD SYSTEM ...................................... 10 Introduction ............................................................. 43 J
Cross-sectional View .............................................. 10 DESCRIPTION .................................................... 43
Control System ........................................................11 DIAGNOSTIC WORKSHEET .............................. 43
ALL-MODE 4WD TRANSFER BASIC CONTROL Work Flow ............................................................... 45
K
... 12 HOW TO PERFORM TROUBLE DIAGNOSES
HYDRAULIC CONTROL CIRCUITS ................... 12 FOR QUICK AND ACCURATE REPAIR ............. 45
OUTLINE ............................................................. 12 TROUBLE DIAGNOSIS — BASIC INSPECTION ... 46
CONTROL SYSTEM DIAGRAM ......................... 13 Listen to Customer Complaints .............................. 46 L
INDICATIONS OF 4WD WARNING LAMP ......... 13 Transfer Fluid Check .............................................. 46
Can Communication ............................................... 13 Road Test ............................................................... 46
SYSTEM DESCRIPTION .................................... 13 PREPARATION FOR ROAD TEST ..................... 46 M
Location of Electrical Parts ..................................... 14 1. CHECK BEFORE ENGINE IS STARTED ....... 47
Description of Electrical Parts ................................ 15 2. CHECK AT IDLE .............................................. 48
TRANSFER MOTOR .......................................... 15 3. CRUISE TEST ................................................. 52
WAIT DETECTION SWITCH .............................. 15 TROUBLE DIAGNOSIS — GENERAL DESCRIP-
2-4WD SHIFT SOLENOID VALVE ...................... 15 TION .......................................................................... 54
LINE PRESSURE SWITCH ................................ 16 Transfer Control Unit Terminals and Reference
Circuit Diagram for Quick Pinpoint Check .............. 17 Value ....................................................................... 54
Wiring Diagram — TF — ........................................ 18 REMOVAL AND INSTALLATION OF TRANSFER
ON BOARD DIAGNOSTIC SYSTEM DESCRIP- CONTROL UNIT ................................................. 54
TION .......................................................................... 27 INSPECTION OF TRANSFER CONTROL UNIT... 54
Trouble Diagnosis without CONSULT-II ................. 27 TRANSFER CONTROL UNIT INSPECTION
DESCRIPTION .................................................... 27 TABLE ................................................................. 54
SELF-DIAGNOSTIC PROCEDURE .................... 28 DTC U1000, U1001 CAN COMMUNICATION LINE... 58
CAN Communication System Inspection ................ 58
4WD SOLENOID VALVE .......................................... 59
Diagnostic Procedure ............................................. 59
Revision: January 2005 TF-1 2004 Pathfinder Armada

2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT FER FLUID TEMPERATURE SENSOR ..............97
SWITCH ..................................................................... 61 4WD SOLENOID VALVE, CLUTCH PRESSURE
Diagnostic Procedure ............................................. 61 SWITCH AND LINE PRESSURE SWITCH .........97
TRANSFER MOTOR AND TRANSFER MOTOR TRANSFER DROPPING RESISTOR ..................97
RELAY ....................................................................... 63 ATP SWITCH, NEUTRAL-4LO SWITCH AND
Diagnostic Procedure ............................................. 63 WAIT DETECTION SWITCH ...............................98
TRANSFER FLUID TEMPERATURE SENSOR ....... 65 TRANSFER MOTOR ...........................................98
Diagnostic Procedure ............................................. 65 TRANSFER MOTOR RELAY ...............................98
ATP SWITCH, WAIT DETECTION SWITCH AND TRANSFER SHIFT RELAY (HIGH & LOW) .........99
NEUTRAL-4LO SWITCH .......................................... 68 ACTUATOR & ACTUATOR POSITION SWITCH...99
Diagnostic Procedure ............................................. 68 TRANSFER CONTROL UNIT ................................. 100
CLUTCH PRESSURE SWITCH ................................ 71 Removal and Installation ....................................... 100
Diagnostic Procedure ............................................. 71 REMOVAL .......................................................... 100
LINE PRESSURE SWITCH ....................................... 74 INSTALLATION .................................................. 100
Diagnostic Procedure ............................................. 74 FRONT OIL SEAL ................................................... 101
DATA ERASE/DISPLAY ............................................ 76 Removal and Installation ....................................... 101
SHIFT ACTUATOR ................................................... 77 INSTALLATION .................................................. 102
Diagnostic Procedure ............................................. 77 REAR OIL SEAL ..................................................... 103
SHIFT ACTUATOR POSITION SWITCH .................. 80 Removal and Installation ....................................... 103
SHIFT ACTUATOR CIRCUIT .................................... 82 INSTALLATION .................................................. 103
Diagnostic Procedure ............................................. 82 SIDE OIL SEAL ....................................................... 105
TROUBLE DIAGNOSES FOR SYMPTOMS ............. 85 Removal and Installation ....................................... 105
Symptom 1. 4WD Shift Indicator Lamp Does Not REMOVAL .......................................................... 105
Turn ON (Although the ignition switch is turned "ON", INSTALLATION .................................................. 105
all the 4WD indicator lamps do not turn ON for 1 TRANSFER CONTROL DEVICE ............................ 106
second) ................................................................... 85 Removal and Installation ....................................... 106
Symptom 2. 4WD Warning Lamp Does Not Turn ON AIR BREATHER HOSE ........................................... 107
(Although the ignition switch is turned "ON", the Removal and Installation ....................................... 107
4WD warning lamp does not turn ON) .................... 87 TRANSFER MOTOR ............................................... 108
Symptom 3. 4WD Shift Indicator Lamp Does Not Removal and Installation ....................................... 108
Turn OFF (When 4WD shift switch is set from "4H" REMOVAL .......................................................... 108
to "4LO", all the 4WD shift indicator lamps do not INSTALLATION .................................................. 108
turn off) ................................................................... 89 TRANSFER OIL FILTER ......................................... 109
Symptom 4. ATP Warning Lamp Does Not Turn ON Removal and Installation ....................................... 109
(When 4WD shift switch is set from "4H" to "4LO" REMOVAL .......................................................... 109
with the A/T selector lever in "P" position, the ATP INSTALLATION .................................................. 109
warning lamp does not turn on) .............................. 90 REMOVAL AND INSTALLATION ............................ 111
Symptom 5. 4LO Indicator Lamp Does Not Turn ON Removal ................................................................ 111
(When 4WD shift switch is set from “4H” to “4LO” Installation ............................................................. 111
position, 4LO indicator lamp does not turn ON) ..... 91 OVERHAUL ............................................................. 112
Symptom 6. 4WD Shift Indicator Lamp Does Not Transfer Components ........................................... 112
Indicate “LOCK” (When 4WD shift switch is set to REAR CASE ............................................................ 114
“4H”, 4WD shift indicator lamp does not indicate Disassembly .......................................................... 114
“LOCK”) .................................................................. 92 CENTER CASE ....................................................... 115
Symptom 7. 4WD Shift Indicator Lamp Repeats Disassembly .......................................................... 115
Flickering (4WD shift indicator lamp keeps flicker- FRONT DRIVE SHAFT AND DRIVE CHAIN ..... 117
ing) .......................................................................... 94 MAINSHAFT AND CLUTCH DRUM .................. 118
Symptom 8. Tight Corner Braking Symptom (Tight CLUTCH PISTON .............................................. 120
corner braking symptom occurs) (Hydraulic system CONTROL VALVE ............................................. 121
failure) ..................................................................... 95 MAINSHAFT REAR BEARING .......................... 124
Symptom 9. 4WD System Does Not Operate (The MAIN OIL PUMP ................................................ 124
vehicle cannot be put into 4WD mode) (Hydraulic SUB OIL PUMP ................................................. 125
system failure) ........................................................ 96 OIL FILTER ........................................................ 126
Component Inspection ............................................ 97 FRONT CASE .......................................................... 127
4WD SHIFT SWITCH .......................................... 97 Disassembly .......................................................... 127
2-4WD SHIFT SOLENOID VALVE AND TRANS- SHIFT ROD COMPONENTS .............................127
PLANETARY CARRIER, SUN GEAR AND

INTERNAL GEAR ............................................. 129 CENTER CASE ....................................................... 142
FRONT CASE ......................................................... 133 Assembly .............................................................. 142 A
Inspection ............................................................. 133 OIL FILTER ........................................................ 142
PLANETARY CARRIER .................................... 133 SUB OIL PUMP ................................................. 142
SUN GEAR ....................................................... 133 MAIN OIL PUMP ............................................... 143 B
INTERNAL GEAR ............................................. 133 CONTROL VALVE ............................................. 144
SHIFT ROD COMPONENTS ............................ 133 CLUTCH PISTON .............................................. 146
CENTER CASE ...................................................... 135 MAINSHAFT AND CLUTCH DRUM .................. 147
Inspection ............................................................. 135 FRONT DRIVE SHAFT AND DRIVE CHAIN ..... 150 C
BEARINGS ........................................................ 135 ASSEMBLY ............................................................. 151
SUB-OIL PUMP ................................................ 135 Final Assembly ..................................................... 151
MAIN OIL PUMP ............................................... 135 SERVICE DATA AND SPECIFICATIONS (SDS) .... 155 TF
MAINSHAFT ..................................................... 135 General Specifications .......................................... 155
CONTROL VALVE ............................................ 136 Inspection and Adjustment ................................... 155
CLUTCH ............................................................ 136 CLEARANCE BETWEEN INNER GEAR AND E
FRONT CASE ......................................................... 138 OUTER GEAR ................................................... 155
Assembly .............................................................. 138 CLUTCH ............................................................ 155
PLANETARY CARRIER, SUN GEAR AND PINION GEAR END PLAY ................................ 155
INTERNAL GEAR ............................................. 138 CLEARANCE BETWEEN SHIFT FORK AND F
SHIFT ROD ASSEMBLY ................................... 141 SLEEVE ............................................................ 155
SELECTIVE PARTS .........................................
G

PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EDS00114
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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the SRS and SB section of this Service Man-
ual.
WARNING:
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Transfer Assembly and Transfer Control Unit Replacement EDS00348
When replacing transfer assembly or transfer control unit, check the 4WD shift indicator lamp as follows.
1. Turn ignition switch “ON”.
2. Check 4WD shift indicator lamp is turned ON for approx. 1 second.
● If OK, the position between transfer assembly and transfer control unit is correct.
● If NG, the position is different between transfer assembly and transfer control unit.
Adjust the position between transfer assembly and transfer control unit. Refer to TF-4, "METHOD FOR
POSITION ADJUSTMENT" .
METHOD FOR POSITION ADJUSTMENT
1. Start engine. Run the engine for at least 10 seconds.
2. Stop vehicle and move A/T selector lever to “N” position with brake pedal depressed. Stay in "N" for at
least 2 seconds.
3. Turn 4WD shift switch to “2WD” position. Stay in "2WD" for at least 2 seconds.
4. Turn ignition switch “OFF”.
5. Start engine.
6. Erase self-diagnosis. Refer to TF-30, "Trouble Diagnosis with CONSULT-II" (with CONSULT-II) or TF-27,
"Trouble Diagnosis without CONSULT-II" (without CONSULT-II).
7. Check 4WD shift indicator lamp. Refer to TF-47, "1. CHECK BEFORE ENGINE IS STARTED" .
If 4WD shift indicator lamp does not indicate "2WD", install new transfer control unit and retry the above
check.
Precautions EDS000YZ
● Before connecting or disconnecting the transfer control

unit harness connector, turn ignition switch OFF and dis-
connect negative battery terminal. Failure to do so may
damage the transfer control unit. Because battery voltage is
applied to transfer control unit even if ignition switch is
turned off.
SEF289H

PRECAUTIONS
● When connecting or disconnecting pin connectors into or

from transfer control unit, take care not to damage pin ter- A
minals (bend or break).
Make sure that there are not any bends or breaks on trans-
fer control unit pin terminal, when connecting pin connec-
B
tors.
SEF291H
TF
● Before replacing transfer control unit, perform transfer con-
trol unit input/output signal inspection and make sure
whether transfer control unit functions properly or not. (See
E
page TF-54 .)
G
MEF040DB
Service Notice EDS000Z0

H
1. Before proceeding with disassembly, thoroughly clean the outside of the all-mode 4WD transfer. It is
important to prevent the internal parts from becoming contaminated by dirt or other foreign matter.
2. Disassembly should be done in a clean work area.
I
3. Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere
with the operation of the all-mode 4WD transfer.
4. Place disassembled parts in order for easier and proper assembly.
J
5. All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
6. Gaskets, seals and O-rings should be replaced any time the all-mode 4WD transfer is disassembled. K
7. It is very important to perform functional tests whenever they are indicated.
8. The valve body contains precision parts and requires extreme care when parts are removed and serviced.
Place removed parts in a parts rack in order to replace them in correct positions and sequences. Care will L
also prevent springs and small parts from becoming scattered or lost.
9. Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight.
10. Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings M
and seals, and to hold bearings and washers in place during assembly. Do not use grease.
11. Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling.
12. After overhaul, refill the transfer with new ATF.
13. When the all-mode 4WD transfer drain plug is removed, only some of the fluid is drained. Old all-mode
4WD transfer fluid will remain in torque converter and ATF cooling system. Always follow the proper pro-
cedure. Refer to MA-24, "Changing Transfer Fluid" .
Wiring Diagrams and Trouble Diagnosis EDS000Z1
When you read wiring diagrams, refer to the following:

● GI-15, “HOW TO READ WIRING DIAGRAMS”
● PG-4, “POWER SUPPLY ROUTING”
When you perform trouble diagnosis, refer to the following:
● GI-11, “HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSIS”
● GI-27, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”

PREPARATION
PREPARATION PFP:00002
Special Service Tools EDS001DX
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
ST30021000 Removing carrier bearing
( — ) a: 110 mm (4.33 in) dia.
Puller b: 68 mm (2.68 in) dia.
NT411
ST30031000 Removing front driveshaft bearing

( — ) a: 90 mm (3.54 in) dia.
Puller b: 50 mm (1.97 in) dia.
NT411
ST30720000 Installing mainshaft front bearing and oil seal

(J-25405) a: 77 mm (3.03 in) dia.
Drift b: 55.5 mm (2.185 in) dia.
NT658
ST33220000 Installation needle bearings

( — ) a: 37 mm (1.46 in) dia.
Drift b: 31 mm (1.22 in) dia.
c: 22 mm (0.87 in) dia.
ZZA1046D
KV40100621 Installing front drive shaft front and rear bear-

(J-25273) ing
Drift a: 76 mm (2.99 in) dia.
b: 69 mm (2.72 in) dia.
NT086
ST30032000 Installing front drive shaft bearing

(J-26010-01) a: 38 mm (1.50 in) dia.
Base b: 80 mm (3.15 in) dia.
NT660
ST33052000 Removing front drive shaft bearing

( — ) a: 28 mm (1.10 in) dia.
Adapter b: 22 mm (0.87 in) dia.
NT431

PREPARATION

(Kent-Moore No.) A
Tool name
ST33200000 Removing mainshaft front bearing
(J-26082) Installing planetary carrier assembly B
Support ring Installing oil seal
a: 74.5 mm (2.933 in) dia.
b: 62.5 mm (2.461 in) dia.
C
NT661
ST3532500 Removing metal bushing TF

( — ) a: 215 mm (8.46 in)
Remover b: 25 mm (0.98 in) dia.
c: M 12 x P=1.5
E
NT663
KV38100500 Installing front oil seal

F
( — ) a: 80 mm (3.15 in) dia.
G
NT115 H
ST30911000
( — ) Removing and installing press flange snap
Puller ring
I
Installing carrier bearing
Installing mainshaft center case
a: 98 mm (3.86 in) dia.
b: 40.5 mm (1.594 in) dia. J
NT664
ST33290001 Removing metal bushing and oil seal

(J-34286)
Outer race puller K
L
NT665
ST22452000 Removing and installing press flange snap

(J-34335) ring M
Drift a: 45 mm (1.77 in) dia.
b: 36 mm (1.42 in) dia.
c: 400 mm (15.76 in) dia.
NT117
KV38100300 Removing mainshaft rear bearing

(J-25523) a: 54 mm(2.13 in) dia.
c: 32 mm (1.26 in) dia.
ZZA1046D

PREPARATION

(Kent-Moore No.)
Tool name
ST35300000 Removing sun gear assembly
( — ) Removing carrier bearing
Drift Installing metal bushing
a: 59 mm (2.32 in) dia.
b: 45 mm (1.77 in) dia.
NT073
ST33710000 Removing needle bearing

( — ) Removing metal bushing
Drift a: 89 mm (3.5 in)
b: 30 mm (1.18 in) dia.
c: 24 mm (0.9 in) dia.
ZZA1057D
ST22360002 Installing oil seal

(J-25679-01) a: 23 mm (0.91 in) dia.
ZZA1091D
ST15310000 Installing mainshaft rear bearing

(J-25640-B) a: 96 mm (3.78 in) dia.
ZZA0908D
KV40105310 Installing dust cover

( — ) Installing carrier bearing
Support ring a: 89.1 mm (3.508 in) dia.
b: 80.7 mm (3.177 in) dia.
NT661
KV31103300 Removing and installing press flange snap

( — ) ring
Drift a: 76.3 mm (3.004 in) dia.
b: 130 mm (5.12 in)
NT668

PREPARATION
Commercial Service Tools EDS001DY
A
Tool name Description
Flange wrench Removing and installing companion flange
B
C
NT771
Puller Removing companion flange

TF
NT077
Pin punch Removing and installing retainer pin F

a: 6 mm (0.24 in) dia.
NT410
H
Power tool Removing transfer case assembly
J
PBIC0190E

ALL-MODE 4WD SYSTEM
ALL-MODE 4WD SYSTEM PFP:00000
Cross-sectional View EDS001DZ
LDIA0053E
1. Center case 2. Chain 3. Multiple disc clutch

4. Rear case 5. Main shaft 6. Clutch hub assembly
7. Sub oil pump 8. Transfer motor 9. Control valve
10. Front drive shaft 11. Drain plug 12. 2-4 sleeve
13. Sun gear assembly 14. L-H sleeve 15. Planetary carrier assembly
16. Internal gear 17. Front case

ALL-MODE 4WD SYSTEM
Control System EDS000Z3
TF
LDIA0054E

ALL-MODE 4WD SYSTEM
ALL-MODE 4WD TRANSFER BASIC CONTROL
LDIA0055E
HYDRAULIC CONTROL CIRCUITS
WDIA0056E
OUTLINE
All-mode 4WD transfer is controlled by the transfer control unit and sensors.
If a malfunction occurs in the all-mode 4WD system, the 4WD warning lamp lights up to indicate the system
malfunction. There are two ways to identify the cause of the malfunction.
1. Performing the self-diagnosis. (The 4WD warning lamp will indicate what kind of malfunction has occurred
by flickering.)
2. Performing diagnosis using CONSULT-II.

ALL-MODE 4WD SYSTEM
CONTROL SYSTEM DIAGRAM

A
TF
LDIA0056E
INDICATIONS OF 4WD WARNING LAMP G

Condition Content 4WD warning lamp
During self-diagnosis Indicates the malfunction position by number of flickers. Flickers at malfunction mode.
H
Checks the lamp by turning ON during engine starting. After
Lamp check* ON
engine starts, it turns OFF if there are no malfunctions.
Turns ON to indicate malfunction. When ignition switch is
Malfunction in 4WD system*
turned to “OFF” or the malfunction is corrected, it turns OFF.
ON I
When vehicle is driven with different Flickers once every 2 seconds. Flickers once every 2 sec-
diameters of front and rear tires Turns OFF when ignition switch is “OFF”. onds.
J
When fluid temperature is high or fluid temperature sensor cir-
High fluid temperature in transfer unit cuit is shorted, it flickers twice every second. Flickers twice a second.
It turns OFF when fluid temperature becomes normal.
Other than above (System is nor- K
Lamp is OFF. OFF
mal.)
*: When 4WD warning lamp is ON, all the 4WD shift indicator lamps turn OFF.
L
Can Communication EDS000Z4
SYSTEM DESCRIPTION
Refer to LAN-5, "CAN COMMUNICATION" . M

ALL-MODE 4WD SYSTEM
Location of Electrical Parts EDS000Z5
WDIA0107E

ALL-MODE 4WD SYSTEM
Description of Electrical Parts EDS000Z6
TRANSFER MOTOR A
1. The transfer motor drives the sub-oil pump to provide proper lubrication and oil pressure control when the
vehicle is at standstill, during low-speed operations or is being driven in reverse.
2. The main oil pump is operated by the driving force of the mainshaft. In other words, sufficient oil pressure B
buildup does not occur when the vehicle is at standstill or during low-speed operations. While the vehicle
is being driven in reverse, the main oil pump rotates in the reverse direction. Therefore the main oil pump
does not discharge oil pressure. During any of the above vehicle operations, the transfer motor drives the C
sub-oil pump to compensate for insufficient oil pressure.
3. The transfer motor operates as follows:
1. The motor relay turns OFF in the 2WD mode. TF
2. The motor relay operates as described in the table below in modes other than the 2WD mode.
Table 1
E
PNP switch “R” position VFF (Vehicle speed) A/T position Motor relay drive command
ON — R ON
Positions other than the “P” or F
0 ON
“N” positions
“P” or “N” position (See Table
— —
2.)
OFF G
0 < VFF ≤ 50 km/h (30 MPH) — ON
50 km/h (30 MPH) < VFF < 55
— HOLD
km/h (35 MPH)
H
55 km/h (35 MPH) ≤ VFF — OFF
Table 2
I
Throttle position
A/T position N-4L SW 4WD mode
0 - 0.07/8 0.07/8 - 1/8 1/8 - MAX
LOCK (4H) ON ON ON J
OFF Positions other than
N the LOCK position See NOTE. HOLD ON
(2WD or AUTO)
K
ON — See NOTE. HOLD ON
P — — See NOTE. HOLD ON
NOTE: L
OFF (after 2.5 seconds have elapsed.)
4. 4WD shift switch, PNP switch, Neutral-4LO switch, vehicle speed sensor and throttle position sensor are
used in conjunction with the transfer motor. M
WAIT DETECTION SWITCH
1. The wait detection switch releases the “booming” torque produced in the propeller shaft. After the release
of the “booming” torque, the wait detection switch helps provide the 4WD lock gear (clutch drum) shifts. A
difference may occur between the operation (“4LO” to “4H” shift only) of the 4WD shift switch and actual
drive mode. At this point, the wait detection switch senses an actual drive mode.
2. The wait detection switch operates as follows:
4WD lock gear (clutch drum) locked: ON
4WD lock gear (clutch drum) released: OFF
3. The wait detection switch senses an actual drive mode and the 4WD shift indicator lamp indicates the
vehicle drive mode.
2-4WD SHIFT SOLENOID VALVE
The 2-4WD shift solenoid valve operates to apply oil pressure to the wet, multiplate clutch, depending on the
drive mode. The driving force is transmitted to the front wheels through the clutch so the vehicle is set in the
4WD mode. Setting the vehicle in the 2WD mode requires no pressure buildup. In other words, pressure force
applied to the wet, multiplate clutch becomes zero.

ALL-MODE 4WD SYSTEM
LINE PRESSURE SWITCH

1. With the transfer system design, control of the oil pressure provides the transmission of drive torque to the
front wheels. The main pressure to control the oil pressure is referred to as the line pressure.
The line pressure switch determines whether or not adequate line pressure has built up under different
operating conditions.
2. The line pressure switch turns ON when line pressure is produced.
3. The line pressure switch senses line pressure abnormalities and turns the 4WD warning lamp ON.

ALL-MODE 4WD SYSTEM
Circuit Diagram for Quick Pinpoint Check EDS000Z7
TF
WDWA0007E

ALL-MODE 4WD SYSTEM
Wiring Diagram — TF — EDS000Z8
WDWA0014E

ALL-MODE 4WD SYSTEM
TF
WDWA0009E

ALL-MODE 4WD SYSTEM
WDWA0003E

ALL-MODE 4WD SYSTEM
TF
WDWA0010E

ALL-MODE 4WD SYSTEM
WDWA0004E

ALL-MODE 4WD SYSTEM
TF
WDWA0011E

ALL-MODE 4WD SYSTEM
WDWA0005E

ALL-MODE 4WD SYSTEM
TF
WDWA0006E

ALL-MODE 4WD SYSTEM
WDWA0012E

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION PFP:00000

A
Trouble Diagnosis without CONSULT-II EDS000Z9
DESCRIPTION
If the engine starts when there is something wrong with the all-mode 4WD system, the 4WD warning lamp B
turns ON or flickers in the combination meter. When the system functions properly, the warning lamp turns ON
when the ignition switch is turned to “ON”, and it turns OFF after engine starts.
To locate the cause of a problem, start the self-diagnosis function. The 4WD warning lamp in the combination
meter will indicate the problem area by flickering according to the self-diagnostic results. As for the details of C
the 4WD warning lamp flickering patterns, refer to TF-29 .
TF

SELF-DIAGNOSTIC PROCEDURE
WDIA0108E
*1: TF-87 *2: TF-29

INDICATIONS OF 4WD WARNING LAMP

Flickering pattern or flick-
A
Malfunction Check items
ering condition
Refer to AT-109, "DTC P0720 VEHI-
2 Rear revolution sensor circuit is shorted or open. CLE SPEED SENSOR A/T (REVO- B
LUTION SENSOR)" .
Refer to TF-59, "Diagnostic Proce-
3 4WD solenoid valve circuit is shorted or open.
dure" . C
2-4WD shift solenoid valve circuit is shorted or 2WD switch of Refer to TF-61, "Diagnostic Proce-
4
4WD shift switch is shorted. dure" .
Refer to TF-63, "Diagnostic Proce- TF
5 Transfer motor relay circuit is shorted or open.
dure" .
If unexpected signal is detected because of ABS wheel sensor Refer to BRC-38, "Wheel Sensor
6
malfunction or communications error within the vehicle System Inspection" . E
Refer to LAN-5, "CAN COMMUNICA-
7 When malfunction in CAN communication system is detected
TION" .
Refer to EC-349, "DTC P0605 ECM" F
8 A/D converter of transfer control unit functions improperly.
.
9 Transfer fluid temperature sensor circuit is open.
dure" .
G
10 Neutral-4LO switch circuit is shorted or open.
dure" .
Refer to TF-61, "Diagnostic Proce- H
2-4WD shift solenoid valve circuit, 2WD switch of 4WD shift
11 dure" or TF-71, "Diagnostic Proce-
switch circuit or clutch pressure switch circuit is shorted or open.
dure" .
12 Line pressure switch circuit is shorted or open. I
dure" .
Refer to AT-112, "DTC P0725
13 Engine speed signal circuit is shorted or open.
ENGINE SPEED SIGNAL" .
J
Refer to EC-349, "DTC P0605 ECM"
14 Throttle position sensor circuit is shorted or open.
.
15 Malfunction in power supply circuit of transfer control unit. Power supply of transfer control unit
K
16 4WD shift switch circuit is shorted.
dure" .
Refer to BRC-54, "CAN Communica-
17 ABS operation signal circuit is shorted.
tion System Inspection" .
L
ATP switch, wait detection switch or neutral-4LO switch circuit is Refer to TF-68, "Diagnostic Proce-
18
shorted or open. dure" .
M
Transfer control device actuator motor is malfunctioning. (Mal- Refer to TF-77, "Diagnostic Proce-
19 functions are detected when actuator motor fails to operate while dure" or TF-82, "Diagnostic Proce-
shifting from “4H” to “4LO” or vice versa.) dure" .
Transfer control device actuator motor arm position sensing
20 dure" or TF-82, "Diagnostic Proce-
switch is malfunctioning.
dure" .
Transfer control device actuator circuit is shorted or open. (Mal-
dure" , TF-80, "Diagnostic Proce-
21 functions are detected when motor relay circuit is open/shorted or
dure" or TF-82, "Diagnostic
relay monitor circuit is open/shorted.)
Procedure" .
If VDC operation signal is being input because of VDC malfunc- Refer to BRC-40, "ABS/TCS/VDC
22
tion or communication error within the vehicle Control Unit Inspection" .
If TCS operation signal is being input because of TCS malfunction Refer to BRC-40, "ABS/TCS/VDC
23
or communication error within the vehicle Control Unit Inspection" .
If unexpected signal is input because of AT PNP switch circuit or Refer to AT-112, "DTC P0725
24
communication error within the vehicle ENGINE SPEED SIGNAL" .

Flickering pattern or flick-

Malfunction Check items
ering condition
Repeats flickering every
Circuits that the self-diagnosis covers have no malfunction. —
2 to 5 sec.
● Power supply failure of memory back-up.
Repeats flickering every Refer to TF-76, "Diagnostic Proce-
● Battery is disconnected for a long time.
0.25 sec. dure" .
● Battery performance is poor.
No flickering PNP switch or 4WD shift switch circuit is shorted or open. ENGINE SPEED SIGNAL" or TF-61,
"Diagnostic Procedure" .
Trouble Diagnosis with CONSULT-II EDS000ZA
CONSULT-II FUNCTION
CONSULT-II can dislay each diagnostic item using the diagnostic test modes shown following.
Reference
Diagnostic test mode Function
page
Self-diagnostic results Self-diagnostic results can be read and erased quickly. TF-31
Data monitor Input/Output data in the transfer control unit can be read. TF-33
This mode enables a technician to adjust some device faster and more accurately by
Work support TF-40
following the indications on CONSULT-II.
CAN diagnostic support mon-
The results of transmit/receive diagnosis of CAN communication can be read. LAN-3
itor
ECU part number Transfer control unit part number can be read. —
SELF-DIAGNOSIS
CONSULT-II Setting Procedure
1. Turn ignition switch to “OFF” position.
SAT601J
2. Connect CONSULT-II and CONSULT-II CONVERTER to data

link connector which is located in instrument lower panel on
driver side.
BBIA0369E

3. Start engine.
4. On CONSULT-II screen, touch “START (NISSAN BASED A
VHCL)”.
BCIA0029E
TF
5. Touch “ALL MODE AWD/4WD” on SELECT SYSTEM screen.
If "ALL MODE AWD/4WD" is not indicated, refer to LAN-5, "CAN
COMMUNICATION" . E
G
BCIA0030E
6. Touch “SELF-DIAG RESULTS” on SELECT DIAG MODE H

screen.
BCIA0031E K
7. Self-diagnostic results are displayed.

L
SELF-DIAGNOSTIC ITEMS
Detected items
(Screen terms for CONSULT-II, Malfunction is detected when... Check items
“SELF-DIAG RESULT” mode) M
● Signal from vehicle speed sensor 1 (installed on A/T) is Refer to AT-109, "DTC P0720
Revolution sensor (rear) not input due to open circuit. VEHICLE SPEED SENSOR A/T
(VHCL SPEED SEN·RR)
● Improper signal is input while driving. (REVOLUTION SENSOR)" .
4WD solenoid valve Refer to TF-59, "Diagnostic Proce-

(DUTY SOLENOID) ● Proper voltage is not applied to solenoid valve due to dure" .
2-4WD shift solenoid valve open or short circuit. Refer to TF-61, "Diagnostic Proce-
(2-4WD SOLENOID) dure" .
Transfer motor relay ● Motor does not operate properly due to open or short cir- Refer to TF-63, "Diagnostic Proce-
(MOTOR RELAY) cuit in transfer motor or motor relay. dure" .
● Signal voltage from fluid temperature sensor is abnor-
Transfer fluid temperature sensor Refer to TF-65, "Diagnostic Proce-
mally high (T/F fluid temperature is abnormally low)
(FLUID TEMP SENSOR) dure" .
while driving.
Neutral-4LO switch Refer to TF-68, "Diagnostic Proce-
● Improper signal is input while driving.
(N POSI SW TF) dure" .

Detected items
(Screen terms for CONSULT-II, Malfunction is detected when... Check items
“SELF-DIAG RESULT” mode)
Clutch pressure ● Improper signal is input due to open or short circuit. (*1) Refer to TF-71, "Diagnostic
(CLUTCH PRESSURE) ● Malfunction occurs in clutch pressure hydraulic circuit. Procedure" .
Line pressure ● Improper signal is input due to open or short circuit. (*1) Refer to TF-74, "Diagnostic
(LINE PRESSURE) ● Malfunction occurs in line pressure hydraulic circuit. Procedure" .
Engine speed signal (Note 1) Refer to AT-112, "DTC P0725

● Engine speed is abnormally low while driving.
(ENGINE SPEED SIG) ENGINE SPEED SIGNAL" .
● Signal voltage from throttle position sensor is abnormally
Throttle position sensor high. Refer to EC-349, "DTC P0605
(THRTL POSI SEN) ● Signal voltage from throttle position sensor is abnormally ECM" .
low when closed throttle position switch is OFF.
Transfer control unit (ADC) ● Power supply voltage for A/D converter system of trans- Refer to EC-349, "DTC P0605
C/U (ADC)/THRTL SEN fer control unit is malfunctioning. ECM" .
Battery voltage (Note 1) ● Power supply voltage for transfer control unit is abnor- Refer to TF-18, "Wiring Diagram —
(BATTERY VOLTAGE) mally low while driving. TF —" .
4WD shift switch ● More than two switch inputs are simultaneously detected Refer to TF-61, "Diagnostic Proce-
(4WD MODE SW) due to short circuit of 4WD shift switch. dure" .
● When a malfunction signal due to disconnection or
ABS operation signal (Note 4) shorting is detected. Refer to BRC-10, "CAN COMMU-
(ABS OPER SIGNAL) ● When a defect signal is entered from the ABS control NICATION" .
unit.
Wait detection switch (Note 2) (*2) Refer to TF-68, "Diagnostic
● Improper signal is input due to open or short circuit.
(WAIT DETECT SWITCH) Procedure" .
Transfer control device actuator motor is malfunctioning. Refer to TF-77, "Diagnostic Proce-
Shift actuator abnormal
(Malfunctions are detected when actuator motor fails to dure" or TF-82, "Diagnostic Proce-
(SHIFT ACT)
operate while shifting from “4H” to “4LO” or vice versa.) dure" .
Shift actuator position switch Refer to TF-80, "Diagnostic Proce-
Transfer control device actuator motor arm position sens-
abnormal dure" or TF-82, "Diagnostic Proce-
ing switch is malfunctioning.
(SHIFT ACT P/S) dure" .
Transfer control device actuator circuit is shorted or open.
Shift actuator circuit abnormal dure" , TF-80, "Diagnostic Proce-
(Malfunctions are detected when motor relay circuit is
(SHIFT ACT CIR) dure"TF-82, "Diagnostic
open/shorted or relay monitor circuit is open/shorted.)
Procedure" .
● Due to removal of battery which cuts off power supply to
Memory power supply stop transfer control unit, self-diagnosis memory function is
dure" .
suspended.
Transfer control unit (RAM) ● Malfunction is detected in the memory (RAM) system of
—
[CONTROL UNIT (RAM)] transfer control unit.
Transfer control unit (ROM) ● Malfunction is detected in the memory (ROM) system of
—
[CONTROL UNIT (ROM)] transfer control unit.
Transfer control unit (EEPROM) ● Malfunction is detected in the memory (EEPROM) sys-
—
[CONTROL UNIT (EEPROM)] tem of transfer control unit.
Longitudinal G-sensor Displayed, but do not use. —
● ABS vehicle speed sensor signal is not input due to an
open circuit. Refer to ABS vehicle speed sensor
ABS VHL SPD SEN
● An unexpected signal is input when vehicle is being diagnosis.
driven.
STEERING ANGLE SENSOR Displayed, but do not use. —
If VDC operation signal is being input because of VDC Refer to BRC-40, "ABS/TCS/VDC
VDC OPER SIG
malfunction or communication error within the vehicle. Control Unit Inspection" .
If TCS operation signal is being input because of TCS mal- Refer to BRC-40, "ABS/TCS/VDC
TCS OPER SIG
function or communication error within the vehicle. Control Unit Inspection" .

Detected items
(Screen terms for CONSULT-II, Malfunction is detected when... Check items A
“SELF-DIAG RESULT” mode)
Refer to LAN-5, "CAN COMMUNI-
CAN COMM (Note 5) Malfunction is detected in CAN communication.
CATION" . B
When AT PNP switch circuit is malfunction or communica-
A/T POSITION SIGNAL PARK/NEUTRAL POSITION
tion error between the vehicles
SWITCH" .
C
Note 1: When a malfunction occurs, it is only displayed and not stored in the memory.
Note 2: When the wait detection switch has been properly fixed, malfunction information is erased from the memory.
Note 3: If 4WD shift switch is left between 4H and 4LO for a while, this indication may be displayed.
(*1): If the malfunction is detected only while driving in reverse, check the continuity of “R” position on A/T PNP switch. When there is TF
nothing wrong with the electrical system, check the hydraulic system.
(*2): If a revolution sensor malfunction is detected at the same time, check the revolution sensor circuit first.
Note 4: When this malfunction is detected with the ABS warning lamp off, first check for disconnection or shorting in the harness E
between the transfer control unit and the ABS control unit.
Note 5: When several systems including CAN communication system indicate malfunctions, perform diagnosis of the CAN communica-
tion first.
F
DATA MONITOR
CONSULT-II Setting Procedure
1. Turn ignition switch to “OFF” position. G
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CON-
VERTER, malfunctions might be detected in self-diagnosis H
depending on control unit which carry out CAN communication.
2. Connect CONSULT-II and CONSULT-II CONVERTER to data
link connector, which is located in instrument lower panel on
driver side. I
3. Turn ignition switch to “ON” position.
4. Touch “START (NISSAN BASED VHCL)”. BBIA0369E J
5. Touch “ALL MODE AWD/4WD”.

If "ALL MODE AWD/4WD" is not indicated, refer to LAN-5, "CAN
COMMUNICATION" . K
BCIA0030E
6. Touch “DATA MONITOR”.
BCIA0031E

7. Touch “ECU INPUT SIGNALS” or “MAIN SIGNALS”.

8. Select “Numerical Display”, “Bar Chart Display” or “Line Graph
Display”.
9. Touch “SETTING” to set record conditions.
WDIA0084E
10. Touch “AUTO TRIG” or “MANU TRIG”.

11. Return to “SELECT MONITOR ITEM” on “DATA MONITOR”
screen and touch “START”.
SAT973J
12. Monitored data are displayed.
SMT963D
DATA MONITOR ITEMS

: Standard : Option
Monitor item
SELEC-
Item [Unit] ECU Remarks
MAIN TION
INPUT
SIGNALS FROM
SIGNALS
MENU
VHCL SPEED SEN-FR [km/h], Indicates average vehicle speed of ABS
[MPH] front left/right wheel.
VHCL SPEED SEN-RR [km/h], Indicates average vehicle speed of ABS
[MPH] rear left/right wheel.
Engine speed [rpm] —
Throttle position sensor —
Transfer fluid temperature sensor

—
[V]
Battery voltage [V] —
2WD switch [ON-OFF] 2WD switch of 4WD shift switch
AUTO switch [ON-OFF] AUTO switch of 4WD shift switch
Lock switch [ON-OFF] 4H switch of 4WD shift switch

Monitor item
A
SELEC-
MAIN TION
INPUT
SIGNALS FROM
SIGNALS
MENU B
4L switch [ON-OFF] 4LO switch of 4WD shift switch
N position switch TF [ON-OFF] N position switch of transfer

C
Line pressure switch [ON-OFF] Line pressure switch
Clutch pressure switch [ON-OFF] Clutch pressure switch

TF
ATP switch [ON-OFF] —
N position switch [ON-OFF] “N” position on A/T PNP switch

E
R position switch [ON-OFF] “R” position on A/T PNP switch
P position switch [ON-OFF] “P” position on A/T PNP switch
ABS operation switch [ON-OFF] ABS operation switch F

Wait detection switch [ON-OFF] —
Throttle opening recognized by transfer G

Throttle opening
control unit
4WD-mode recognized by transfer control
4WD-mode
unit (2WD, AUTO, 4H & 4LO)
H
Vehicle speed recognized by transfer con-
Vehicle speed comp [km/h (MPH)]
trol unit
Calculated torque recognized by transfer I
*Control torque [N·m (kg-m, ft.-lb.)]
control unit
Duty solenoid valve [%]
—
(Transfer 4WD solenoid valve)
J
2-4WD shift solenoid valve [ON-
OFF]
Transfer motor relay [ON-OFF] Control signal outputs of transfer control K

unit
Shift activating 1 [ON-OFF]
Shift activating 2 [ON-OFF]

L
2-4WD shift solenoid valve monitor
[ON-OFF]
Check signal (re-input signal) of transfer
Transfer motor relay monitor [ON- M
control unit control signal output is dis-
OFF]
played. If circuit is shorted or open, ON/OFF
Shift activating monitor 1 [ON-OFF] state does not change.
Shift activating monitor 2 [ON-OFF]
Transfer control unit control signal output for

4WD fail lamp [ON-OFF]
4WD warning lamp (left)
Shift position switch 1 [ON-OFF] —
Shift position switch 2 [ON-OFF] —

2WD indicator lamp [ON-OFF]
4WD shift indicator lamp (rear)
AUTO indicator lamp [ON-OFF]
4WD shift indicator lamp (front & rear)
LOCK indicator lamp [ON-OFF]
4WD shift indicator lamp (center)

Monitor item
SELEC-
MAIN TION
INPUT
SIGNALS FROM
SIGNALS
MENU
4LO indicator lamp [ON-OFF]
4WD shift indicator lamp (right)
Clutch force release limit value set in
Clutch limit [N·m (kg-m, ft.-lb.)]
WORK SUPPORT
Value measured by voltage probe is dis-
Voltage [V]
played.
Value measured by pulse probe is dis-
played. If measurement is impossible, “#”
Frequency [Hz] sign is displayed. “#” sign is also displayed
at the final data value until the measure-
ment result is obtained.
DUTY-HI Duty cycle value for measurement probe is

DUTY-LOW displayed.
PLS WIDTH-HI Measured pulse width of measurement

PLS WIDTH-LOW probe is displayed.
LONGITUDINAL G-SENSOR [G] Displayed, but do not use.
TF VHCL SPD-FR [km/h], [MPH] Displayed, but do not use.
AT VHCL SPD-RR [km/h], [MPH] Indicates A/T rear vehicle speed.
A/T actual gear position Indicates A/T actual gear position.
VDC OPER SIG [ON-OFF] Indicates VDC operation switch.
TCS OPER SIG [ON-OFF] Indicates TCS operation switch.
Indicates C/U control signal output of ATP

ATP LAMP [ON-OFF]
lamp.
*: This item is indicated as “COMP CL TORQ”.

REFERENCE VALUE IN DATA MONITOR MODE

Indicated items
A
(Screen terms for CONSULT-II, “DATA Display Conditions
MONITOR” mode)
Throttle position sensor B
0.0/8 - 8.0/8 Throttle valve fully closed to fully open
(THRTL POS SEN)
Transfer fluid temperature sensor
Approx. 1.5 - 0.5V Transfer fluid temperature approx. 20 - 80°C (68 - 176°F)
(FLUID TEMP SE) C
ABS operation switch OFF ABS is not operating.
(ABS OPER SW) ON ABS is operating.
TF
2WD position ON 4WD shift switch is in “2WD”.
(2WD SWITCH) OFF Except the above condition
Lock position ON 4WD shift switch is in “4H”. E

(LOCK SWITCH) OFF Except the above condition
2WD,
4WD shift switch position (N) 4LO
Neutral-4LO switch AUTO, 4H F
(N POSI SW TF) ATP switch OFF ON OFF
ATP switch
(ATP SWITCH) Neutral-4LO switch/Wait detec-
OFF ON
Wait detection switch tion switch See Note. G
(WAIT DETCT SW) Note: When shifting into or out of “4LO” the switches turn ON when “Wait” function is oper-
ating and they turn OFF when “Wait” function is canceled.
4WD Motor relay/ H
A/T selector
Throttle valve shift Motor relay Remarks
lever
switch mon
Transfer motor relay 2WD — OFF — I
(MOTOR RELAY)
Transfer motor relay monitor AUTO, P, N OFF ON for approx. 2 sec. after
(MOTOR RELAY MON) Fully closed 4LO Others ON shifting to “P” and “N”
J
P OFF ON for approx. 2 sec. after
4H
Others ON shifting to “P”
The vehicle has been left at room temperature for 5 min- K

OFF
Line pressure switch utes and more with ignition switch in “OFF” position.
(LINE PRES SW) Ignition switch in “ON”, and 4WD shift switch in “AUTO” or
ON
“4H” and A/T selector lever in “D”.
L
Ignition switch in “ON”, and 4WD shift switch in “2WD”.
OFF
(“Wait” function is not operating.)
Clutch pressure switch
(CL PRES SW) Ignition switch in “ON”, and 4WD shift switch in “AUTO” or
M
ON “4H” and A/T selector lever in “D”. (“Wait” function is not
operating.)
Vehicle speed
0 km/h (0 MPH) — —
(VHCL/S COMP)
0 kg-m In “2WD” position
39 - 1,353 N·m
Control torque In “AUTO” position
(4 - 138 kg-m, 29 - 998 ft.-lb.)
(COMP CL TORQ)
1,353 N·m 4WD shift switch
(“Wait” function is not oper- In “4H” or “4LO” position
(138 kg-m, 998 ft.-lb.)
ating.)
4% In “2WD” position
4WD solenoid
96 - 4% In “AUTO” position
(DUTY SOLENOID)
4% In “4H” or “4LO” position

Indicated items
MONITOR” mode)
OFF In “2WD” position
ON (“Wait” function is not oper-
ating.)
In “AUTO” position
2-4WD shift solenoid valve OFF (“Wait” function is operat-
(2-4WD SOL) ing.)
4WD shift switch
2-4WD shift solenoid monitor ON (“Wait” function is not oper-
(2-4WD SOL MON) ating.)
In “4H” position
OFF (“Wait” function is operat-
ing.)
ON In “4LO” position
Approx. 12V Key switch “ON” and engine at rest

Battery voltage
(BATTERY VOLT)
Approx. 13 - 14V During idling
OFF 4WD shift switch in other than “AUTO” position
AUTO switch
ON 4WD shift switch in “AUTO” position
OFF 4WD shift switch in other than “4LO” position
4L switch
ON 4WD shift switch in “4LO” position
OFF A/T selector lever in other than “N” position

N position switch
(N POSI SW AT)
ON A/T selector lever in “N” position
OFF A/T selector lever in other than “R” position

R position switch
(R POSI SW AT)
ON A/T selector lever in “R” position
OFF A/T selector lever in other than “P” position

P position switch
(P POSI SW AT)
ON A/T selector lever in “P” position
Throttle opening
0.0/8 - 8.0/8 Throttle fully closed (0.0/8) or throttle fully open (8.0/8)
(THROTTLE POSI)

Indicated items
(Screen terms for CONSULT-II, “DATA Display Conditions A
MONITOR” mode)
2WD In “2WD” position B
AUTO In “AUTO” position

C
4WD shift
4WD-mode
switch
LOCK In “4H” position
TF
4L In “4LO” position
E
Front wheel speed
0 - 255 km/h (0 - 158 MPH) 0 km/h (vehicle at standstill)
(VHCL/S SEN-FR)
F
Rear wheel speed
0 - 255 km/h (0 - 158 MPH) 0 km/h (vehicle at standstill)
(VHCL/S SEN-RR)
G
Shift ACTR operating 1 OFF During normal operation
(SHIFT ACT 1)
Shift activating monitor 1 H
(SHIFT AC MON 1) ON During shifts from “4H” to “4LO” position
I
Shift ACTR operating 2 OFF During normal operation
(SHIFT ACT 2)
Shift activating monitor 2
J
(SHIFT AC MON 2) ON During shifts from “4LO” to “4H” position
OFF During normal operation

K
4WD fail lamp

During 2-second period (after key switch turned to “ON”) L
ON
or when system is out of order
OFF 4WD shift switch is in a position other than “4LO”. M

Shift ACTR position sensing switch 1
(SHIFT POS SW 1)
OFF 4WD shift switch in “4LO” position

Shift ACTR position sensing switch 2
(SHIFT POS SW 2)
ON 4WD shift switch is in a position other than “4LO”.
OFF Engine at rest or system out of order

2WD indicator lamp
(2WD IND)
ON Except the above condition

Indicated items
MONITOR” mode)
Engine at rest during 2WD-mode operation or system out

OFF
of order
AUTO indicator lamp
(AUTO IND)
ON 4WD shift switch in “4LO” or “4H” or “AUTO” position
Engine at rest and 4WD shift switch in “AUTO” position

OFF
during 2WD-mode operation or system out of order
LOCK indicator lamp
(LOCK IND)
ON 4WD shift switch in “4H” or “4LO” position
Engine at rest and 4WD shift switch in “AUTO” position

OFF
during 2WD-mode operation or system out of order
4LO indicator lamp
(4L IND)
Clutch force release limit Indicates the clutch force release setting applied using the
0.2, 0.3, 1.2 kgm
(CL/F RLS LIM) scan tool. 0.3 kgm is the default setting.
OFF VDC is not operating.

VDC operation switch
(VDC OPER SW)
ON VDC is operating.
OFF TCS is not operating.

TCS operation switch
(TCS OPER SW)
ON TCS is operating.
OFF Normal operation.

ATP indicator lamp
(ATP IND)
Driver is attempting to shift into or out of 4L while the AT is
ON
not in neutral.
Transfer case F speed

0.0 km/h (0.0 MPH) —
(T/F F SPEED)
Automatic transmission R speed

0.0 km/h (0.0 MPH) —
(AT R SPEED)
Automatic transmission gear position

1,2,3,4 Displays actual AT gear position.
(AT GEAR POSI)
WORK SUPPORT
Purpose
When there is no problem with transfer and 4WD system, following symptom in “AUTO” mode may be claimed
by a customer.
● Vibration when accelerating on a low µ road (snow-covered or icy road) (Note)

It is possible to deal with these symptoms by changing “CLUTCH FORCE RELEASE LIMIT VALUE”.
However, be careful when changing the values because it may adversely affect driving performance. A
NOTE:
A slight shock is felt at a few hertz as if it were being pushed lightly from behind.
CONSULT-II Setting Procedure B
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CON- C
VERTER, malfunctions might be detected in self-diagnosis
depending on control unit which carry out CAN communication.
2. Connect CONSULT-II and CONSULT-II CONVERTER to data TF
link connector, which is located in instrument lower panel on
driver side.
3. Turn ignition switch to “ON” position. E
4. Touch “START (NISSAN BASED VHCL)”. BCIA0029E
5. Touch “ALL MODE AWD/4WD”.
If "ALL MODE AWD/4WD" is not indicated, refer to LAN-5, "CAN COMMUNICATION" . F
6. Touch “WORK SUPPORT”.

G
BCIA0031E
J
7. Select WORK ITEM by touching “CLUTCH/F RLS LIM ADJ”.
M
WDIA0085E
CLUTCH FORCE RELEASE LIMIT ADJUSTMENT

1.2 kg-m: Tight corner braking symptom is alleviated. However, vibration may occur when accelerating on a
low µ road (icy road, etc.).
0.3 kg-m: Initial set value
0.2 kg-m: Do not set to this value because the tight corner braking symptom will get worse.
1. Current CLUTCH FORCE RELEASE LIMIT value “0.3 kgm”
appears under “CONDITION SETTING” on CONSULT-II display.
2. Touch “1.2” on the display.
SMT968D

3. Display changes to “NOW ADJUSTING” in a short time.
SMT969D
4. When clutch force release limit value is set to “1.2 kgm”, current
value “0.3 kgm” shown on display will be replaced by “1.2 kgm”
and “ADJUSTMENT COMPLETE” will appear at the same time.
Clutch force release limit value setting is now complete.
SMT970D

TROUBLE DIAGNOSIS — INTRODUCTION
TROUBLE DIAGNOSIS — INTRODUCTION PFP:00000

A
Introduction EDS000ZB
DESCRIPTION
When a malfunction (indicated by the 4WD warning lamp illumination) occurs, collect information first from the B
customer about how the malfunction occurs. Then, proceed with the diagnosis presuming it is the cause. Also
inspect the electrical system, paying close attention to other possibilities such as fluid level and leaks.
All-mode 4WD transfer is controlled by transfer control unit and sensors.
If a malfunction occurs in the all-mode 4WD system, the 4WD warning lamp lights up to inform of the system C
malfunction. There are two ways to identify the cause of the malfunction.
1. Performing the self-diagnosis. (The 4WD warning lamp will indicate what kind of malfunction has occurred
by flickering.) TF
2. Performing diagnosis using CONSULT-II.
DIAGNOSTIC WORKSHEET
E
Information from Customer
KEY POINTS
● WHAT ..... Vehicle model F
● WHEN..... Date, Frequencies
● WHERE..... Road conditions
● HOW..... Operating conditions, Symptoms G
Information sheet from customer
Customer name MR/MS Model & Year VIN
H
Transfer model Engine Mileage
ATX14A
Incident Date Manuf. Date In Service Date I
Frequency ❏ Continuous ❏ Intermittent ( times a day)
Symptoms ❏ 4WD shift indicator lamp does not turn on.
❏ 4WD warning lamp does not turn on. J
❏ 4WD shift indicator lamp does not turn off.
❏ ATP warning lamp does not turn on.
K
❏ 4LO indicator lamp does not turn on.
❏ 4WD shift indicator lamp does not indicate “4H”.
❏ 4WD shift indicator lamp repeats flicking. L
❏ Tight corner braking symptom occurs.
❏ 4WD system does not operate.
M
❏ Others.
4WD warning lamp ❏ Continuously lit ❏ Not lit

Diagnostic Worksheet
1. ❏ Listen to customer complaints. TF-46
2. ❏ Check transfer fluid. TF-46
❏ Leakage
❏ Fluid condition
❏ Fluid level
3. ❏ Road testing TF-46
❏ 1. Check before engine is started.
❏ 2. Check at idle.
❏ 3. Cruise test
4. ❏ Perform self-diagnosis NG items (with CONSULT-II and without CONSULT-II). TF-30, TF-28
5. ❏ Check component. Repair or replace the damaged parts. TF-111
6. ❏ Perform final check. Perform road test (1 through 3). TF-46

Work Flow EDS000ZC
HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR A

A good understanding of the malfunction conditions can make troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is important to fully understand the symptoms or
conditions for a customer complaint. B
Make good use of the two sheets provided, “Information from Customer” (Refer to TF-43 ) and “Diagnostic
Worksheet” (Refer to TF-44 ), to perform the best troubleshooting possible.
C
TF
WDIA0102E
*1: TF-46 *2: TF-46 *3: TF-46

*4: TF-85 - TF-96 *5: TF-59 - TF-82 *6: TF-46

TROUBLE DIAGNOSIS — BASIC INSPECTION
TROUBLE DIAGNOSIS — BASIC INSPECTION PFP:00000
Listen to Customer Complaints EDS000ZD
● Each customer feels differently about a problem. It is important to fully understand the symptoms or condi-
tions for a customer complaint.
● Listen to the customer about how and when the malfunction occurs, and make good use of it when per-
forming the road test.
Transfer Fluid Check EDS000ZE
● Check fluid for leaks and fluid level. Refer to TF-46, "Transfer Fluid Check" .
Road Test EDS000ZF
PREPARATION FOR ROAD TEST

● The purpose of the test is to determine overall performance of
transfer and analyze causes of problems.
● The road test consists of the following three parts:
● When a malfunction is found in any part of transfer, perform the
road test to locate the malfunction area and repair the malfunc-
tion parts.
1. Check before engine is started
2. Check at idle
3. Cruise test
● Perform road test and place checks for NG items on the diag- SMT089D
nostic worksheet. Refer to TF-44, "Diagnostic Worksheet" .

1. CHECK BEFORE ENGINE IS STARTED

A
1. CHECK 4WD SHIFT INDICATOR LAMP
1. Park vehicle on flat surface. B
3. Move A/T selector lever to “P” position.
4. Set 4WD shift switch to “4H” position. C
5. Set 4WD shift switch to “2WD” position.
6. Turn ignition switch to “ON” position. (Do not start engine.)
TF
LDIA0061E
E
7. Does 4WD shift indicator lamp turn ON for approx. 1 second?

Yes or No F
Yes >> GO TO 2.
No >> Go to Symptom 1. Refer to TF-85, "Symptom 1. 4WD
Shift Indicator Lamp Does Not Turn ON (Although the G
ignition switch is turned "ON", all the 4WD indicator
lamps do not turn ON for 1 second)" .
H
LDIA0062E
I
2. CHECK 4WD WARNING LAMP
Is 4WD warning lamp turned ON? J
Yes or No
Yes >> 1. Turn ignition switch to “OFF” position.
2. Perform self-diagnosis. K
Refer to TF-27, "Trouble Diagnosis without CON-
SULT-II" .
3. Go to “2. CHECK AT IDLE”. Refer to TF-48, "2. L
CHECK AT IDLE" .
No >> Go to Symptom 2. Refer to TF-87, "Symptom 2. 4WD
Warning Lamp Does Not Turn ON (Although the ignition LDIA0062E
M
switch is turned "ON", the 4WD warning lamp does not
turn ON)" .

2. CHECK AT IDLE

1. Park vehicle on flat surface.
3. Move A/T selector lever to “P” or “N” position.
4. Set 4WD shift switch to “4H” position.
6. Start engine.
7. Is 4WD shift indicator lamp turned OFF?
Yes or No
Yes >> Go to “ATP SWITCH, WAIT DETECTION SWITCH AND LDIA0062E
NEUTRAL-4LO SWITCH”. Refer to TF-68, "ATP
SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH" .
No >> GO TO 2.

Is 4WD warning lamp turned OFF?
Yes or No
Yes >> GO TO 3.
No >> Perform self-diagnosis. Refer to TF-27, "Trouble Diagnosis without CONSULT-II" .

3. CHECK 4WD SHIFT INDICATOR LAMP A

1. Set 4WD shift switch to “2WD”, “AUTO”, “4H”, “4LO”, “4H” and
“2WD” in order.
(Stay at each switch position for at least 1 second.) B
TF
LDIA0063E
2. Does 4WD shift indicator lamp change properly and does E

buzzer sound?
Yes or No
Yes >> GO TO 4. F
No >> Go to “2-4WD SHIFT SOLENOID VALVE AND 4WD
SHIFT SWITCH”. Refer to TF-61, "2-4WD SHIFT SOLE-
NOID VALVE AND 4WD SHIFT SWITCH" .
G
K
LDIA0064E
4. CHECK 4WD WARNING LAMP L
Is 4WD warning lamp turned ON?

Yes or No M
Yes >> Perform self-diagnosis. Refer to TF-27, "Trouble Diagnosis without CONSULT-II" .
No >> GO TO 5.


2. Set 4WD shift switch from “4H” to “4LO”.
LDIA0061E
3. While shifting from “4H” to “4LO”, does 4WD shift indicator lamp
turn OFF and ATP warning lamp turn ON?
Yes or No
Yes >> GO TO 6.
No >> Go to Symptoms 3 and 4. Refer to TF-89, "Symptom 3.
4WD Shift Indicator Lamp Does Not Turn OFF (When
4WD shift switch is set from "4H" to "4LO", all the 4WD
shift indicator lamps do not turn off)" and TF-90, "Symp-
tom 4. ATP Warning Lamp Does Not Turn ON (When
4WD shift switch is set from "4H" to "4LO" with the A/T
selector lever in "P" position, the ATP warning lamp LDIA0062E
does not turn on)" .

Does 4WD shift indicator lamp indicate 4LO indicator lamp turn ON
when 4WD shift switch is set in “4LO”?
LDIA0061E
LDIA0065E
Yes or No
Yes >> GO TO 7.
No >> Go to Symptom 5. Refer to TF-91, "Symptom 5. 4LO Indicator Lamp Does Not Turn ON (When
4WD shift switch is set from “4H” to “4LO” position, 4LO indicator lamp does not turn ON)" .

7. CHECK 4WD SHIFT INDICATOR LAMP (*1) A

1. Set 4WD shift switch from “4LO” to “4H”.
2. Does 4LO indicator lamp flicker? (*1)
*1: While “Wait” function is operating, 4LO indicator lamp flashes. B
Yes or No
Yes >> Go to Symptoms 6 and 7. Refer to TF-92, "Symptom 6. 4WD Shift Indicator Lamp Does Not Indi-
cate “LOCK” (When 4WD shift switch is set to “4H”, 4WD shift indicator lamp does not indicate C
“LOCK”)" and TF-94, "Symptom 7. 4WD Shift Indicator Lamp Repeats Flickering (4WD shift indi-
cator lamp keeps flickering)" .
No >> Go to “3. CRUISE TEST”. Refer to TF-52, "3. CRUISE TEST" . TF

3. CRUISE TEST
1. INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes >> GO TO 2.
No >> GO TO 3.
2. CHECK INPUT SIGNAL

With CONSULT-II
1. Warm up engine to normal operating temperature.
5. Set 4WD shift switch to “AUTO” position.
6. Start engine.
7. Drive for at least 30 seconds at a speed higher than 20 km/h (12 MPH).
(Drive vehicle until “FLUID TEMP SE” exceeds 0.9V.)
11. Leave vehicle for at least 80 seconds with “FLUID TEMP SE” at
0.9V or less.
12. Is 4WD warning lamp turned ON?
Yes or No
Yes >> Perform self-diagnosis. Refer to TF-30, "Trouble Diag-
nosis with CONSULT-II" .
No >> GO TO 4.
SMT972D

Without CONSULT-II
1. Warm up engine to normal operating temperature.
6. Start engine.
7. Drive vehicle for at least 30 seconds at a speed higher than 20 km/h (12 MPH).
11. Is 4WD warning lamp turned ON?
Yes or No
No >> GO TO 4.

4. (1) CHECK TIGHT CORNER BRAKING SYMPTOM A

2. Drive vehicle at speed lower than 20 km/h (12 MPH) with steering wheel fully turned.
3. Does tight corner braking symptom occur? B
Yes or No
Yes >> GO TO 5.
No >> GO TO 6. C
5. CONFIRM SYMPTOM AGAIN

TF
Confirm symptom and self-diagnosis again.
Refer to TF-27, "Trouble Diagnosis without CONSULT-II" and TF-30, "Trouble Diagnosis with CONSULT-II" .
OK or NG E
OK >> GO TO 6.
NG >> Go to Symptoms 8 and 9. Refer to TF-95, "Symptom 8. Tight Corner Braking Symptom (Tight cor-
ner braking symptom occurs) (Hydraulic system failure)" and TF-96, "Symptom 9. 4WD System
Does Not Operate (The vehicle cannot be put into 4WD mode) (Hydraulic system failure)" . F
6. (2) CHECK TIGHT CORNER BRAKING SYMPTOM

G
2. Drive vehicle at speed lower than 20 km/h (12 MPH) with steering wheel fully turned.
3. Does tight corner braking symptom occur? H
Yes or No
Yes >> Inspection End.
No >> GO TO 7. I
7. CONFIRM SYMPTOM AGAIN

Confirm symptom and self-diagnosis again. J
OK or NG
OK >> Inspection End. K
NG >> Go to Symptoms 8 and 9. Refer to TF-95, "Symptom 8. Tight Corner Braking Symptom (Tight cor-
ner braking symptom occurs) (Hydraulic system failure)" and TF-96, "Symptom 9. 4WD System
Does Not Operate (The vehicle cannot be put into 4WD mode) (Hydraulic system failure)" . L

TROUBLE DIAGNOSIS — GENERAL DESCRIPTION
TROUBLE DIAGNOSIS — GENERAL DESCRIPTION PFP:00000
Transfer Control Unit Terminals and Reference Value EDS000ZG
REMOVAL AND INSTALLATION OF TRANSFER CONTROL UNIT

Removal
1. Turn ignition switch OFF and disconnect negative battery termi-
nal.
2. Remove glove box.
3. Remove instrument lower panel on passenger side.
4. Remove transfer control unit.
● For steps 2 through 4 above, refer to IP-10, "INSTRUMENT
PANEL ASSEMBLY" .
LDIA0103E
Installation
● Installation is in the reverse order of removal.
INSPECTION OF TRANSFER CONTROL UNIT
● Pin connector terminal layout
LDIA0066E
TRANSFER CONTROL UNIT INSPECTION TABLE

Terminal Judgement standard
Item Condition
No. (Approx.)
4WD shift switch is set to “2WD”
Less than 1V
position.
2-4WD shift solenoid

1
valve & 4WD shift switch is set to any posi-
Battery voltage
tion other than “2WD”.


Item Condition
No. (Approx.) A
Lamp lights while system is operating

Less than 1V
4WD shift indicator lamp properly. B
2
(2WD)
2WD indicator lamp does not come
Battery voltage
on.
C
3 Ground — —
While actuator is operating (4H →
Battery voltage
4 Transfer shift relay (High) 4LO)
TF
Actuator does not operate. Less than 1V
& Lamp comes ON (when engine is

stopped). E
(Fail-safe condition appears on dis-
play, engine is stopped, actuator Less than 1V
5 4WD warning lamp position detection switch is inopera-
tive, oil temperature is too high and/ F
or tires of different size are installed.)
Except above Battery voltage
6 Ground — — — G
7 CAN H — — —
8 CAN L — — —
H
4WD shift switch is set to “2WD”
Battery voltage
position.
9 4WD shift switch (2WD)
4WD shift switch is set to any posi-
Less than 1V I
& 4WD shift switch is set to “AUTO”
4 - 14V
position.
10 Transfer dropping resistor J
Less than 1V
“4H” indicator lamp comes ON. Less than 1V
11
4WD shift indicator lamp K
(4H) 4WD shift switch is set to any posi-
Battery voltage
tion other than “4H”.
“4LO” indicator lamp comes ON. 0V
4WD shift indicator lamp L
12 4WD shift switch is set to any posi-
(4LO) Battery voltage
tion other than “4LO”.
While actuator is operating (4LO →
Battery voltage M
13 Transfer shift relay (Low) 4H)
Actuator does not operate. 0V
Transfer motor relay is ON. Battery voltage
14 Transfer motor relay
& Transfer motor relay is OFF. Less than 1V
AT selector lever is set to “P” posi-
Battery voltage
tion.
15 ATP lamp
AT selector lever is set to any posi-
0V
tion other than “P”.
Ignition key is set to “ON” position. Battery voltage
16 Power supply —
Ignition key is set to “OFF” position. 0V


Item Condition
No. (Approx.)
4WD shift switch is set to “4H” posi-
Battery voltage
tion.
18 4WD shift switch (4H)
Less than 1V
& 4WD shift switch is set to “AUTO”
1.5 - 3V
position.
19 4WD solenoid valve
Less than 1V
“AUTO” indicator lamp comes ON. 0V
4WD shift indicator lamp
21 4WD shift switch is set to any posi-
(AUTO) Battery voltage
tion other than “AUTO”.
Ignition key is set to “ON” position. Battery voltage

22 Power supply —
Ignition key is set to “OFF” position. 0V
4WD shift switch is set to “4LO” posi-
Battery voltage
tion.
23 4WD shift switch (4LO)
Less than 1V
tion other than “4LO”.
4WD shift switch is set to “AUTO”
Battery voltage
position.
24 4WD shift switch (AUTO)
Less than 1V
tion other than “AUTO”.
& Transfer is set to “4LO” position. 0V
25 Neutral-4LO switch Transfer is set to any position other
Power supply
than “4LO”.
4WD shift switch is set to “4H” posi-
Less than 1V
Transfer 4H actuator tion.
27
switch 4WD shift switch is set to any posi-
Battery voltage
28 Sensor ground — Less than 1V
Ignition key is set to “ON” position. 4.5 - 5.5V
Power supply for A/D

30
converter & Ignition key is set to “OFF” position. 0V
At 20°C (68°F) 1.1V
Transfer fluid tempera-

31
ture sensor & At 80°C (176°F) 0.3V


Item Condition
No. (Approx.) A
While actuator is operating from “4H”
Battery voltage
33 Transfer shift relay (High) to “4LO”
Actuator does not operate. 0V B
4WD shift switch is set to “AUTO” or
“4H”, then A/T selector lever is set to
Battery voltage
“D” position. (wait detection system: C
OFF)
34 Clutch pressure switch
& 4WD shift switch is set to “2WD”,
“AUTO” or “4H”, then A/T selector TF
0V
lever is set to “D” position. (wait
detection system: ON)
4WD shift switch is set to “2WD”,
“AUTO” or “4H”, then A/T selector Battery voltage E
35 Line pressure switch lever is set to “D” position.
— 0V
36 CONSULT-II (RX) — — —
F
A/T selector lever is set to “P” posi-
Battery voltage
tion.
40 ATP switch G
A/T selector lever is set to any posi-
Less than 1V
tion other than “P”.
Transfer motor relay Transfer motor relay is ON. Battery voltage

41 H
monitor Transfer motor relay is OFF. Less than 1V
While actuator is operating from
Transfer shift relay Battery voltage
42 “4LO” to “4H” position
(LOW) I
Actuator does not operate. 0V
&
Battery voltage
tion other than “4LO”. J
43 Wait detection switch
Less than 1V
tion.*3
4WD shift switch is set to any posi- K
tion other than “4LO”. (Actuator: High Battery voltage
Transfer 4LO actuator position)
44
switch
Less than 1V L
tion. (Actuator: Low position)
45 Ground — — —
Power supply (memory

47 — Battery voltage
back up) &
48 CONSULT-II (TX) — — —
*3: While wait detection system is operating, terminal 43 has battery voltage.

DTC U1000, U1001 CAN COMMUNICATION LINE
DTC U1000, U1001 CAN COMMUNICATION LINE PFP:23710
CAN Communication System Inspection EDS00110
INSPECTION PROCEDURE
1. PERFORM SELF-DIAGNOSIS
Perform transfer control unit self-diagnosis.
Is “CAN COMM CIRCUIT” displayed in the self-diagnosis display items?
Yes >> After printing out the monitor items, go to CAN system. Refer to LAN-5, "CAN COMMUNICA-
TION" .
No >> Inspection End.

4WD SOLENOID VALVE
4WD SOLENOID VALVE PFP:00000

A
Diagnostic Procedure EDS000ZN
1. CHECK 4WD SOLENOID VALVE B
Refer to TF-97, "4WD SOLENOID VALVE, CLUTCH PRESSURE C

SWITCH AND LINE PRESSURE SWITCH" .
OK or NG
OK >> GO TO 2. TF
NG >> Repair or replace 4WD solenoid valve.
SMT775D
F
2. CHECK POWER SOURCE CIRCUIT
2. Disconnect transfer control unit harness connector E142. G
3. Check resistance between transfer terminal cord assembly har-
ness connector F56 terminal 6 (L) and transfer control unit har-
ness connector E142 terminal 10 (L/W). H
Resistance : 11.2 - 12.8Ω

OK or NG I
OK >> GO TO 3.
NG >> Check the following.
LDIA0067E
● Transfer dropping resistor J
Refer to TF-97, "TRANSFER DROPPING RESISTOR" .
● Continuity between transfer terminal cord assembly harness connector F56 terminal 6 (L) and
transfer dropping resistor harness connector E135 terminal 2 (L). K
● Continuity between transfer dropping resistor harness connector E135 terminal 1 (L/W) and
transfer control unit harness connector E142 terminal 10 (L/W).
L
3. CHECK POWER SOURCE CIRCUIT
2. Check continuity between transfer terminal cord assembly har- M
ness connector F56 terminal 6 (L) and transfer control unit har-
ness connector E142 terminal 19 (L).
Continuity should exist.
OK or NG
OK >> GO TO 4.
NG >> Repair or replace harness between transfer terminal
cord assembly harness connector F56 terminal 6 (L)
and transfer control unit harness connector E142 termi-
nal 19 (L). LDIA0068E

4WD SOLENOID VALVE
4. PERFORM SELF-DIAGNOSIS
After driving for a while, perform self-diagnosis.
Refer to TF-27, "Trouble Diagnosis without CONSULT-II" or TF-30, "Trouble Diagnosis with CONSULT-II" .
OK or NG
OK >> Inspection End.
NG >> 1. Perform transfer control unit input/output signal inspection. Refer to TF-54, "TRANSFER CON-
TROL UNIT INSPECTION TABLE" .
2. If NG, recheck transfer control unit pin terminals for damage or loose connection with harness
connector.

2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH
2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH PFP:00000

A
Diagnostic Procedure EDS000ZO
1. CHECK 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH B
Refer to TF-97, "2-4WD SHIFT SOLENOID VALVE AND TRANS-

FER FLUID TEMPERATURE SENSOR" and TF-97, "4WD SHIFT C
SWITCH" .
OK or NG
OK >> GO TO 2. TF
NG >> Repair or replace 2-4WD shift solenoid valve or 4WD
shift switch.
E
SMT778D
F
With CONSULT-II
G
1. Select “ECU INPUT SIGNALS” in Data Monitor.
2. Read out ON/OFF status of “2WD SW” and “LOCK SWITCH”.
OK or NG H
OK >> 1. Perform transfer control unit input/output signal
inspection. Refer to TF-54, "TRANSFER CONTROL
UNIT INSPECTION TABLE" . I
2. If NG, recheck transfer control unit pin terminals for
damage or loose connection with harness connector.
NG >> GO TO 3. J
SMT974D

2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH
3. CHECK 4WD SHIFT SWITCH POWER SOURCE

1. Disconnect 4WD shift switch harness connector.
3. Check voltage between 4WD shift switch harness connector ter-
minal 1 and body ground.
Voltage : Battery voltage
OK or NG
OK >> GO TO 4.
● No. 49 fuse (10A) SMT852D
● Continuity between ignition switch and 4WD shift

switch
4. CHECK HARNESS CONTINUITY

2. Disconnect transfer control unit harness connector E142.
3. Check continuity between the following terminals:
– Transfer control unit harness connector E142 terminal 9 (G/
W) and 4WD shift switch harness connector M141 terminal
2 (G/W) (2WD)
– Transfer control unit harness connector E142 terminal 18
(O) and 4WD shift switch harness connector M141 terminal
5 (O) (4H)
– Transfer control unit harness connector E142 terminal 24 LDIA0069E
(LG/R) and 4WD shift switch harness connector M141 termi-
nal 3 (LG/R) (AUTO)
– Transfer control unit harness connector E142 terminal 23 (R) and 4WD shift switch harness con-
nector M141 terminal 6 (R) (4LO)
– Transfer control unit harness connector E142 terminal 1 (GR) and 4WD shift switch harness con-
nector M141 terminal 4 (G/R)
– Continuity should exist.
OK or NG
OK >> GO TO 5.
NG >> Repair harness or connector.
5. PERFORM SELF-DIAGNOSIS AGAIN

After driving for a while, perform self-diagnosis again.
Refer to TF-27, "Trouble Diagnosis without CONSULT-II" .
OK or NG
connector.

TRANSFER MOTOR AND TRANSFER MOTOR RELAY
TRANSFER MOTOR AND TRANSFER MOTOR RELAY PFP:00000

A
Diagnostic Procedure EDS000ZP
1. CHECK TRANSFER MOTOR AND TRANSFER MOTOR RELAY B
Refer to TF-98, "TRANSFER MOTOR" and TF-98, "TRANSFER

MOTOR RELAY" . C
OK or NG
OK >> GO TO 2.
NG >> Repair or replace transfer motor and transfer motor TF
relay.
LDIA0102E
F
With CONSULT-II
G
1. Select “MAIN SIGNALS” in Data Monitor.
2. Read out ON/OFF status of “MOTOR RELAY”.
3. When the value is different from standard value although ON/ H
OFF switching occurs, check the following items.
● PNP switch and throttle position sensor circuits
Refer to AT-106, "DTC P0705 PARK/NEUTRAL POSITION I
SWITCH" , AT-126, "DTC P1705 THROTTLE POSITION SEN-
SOR" .
OK or NG
J
OK >> GO TO 3. SMT975D
NG >> 1. Perform transfer control unit input/output signal
inspection. Refer to TF-54, "TRANSFER CONTROL UNIT INSPECTION TABLE" .
K
connector.
3. CHECK TRANSFER MOTOR RELAY POWER SOURCE L
1. Disconnect transfer motor relay harness connectors E153 and

E154.
M
3. Check voltage between transfer motor relay harness connector
E153 and E154 terminals 2 (Y/R), 5 (G/R) and ground.
OK or NG
OK >> GO TO 4.
LDIA0070E
● No. 58 fuse (20A)
● No. 49 fuse (10A)
● Harness continuity between ignition switch and No. 58 fuse (20A) and No. 49 fuse (10A).
● Harness continuity between fuse and transfer motor relay.

TRANSFER MOTOR AND TRANSFER MOTOR RELAY

2. Disconnect transfer control unit harness connectors E142 and
E143.
3. Check continuity between the following terminals.
(R) and transfer motor harness connector F57 terminal 14
(R)
(R) and transfer motor relay harness connector E153 termi-
nal 3 (R)
(LG) and Transfer motor relay harness connector E152 ter-
minal 1 (LG)
– Transfer motor harness connector F57 terminal 15 (B) and
ground
OK or NG
OK >> GO TO 5.
NG >> Repair or replace harness or connector.
LDIA0071E

Refer to TF-27, "Trouble Diagnosis without CONSULT-II" or TF-30, "Trouble Diagnosis with CONSULT-II" .
OK or NG
connector.

TRANSFER FLUID TEMPERATURE SENSOR
TRANSFER FLUID TEMPERATURE SENSOR PFP:00000

A
Diagnostic Procedure EDS000ZQ
1. CHECK TRANSFER FLUID TEMPERATURE SENSOR B
Refer to TF-97, "2-4WD SHIFT SOLENOID VALVE AND TRANSFER FLUID TEMPERATURE SENSOR" .
OK or NG C
OK >> GO TO 2.
NG >> Repair or replace fluid temperature sensor.
TF
E
Yes or No
Yes >> GO TO 3.
No >> GO TO 4.
F


With CONSULT-II
1. Start engine.
3. Read out the value of “FLUID TEMP SE”.
Voltage
20°C (68°F) : Approx. 1.1V
80°C (176°F) : Approx. 0.3V
SMT784D
SMT974D
OK or NG
OK >> GO TO 5.
● Continuity between transfer control unit and transfer terminal cord assembly harness connector

4. CHECK INPUT SIGNAL A

Without CONSULT-II
B
2. Check voltage between transfer control unit harness connector
E143 terminals 28 (B/G) and 31(G).
Voltage C
20°C (68°F) : Approx. 1.1V
80°C (176°F) : Approx. 0.3V
TF
OK or NG
OK >> GO TO 5.
NG >> Check the following. LDIA0072E
E
● Continuity between transfer control unit and transfer
terminal cord assembly harness connector
5. PERFORM SELF-DIAGNOSIS AGAIN F

Refer to TF-27, "Trouble Diagnosis without CONSULT-II" . G
OK or NG
NG >> 1. Perform transfer control unit input/output signal inspection. Refer to TF-54, "TRANSFER CON- H
connector. I

ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH
ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH PFP:00000
Diagnostic Procedure EDS000ZR
1. CHECK ATP SWITCH, WAIT DETECTION SWITCH AND NEUTRAL-4LO SWITCH

Refer to TF-98, "ATP SWITCH, NEUTRAL-4LO SWITCH AND WAIT
DETECTION SWITCH" .
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ATP switch, neutral-4LO switch, or
wait detection switch.
SMT786D

Yes or No
Yes >> GO TO 3.
No >> GO TO 4.

With CONSULT-II
2. Read out the ON/OFF status of “ATP SW”, “NEUTRAL SW” and
“WAIT DETCT SW”. Refer to TF-37, "REFERENCE VALUE IN
DATA MONITOR MODE" .
OK or NG
OK >> GO TO 7.
● Harness continuity between neutral-4LO switch, ATP
switch, wait detection switch harness connectors and
transfer control unit SMT976D
● Continuity between neutral-4LO switch, ATP switch,
wait detection switch harness connectors and ground

4. CHECK HARNESS GROUND CONTINUITY A

Without CONSULT-II
B
2. Disconnect ATP switch F55, neutral-4LO switch F60, and wait detection switch F59 harness connectors.
3. Check continuity from harness connectors to ground.
Terminal C
Connector Continuity
(Wire color)
F55 9 (B)
F60 12 (B) Ground Yes TF
F59 11 (B)
OK or NG E
OK >> GO TO 5.
● Circuit between neutral-4LO switch, ATP switch, wait WDIA0076E
F
detection switch harness connectors and ground

G
Without CONSULT-II
H
2. Disconnect transfer control unit E143, ATP switch F55, neutral-4LO switch F60, and wait detection switch
F59 harness connectors.
3. Check continuity between the following terminals.
I
Terminal Terminal
Connec- Connec- Continu-
(Wire (Wire
tor tor ity
color) color) J
F55 8 (L/Y) 40 (L)
F60 13 (V) E143 25 (V) Yes
F59 10 (G/Y) 43 (G/Y) K
OK or NG
OK >> GO TO 6.
L
NG >> Check the following. WDIA0077E
● Circuits between transfer control unit harness con-

nector and neutral-4LO switch, ATP switch, and wait detection switch harness connectors.
M
6. CHECK SWITCH POWER SOURCE
Without CONSULT-II
2. Operate the 4WD shift switch and check continuity between the following terminals.
Terminal Battery
Connector
(Wire color) voltage
40 (L)
E143 25 (V) Ground Yes
43 (G/Y)
OK or NG
NG >> GO TO 7.
WDIA0059E


OK or NG
connector.

CLUTCH PRESSURE SWITCH
CLUTCH PRESSURE SWITCH PFP:00000

A
Diagnostic Procedure EDS000ZS
1. CHECK MALFUNCTION B
Is this malfunction detected only while driving in reverse?

Yes or No C
Yes >> Check A/T PNP switch "R" position.
● Refer to AT-106, "DTC P0705 PARK/NEUTRAL POSITION SWITCH" .
No >> GO TO 2. TF
2. CHECK OTHER MALFUNCTION

E
Are other malfunctions also detected by self-diagnosis and CONSULT-II?
Yes or No
F
Yes >> Check for other malfunctions.
● (When other malfunctions are eliminated, clutch pressure switch malfunction display may dis-
appear.) G
No >> GO TO 3.
3. CHECK 2-4WD SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH CIRCUITS H
Check 2-4WD shift solenoid valve and 4WD shift switch circuits.
OK or NG
OK >> GO TO 4. I
NG >> Check, repair or replace faulty parts.
4. CHECK INPUT SIGNAL J

Yes or No? K
Yes >> GO TO 5.
No >> GO TO 6.
L


With CONSULT-II
SMT788D
3. Read out ON/OFF status of “CL PRES SW”.

OK or NG
OK >> GO TO 7.
● Clutch pressure switch
Refer to TF-97, "4WD SOLENOID VALVE, CLUTCH
PRESSURE SWITCH AND LINE PRESSURE
SWITCH" . SMT977D

Without CONSULT-II
1. Turn ignition switch to “ON” position and set 4WD shift switch to
“4H” position.
E143 terminal 34 (BR) and ground.
When 4WD shift switch : Battery voltage should
is in “2WD” exist.
When 4WD shift switch is in “AUTO” or “4H” and A/
T selector lever is in “D”
“Wait” operating : Battery voltage should
LDIA0075E
exist.
“Wait” not operating : Approx. 0 volts should
exist.
OK or NG
OK >> GO TO 7.
● Clutch pressure switch

Refer to TF-97, "4WD SOLENOID VALVE, CLUTCH PRESSURE SWITCH AND LINE PRES-
SURE SWITCH" .

7. PERFORM SELF-DIAGNOSIS AGAIN A

1. Check hydraulic parts.
2. After driving for a while, perform self-diagnosis again. Refer to TF-27, "Trouble Diagnosis without CON-
SULT-II" . B
OK or NG
NG >> 1. Perform transfer control unit input/output signal inspection. Refer to TF-54, "TRANSFER CON- C
connector. TF

LINE PRESSURE SWITCH PFP:00000
Diagnostic Procedure EDS000ZT
1. CHECK MALFUNCTION
Is this malfunction detected only while driving in reverse?
Yes or No
Yes >> Check A/T PNP switch “R” position.
● Refer to AT-106, "DTC P0705 PARK/NEUTRAL POSITION SWITCH" .
No >> GO TO 2.
2. CHECK OTHER MALFUNCTIONS

Are other malfunctions also detected by self-diagnosis and CONSULT-II?
Yes or No
Yes >> Check for other malfunctions.
● (When other malfunctions are eliminated, line pressure switch malfunction display may disap-
pear.)
No >> GO TO 3.

Yes or NO
Yes >> GO TO 4.
No >> GO TO 5.

With CONSULT-II
SMT790D
2. Read out the ON/OFF status of “LINE PRES SW”.

OK or NG
OK >> GO TO 6.
● Line pressure switch
Refer to TF-97, "4WD SOLENOID VALVE, CLUTCH
PRESSURE SWITCH AND LINE PRESSURE
SWITCH" . SMT977D


Without CONSULT-II
B
2. Check voltage between transfer control unit harness connector E143 terminal 35 (BR/W) and ground.
After the vehicle has : Approx. 0 volts should
been left for at least 5 exist. C
minutes in a room tem-
perature with ignition
switch “OFF” TF
With ignition switch in : Battery voltage should
“ON”, 4WD shift switch exist.
in “AUTO” or “4H” and E
A/T selector lever in
“D” LDIA0076E
I
LDIA0077E
OK or NG
OK >> GO TO 6. J
● Line pressure switch K

Refer to TF-97, "4WD SOLENOID VALVE, CLUTCH PRESSURE SWITCH AND LINE PRES-
SURE SWITCH" .
L
1. Check hydraulic parts.
2. After driving for a while, perform self-diagnosis again. Refer to TF-27, "Trouble Diagnosis without CON- M
SULT-II" .
OK or NG
connector.

DATA ERASE/DISPLAY
DATA ERASE/DISPLAY PFP:00000
Diagnostic Procedure EDS000ZV
1. CHECK TRANSFER CONTROL UNIT POWER SOURCE

1. Turn ignition switch to “OFF” position and perform self-diagnosis
again.
Refer to TF-27, "Trouble Diagnosis without CONSULT-II" and
TF-30, "Trouble Diagnosis with CONSULT-II" .
3. Disconnect transfer control unit harness connector E143.
E143 terminal 47 (W) and ground.
LDIA0078E
OK or NG
OK >> GO TO 2.
● No. 53 fuse (20A)
● Harness continuity between fuse and transfer control unit

OK or NG
connector.

SHIFT ACTUATOR
SHIFT ACTUATOR PFP:00000

A
Diagnostic Procedure EDS000ZW
1. SHIFT ACTUATOR B
Refer to TF-99, "ACTUATOR & ACTUATOR POSITION SWITCH" .

OK or NG C
OK >> GO TO 3.
NG >> GO TO 2.
TF
2. CHECK POWER SOURCE
1. Disconnect transfer control device harness connector F58.
E
2. Turn ignition switch to “ON”. (Do not start engine.)
3. Check voltage between transfer control device harness connec-
tor F58 terminal 21 (R/L) [or 24 (P/G)] and ground while 4WD
shift switch is set from 4H to 4LO (or from 4LO to 4H). F

OK or NG G
OK >> Repair or replace actuator.
NG >> 1. Recheck the following.
WDIA0089E
– Continuity between ignition switch and transfer shift H
HIGH & LOW relays
– Ignition switch and No. 57 fuse (20A)
– Continuity between transfer shift HIGH & LOW relays and transfer control device I
2. If NG, repair or replace damaged part.
3. CHECK INPUT SIGNAL J

Yes or No K
Yes >> GO TO 4.
No >> GO TO 5.
L

SHIFT ACTUATOR

With CONSULT-II
1. Start engine (idling).
2. Select “SELF-DIAG RESULTS” in Select Diag Mode.
SMT826D
3. Read out self-diagnostic result.

OK or NG
OK >> GO TO 7.
NG >> GO TO 6.
SMT978D

Without CONSULT-II
E143 terminal 33 (R/L) [or 42 (P/G)] and ground while 4WD shift
switch is set from 4H to 4LO (or from 4LO to 4H).
3. Result
Terminal Condition Voltage
While actuator is
operating for 4H to Battery voltage
33 4LO
SMT828D
Actuator does not
Approx. 0V
operate
While actuator is
operating for 4LO to Battery voltage
42 4H
Actuator does not
Approx. 0V
operate
OK or NG
OK >> GO TO 7.
NG >> GO TO 6.

SHIFT ACTUATOR
6. CHECK HARNESS CONTINUITY BETWEEN TRANSFER CONTROL UNIT AND TRANSFER CON- A
TROL DEVICE
OK or NG B
OK >> GO TO 7.
NG >> Repair and replace harness connector between transfer control unit and transfer control device.
C
Refer to TF-27, "Trouble Diagnosis without CONSULT-II" . TF
OK or NG
NG >> 1. Perform transfer control unit/output signal inspection. Refer to TF-54, "TRANSFER CONTROL E
UNIT INSPECTION TABLE" .
connector. F

SHIFT ACTUATOR POSITION SWITCH
SHIFT ACTUATOR POSITION SWITCH PFP:00000
Diagnostic Procedure EDS000ZX
1. SHIFT ACTUATOR POSITION SWITCH

OK or NG
OK >> GO TO 3.
NG >> GO TO 2.
2. CHECK POSITION SWITCH

1. Recheck continuity of shift actuator position switch.
OK or NG
OK >> GO TO 3.
NG >> Repair or replace position switch.

Yes or No
Yes >> GO TO 4.
No >> GO TO 5.

With CONSULT-II
SMT829DA

OK or NG
OK >> GO TO 6.
control device.
● Check ground circuit between transfer control device
and ground.
SMT978D

SHIFT ACTUATOR POSITION SWITCH

Without CONSULT-II
B
2. Check voltage transfer control unit harness connector E143 ter-
minal 27 (W/L) [or 44 (LG/B)] and ground while 4WD shift switch
is set from 4H to 4LO (or from 4LO to 4H).
C
TF
SMT830D
E
3. Result
Terminal Condition Voltage F
4WD shift switch is
Less than 1V
set to 4H
27
4WD shift switch is G
Battery voltage
set except 4H
4WD shift switch is
Less than 1V H
set to 4LO
44
4WD shift switch is
Battery voltage
set except 4LO
I
OK or NG
OK >> GO TO 6.
J
● Continuity between transfer control unit and transfer control device.
● Check ground circuit between transfer control device and ground.
6. PERFORM SELF-DIAGNOSIS AGAIN K

Refer to TF-27, "Trouble Diagnosis without CONSULT-II" . L
OK or NG
NG >> 1. Perform transfer control unit/output signal inspection. Refer to TF-54, "TRANSFER CONTROL M
connector.

SHIFT ACTUATOR CIRCUIT
SHIFT ACTUATOR CIRCUIT PFP:00000
Diagnostic Procedure EDS000ZY
1. SHIFT ACTUATOR CIRCUIT

Refer to TF-99, "TRANSFER SHIFT RELAY (HIGH & LOW)" and TF-99, "ACTUATOR & ACTUATOR POSI-
TION SWITCH" .
OK or NG
OK >> GO TO 2.
NG >> Repair or replace transfer shift relay and actuator and actuator position switch.
2. CHECK POWER SOURCE OF TRANSFER SHIFT (HI & LOW) RELAY

2. Turn ignition switch to “ON” (Do not start engine).
WDIA0089E
3. Check voltage between transfer shift HIGH relay E46 and LOW relay E47 terminal 5 (R) and ground.
LDIA0080E
OK or NG
OK >> GO TO 3.
● Continuity between ignition switch and transfer shift HIGH & LOW relays
● Ignition switch and No. 57 fuse (20A)

3. CHECK POWER SOURCE OF TRANSFER CONTROL DEVICE A

2. Turn ignition switch to “ON”. (Do not start engine.)
3. Turn 4WD shift switch from “4H” to “4LO” (or from “4LO” to B
“4H”).
4. Check voltage between transfer control device harness connec-
tor F58 terminal 21 (R/L) [or 24 (P/G)] and ground. C
TF
LDIA0081E
OK or NG E
OK >> GO TO 4.
● Harness and connector from transfer shift HIGH and LOW relays to transfer control device har-
F
ness terminal
● Ground circuit between transfer control device and ground.
4. CHECK INPUT SIGNAL G

Yes or No H
Yes >> GO TO 5.
No >> GO TO 6.
I
With CONSULT-II J
M
LDIA0082E

OK or NG
OK >> GO TO 8.
NG >> GO TO 7.
SMT978D


Without CONSULT-II
E142 terminal 4 (Y/L) [or 13 (G/B)] and ground while 4WD shift
switch is set from 4H to 4LO (or from 4LO to 4H).
LDIA0083E
3. Result
Terminal Condition Voltage
While actuator is
operating for 4H to Battery voltage
4 4LO
Actuator does not
Approx. 0V
operate
While actuator is
operating for 4LO to Battery voltage
13 4H
Actuator does not
Approx. 0V
operate
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.
7. CHECK HARNESS CONTINUITY BETWEEN TRANSFER CONTROL UNIT AND TRANSFER SHIFT
HIGH AND LOW RELAYS
OK or NG
OK >> GO TO 8.
NG >> Repair and replace harness connector between transfer control unit and transfer shift HIGH or
LOW relay.

OK or NG
NG >> 1. Perform transfer control unit/output signal inspection. Refer to TF-54, "TRANSFER CONTROL
connector.

TROUBLE DIAGNOSES FOR SYMPTOMS
TROUBLE DIAGNOSES FOR SYMPTOMS PFP:00007

A
Symptom 1. 4WD Shift Indicator Lamp Does Not Turn ON (Although the ignition
switch is turned "ON", all the 4WD indicator lamps do not turn ON for 1 second)
EDS000ZZ
B
1. CHECK TRANSFER CONTROL UNIT POWER SOURCE

C
1. Turn ignition switch to “OFF” position and disconnect transfer control unit harness connector E142.
2. Turn ignition switch to “ON” position. (Do not start engine.)
TF
LDIA0062E
J
LDIA0085E

E142 terminals 16 (Y/R), 22 (Y/R) and ground. K
L
LDIA0086E
OK or NG
OK >> GO TO 2.
● Continuity between ignition switch and transfer control unit

2. CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT

E143.
3. Measure resistance between transfer control unit harness con-
nectors E142 and E143 terminals 3(B), 6(B), 45(B) and ground.
Resistance : 0Ω
OK or NG
OK >> GO TO 3.
NG >> Check continuity between transfer control unit and
LDIA0087E
ground.
3. CHECK PROCEDURES FROM THE BEGINNING AGAIN

Check again.
OK or NG
connector.

Symptom 2. 4WD Warning Lamp Does Not Turn ON (Although the ignition
switch is turned "ON", the 4WD warning lamp does not turn ON) EDS00100
A
1. CHECK TRANSFER CONTROL UNIT POWER SOURCE B

1. Turn ignition switch to “OFF” position and disconnect transfer control unit harness connector E142.
2. Turn ignition switch to “ON” position (do not start engine).
C
TF
LDIA0088E
F
E142 terminals 16 (Y/R), 22 (Y/R) and ground.
G
OK or NG
OK >> GO TO 2. H
● Continuity between ignition switch and transfer con-
trol unit I
LDIA0089E
2. CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT J

2. Disconnect transfer control unit harness connectors E142 and K
E143.
nectors E142 and E143 terminals 3(B), 6(B), 45(B) and ground. L
Resistance : 0Ω
OK or NG
M
OK >> GO TO 3.
LDIA0087E
ground.
3. CHECK 4WD WARNING LAMP CIRCUIT

Check the following.
● 4WD warning lamp
● Continuity between ignition switch and 4WD warning lamp
● Continuity between 4WD warning lamp and transfer control unit
OK or NG
OK >> GO TO 4.
NG >> ● Repair or replace harness or connector.
● Replace 4WD warning lamp.


Check again.
OK or NG
connector.

Symptom 3. 4WD Shift Indicator Lamp Does Not Turn OFF (When 4WD shift
switch is set from "4H" to "4LO", all the 4WD shift indicator lamps do not turn A
off) EDS00101
B
1. CHECK ATP SWITCH CIRCUIT
C
Check ATP switch circuit.
Refer to TF-68, "Diagnostic Procedure" .
OK or NG
TF
OK >> GO TO 2.
LDIA0062E
F
2. CHECK PROCEDURE FROM THE BEGINNING AGAIN
Check again. G
OK or NG
NG >> Recheck each connector's pin terminals for damage or loose connection. H

Symptom 4. ATP Warning Lamp Does Not Turn ON (When 4WD shift switch is
set from "4H" to "4LO" with the A/T selector lever in "P" position, the ATP warn-
ing lamp does not turn on) EDS00102
LDIA0090E
1. CHECK ATP SWITCH CIRCUIT

Check ATP switch circuit.
OK or NG
OK >> GO TO 2.
2. CHECK FOLLOWING ITEMS

● ATP warning lamp
● Continuity between transfer control unit harness connector E142 terminal 15 (L/B) and ATP warning lamp
● Continuity between ATP warning lamp and ATP switch
OK or NG
OK >> GO TO 3.
NG >> Repair or replace ATP warning lamp, harness or connector.

Check again.
OK or NG
NG >> Recheck each connector's pin terminals for damage or loose connections.

Symptom 5. 4LO Indicator Lamp Does Not Turn ON (When 4WD shift switch is
set from “4H” to “4LO” position, 4LO indicator lamp does not turn ON) EDS00103
A
1. CHECK TRANSFER CONTROL UNIT POWER SUPPLY CIRCUIT B

1. Disconnect battery negative terminal (−), then transfer control unit connectors.
2. Connect battery negative terminal (−) and turn ignition switch “ON” (with engine stopped).
C
3. Check voltage across transfer control unit body-side connector terminals 16 (Y/R), 47 (W) and ground.
TF
LDIA0062E
J
LDIA0063E
OK or NG K
OK >> GO TO 2.
● Continuity between battery, ignition switch and trans- L
fer control unit
● Ignition switch. Refer to PG-4, "POWER SUPPLY
ROUTING CIRCUIT" . M
● No. 53 fuse (20A) and No. 49 fuse (10A)
WDIA0081E
2. CHECK TRANSFER CONTROL UNIT GROUND CIRCUIT

E143.
nectors E142 and E143 terminals 3(B), 6(B), 45(B) and ground.
Resistance : 0Ω
OK or NG
OK >> GO TO 3.
LDIA0087E
ground.

3. CHECK 4LO INDICATOR LAMP CIRCUIT

Disconnect battery negative terminal (−) and check the following items:
1. Check condition of 4LO indicator lamp.
2. Check continuity between battery and 4LO indicator lamp.
3. Check continuity between 4LO indicator lamp and transfer control unit connector E142 terminal 12 (W/G).
4. Check condition of ATP switch.
5. Check condition of neutral-4LO switch.
6. Check continuity between neutral-4LO switch ground terminal 12 (B) and ground.
OK or NG
OK >> GO TO 4.
● 4LO indicator lamp
● Neutral-4LO switch
Refer to TF-98, "ATP SWITCH, NEUTRAL-4LO SWITCH AND WAIT DETECTION SWITCH" .
4. CHECK PROCEDURES FROM THE BEGINNING

Check again.
OK or NG
connector.
Symptom 6. 4WD Shift Indicator Lamp Does Not Indicate “LOCK” (When 4WD
shift switch is set to “4H”, 4WD shift indicator lamp does not indicate “LOCK”)
EDS00104

Is 4WD warning lamp turned ON?
Yes or No
Yes >> Refer to TF-27, "Trouble Diagnosis without CONSULT-
II" .
No >> GO TO 2.
LDIA0062E
2. CHECK FOLLOWING ITEMS

● Neutral-4LO switch circuit. Refer to TF-68, "Diagnostic Procedure" .
● Wait detection switch circuit. Refer to TF-68, "Diagnostic Procedure" .
● ATP switch circuit. Refer to TF-68, "Diagnostic Procedure" .
OK or NG
OK >> GO TO 3.

3. CHECK PROCEDURES FROM THE BEGINNING AGAIN A

Check again.
OK or NG
OK >> Inspection End. B
NG >> Recheck each connector's pin terminals for damage or loose connection.
TF

Symptom 7. 4WD Shift Indicator Lamp Repeats Flickering (4WD shift indicator
lamp keeps flickering) EDS00105

2. Move vehicle forward and backward. Or drive straight increasing
or decreasing speed under 20 km/h (12 MPH).
3. Does 4WD shift indicator lamp keep flickering?
Yes or No
Yes >> GO TO 2.
LDIA0062E
2. CHECK TIGHT CORNER BRAKING SYMPTOM

Drive vehicle at speed under 20 km/h (12 MPH), turning steering wheel to the limit. Does tight corner braking
symptom occur?
Yes or No
Yes >> GO TO 3.
No >> GO TO 4.

Does the 4WD shift indicator lamp keep flickering when the front wheels are jacked up?
Yes or No
Yes >> Check transfer unit operating system.
No >> Check tires.

Does 4WD warning lamp flicker? (4WD shift indicator lamp is turned OFF.)
Yes or No
No >> GO TO 5.

Does 4WD shift indicator lamp keep flickering?
Yes or No
Yes >> Check again.

Symptom 8. Tight Corner Braking Symptom (Tight corner braking symptom

occurs) (Hydraulic system failure) EDS00106
A
1. CHECK INPUT SIGNAL B
With CONSULT-II
1. Select “ECU INPUT SIGNALS” in Data Monitor. C
2. Read out the ON/OFF status of “CLUTCH PRES SW”.
Without CONSULT-II
Check voltage between transfer control unit harness connector E143 TF
terminal 34 (BR) and ground.
Refer to TF-54, "TRANSFER CONTROL UNIT INSPECTION
TABLE" . E
OK or NG
OK >> Disassemble transfer unit and check the following.
● Control valve assembly SMT977D F
● 4WD solenoid valve
● 2-4WD shift solenoid valve

G
● Clutch piston
● Clutch assembly
NG >> GO TO 2. H
2. CHECK CLUTCH PRESSURE SWITCH CIRCUIT
Check clutch pressure switch circuit. I
OK or NG
OK >> GO TO 3. J
3. CHECK PROCEDURES FROM THE BEGINNING AGAIN K

Check again.
OK or NG
L

Symptom 9. 4WD System Does Not Operate (The vehicle cannot be put into
4WD mode) (Hydraulic system failure) EDS00107

With CONSULT-II
2. Read out the ON/OFF status of “CLUTCH PRES SW”.
Without CONSULT-II
Check voltage between transfer control unit harness connector E143
terminal 34 (BR) and ground.
Refer to TF-54, "TRANSFER CONTROL UNIT INSPECTION
TABLE" .
OK or NG
OK >> 1. Check transfer fluid level.
2. Disassemble transfer unit and check the following. SMT977D
– Transfer motor
– Main oil pump assembly
– Sub-oil pump assembly
– Oil strainer
– Control valve assembly
– 2-4WD shift solenoid valve
– Oil filter element
– Lip seal
– Strainer O-ring
– Main oil pump drive gear
– Seal ring
– D-ring
– Clutch piston
– Clutch assembly
NG >> GO TO 2.
2. CHECK CLUTCH PRESSURE CIRCUIT

Check clutch pressure switch circuit.
OK or NG
OK >> GO TO 3.
3. CHECK PROCEDURES FROM THE BEGINNING

Check again.
OK or NG

Component Inspection EDS00115
4WD SHIFT SWITCH A

Check continuity between each terminal.
Terminals Switch position Continuity B
2WD Yes
1-2
Except 2WD No
AUTO Yes C
1 - 3, 1 - 4
Except AUTO No
4H Yes
1 - 4, 1 - 5 TF
Except 4H No
4LO Yes SMT858D
1 - 4, 1 - 6
Except 4LO No E
2-4WD SHIFT SOLENOID VALVE AND TRANSFER FLUID TEMPERATURE SENSOR

Measure resistance between terminals of transfer terminal cord F
assembly harness connector F56.
Resistance
Component parts Terminals
(Approx.) G
20°C (68°F):
2-4WD shift solenoid valve 4-5
22.8 - 25.2Ω
Transfer fluid temperature 20°C (68°F): 2.5 kΩ H
2-3
sensor 80°C (176°F): 0.3 kΩ
LDIA0093E
I
4WD SOLENOID VALVE, CLUTCH PRESSURE SWITCH AND LINE PRESSURE SWITCH
Measure resistance between terminals of transfer terminal cord
assembly harness connector F56. J
Component
Terminals Remarks
parts
K
4WD sole-
6 Approx. 20°C (68°F): Approx. 3.0 - 3.4Ω
noid valve
In room temperature
L
● 2-4WD shift solenoid valve “OFF”: No conti-
Clutch pres-
7 nuity
sure switch
Ground ● 2-4WD shift solenoid valve and transfer LDIA0094E
terminal motor “ON”: Continuity exists M

In room temperature
● Turn ignition switch to “OFF” position and
Line pressure
1 leave vehicle for more than 5 minutes.
switch
(OFF): No continuity
● Transfer motor “ON”: Continuity exists
TRANSFER DROPPING RESISTOR
LDIA0095E

Check resistance between terminals.

Resistance : 11.2 - 12.8 Ω
ATP SWITCH, NEUTRAL-4LO SWITCH AND WAIT DETECTION SWITCH
1. Remove the ATP switch, neutral-4LO switch and the wait detection switch.
2. Measure the resistance between terminals of ATP switch F55, neutral-4LO switch F60 , and wait detection
switch F59.
Switch released state : No continuity should
exist
Switch pushed state : Continuity should exist
WDIA0082E
TRANSFER MOTOR
Apply battery voltage directly to transfer motor harness connector
F57. (Positive: Terminal 14, Negative: Terminal 15)
Transfer motor should operate.
LDIA0097E
TRANSFER MOTOR RELAY

1. Apply battery voltage directly to transfer motor relay E152 termi-
nals 1 and 2.
2. Check continuity between transfer motor relay E153 terminals 3
and 5.
Condition Continuity (3-5)
Battery voltage is applied Yes
No voltage is applied No
LDIA0098E

TRANSFER SHIFT RELAY (HIGH & LOW)

Check continuity between transfer shift high relay E46 and low relay A
E47 terminals 3 and 4.
Condition Continuity
B
12V direct current supply
No
between terminals 1 and 2
No current supply Yes C
LDIA0099E
TF
ACTUATOR & ACTUATOR POSITION SWITCH

Actuator E
Operation & resistance check
● Apply battery voltage directly to actuator assembly.
F
Operating check Battery positive terminal Battery negative terminal
1 21 24
2 24 21 G
Check Approx. 0.2Ω (When the motor is not operated.)
H
LDIA0100E
Actuator Position Switch

Continuity check I
Battery positive Battery negative

Continuity check Continuity
terminal terminal
J
1 21 24 20 - 22
2 24 21 23 - 22
K
L
LDIA0101E

TRANSFER CONTROL UNIT
TRANSFER CONTROL UNIT PFP:33084
Removal and Installation EDS0031P
REMOVAL
1. Set transfer state as 2WD when 4WD shift switch is at 2WD, or as AUTO when 4WD shift switch is at
AUTO.
CAUTION:
When removing transfer control unit, transfer state must be at 2WD or AUTO.
2. Turn the ignition switch OFF and disconnect negative battery terminal.
3. Remove the glove box assembly. Refer to IP-13, "LOWER INSTRUMENT PANEL RH AND GLOVE BOX"
.
4. Disconnect the two transfer control unit connectors.
5. Remove the transfer control unit bolts.
6. Remove the transfer control unit.
BDIA0014E
INSTALLATION
Installation is in the reverse order of removal.
● When installing the transfer control unit, tighten bolts to the specified torque.
Transfer control unit bolts : 5.1 N·m (0.52 kg-m, 45 in-lb)
CAUTION:
Do not connect harness connector to transfer control unit when 4WD shift switch is at 4LO.
● After the installation, check perform self-diagnosis. Refer to TF-28, "SELF-DIAGNOSTIC PROCEDURE" .
If NG, adjust position between transfer assembly and transfer control unit. Refer to TF-4, "METHOD FOR
POSITION ADJUSTMENT" .

FRONT OIL SEAL
FRONT OIL SEAL PFP:38189

A
Removal and Installation EDS0031Q
REMOVAL
1. Partially drain the transfer fluid. Refer to MA-24, "DRAINING" .
B
2. Remove the front propeller shaft. Refer to PR-5, "REMOVAL" .
3. Remove the companion flange self-lock nut, using Tool.
Tool number : KV40104000 ( — ) C
TF
SDIA2657E
4. Put a matching mark on top of the front drive shaft in line with F
the mark on the companion flange.
CAUTION:
Use paint to make the matching mark on the front drive G
shaft. Do not damage the front drive shaft.
I
SDIA2658E
5. Remove the companion flange, using suitable tool.

J
WDIA0193E
M
6. Remove the oil seal from the front case, using Tool.
Tool number : ST33290001 (J-34286)
CAUTION:
Do not damage front case.
LDIA0144E

FRONT OIL SEAL
INSTALLATION
1. Install the oil seal until it is flush with the end face of the front
case, using Tool.
Tool number : KV38100500 ( — )
CAUTION:
● Do not reuse oil seal.
● Apply petroleum jelly to oil seal.
SDIA2662E
2. Align the matching mark of the front drive shaft with the match-
ing mark of the companion flange, then install the companion
flange.
SDIA2658E
3. Install the self-lock nut. Tighten to the specified torque, using

Tool. Refer to TF-112, "Transfer Components" .
CAUTION:
Do not reuse self-lock nut.
4. Install the front propeller shaft. Refer to PR-5, "INSTALLATION"
.
5. Refill the transfer with fluid and check fluid level. Refer to MA-
24, "FILLING" .
6. Check the transfer for fluid leakage. Refer to MA-24, "FLUID LDIA0147E
LEAKAGE AND FLUID LEVEL" .

REAR OIL SEAL
REAR OIL SEAL PFP:33140

A
Removal and Installation EDS0031R
REMOVAL
1. Partially drain the transfer fluid. Refer to MA-24, "DRAINING" .
B
2. Remove the rear propeller shaft. Refer to PR-9, "REMOVAL" .
3. Remove the dust cover from the rear case.
CAUTION: C
Do not damage the rear case.
TF
WDIA0127E
F
4. Remove the rear oil seal from the rear case, using Tool.
CAUTION:
Do not damage the rear case.
G
Tool number : ST33290001 (J-34286)
I
LDIA0139E
INSTALLATION
1. Install the oil seal until it is flush with the end face of the rear J
case, using Tool.
Tool number : ST30720000 (J-25405)
CAUTION: K

L
LDIA0140E M
2. Apply petroleum jelly to the circumference of the new dust cover.

Position the dust cover using the identification mark as shown.
CAUTION:
● Do not reuse dust cover.
● Position the identification mark at the position shown.
SDIA2208E

REAR OIL SEAL
3. Install the dust cover to the rear case, using Tool.

CAUTION:
● Do not reuse dust cover.
● Apply petroleum jelly to dust cover.
4. Install the rear propeller shaft. Refer to PR-9, "INSTALLATION" .

5. Refill the transfer with fluid and check fluid level. Refer to MA-
24, "FILLING" .
6. Check the transfer for fluid leakage. Refer to MA-24, "FLUID
PDIA0116E
LEAKAGE AND FLUID LEVEL" .

SIDE OIL SEAL
SIDE OIL SEAL PFP:33142

A
Removal and Installation EDS0031S
REMOVAL
1. Remove the front propeller shaft. Refer to PR-5, "REMOVAL" .
B
2. Remove the companion flange. Refer to TF-101, "REMOVAL" .
3. Remove the transfer control device from the transfer assembly. Refer to TF-106, "Removal and Installa-
tion" .
C
4. Remove the side oil seal.
CAUTION:
Do not damage shift cross. TF
F
SDIA2666E
INSTALLATION
1. Install the side oil seal until it is flush with the end face of case, G
using Tool.
Tool number : ST22360002 (J-25679-01)
H
CAUTION:

I
2. Install the transfer control device to the transfer assembly. Refer
to TF-106, "Removal and Installation" .
3. Install the companion flange. Refer to TF-101, "Removal and J
Installation" . SDIA2665E
4. Install the front propeller shaft. Refer to PR-5, "INSTALLATION" .

K

TRANSFER CONTROL DEVICE
TRANSFER CONTROL DEVICE PFP:33251
Removal and Installation EDS0031T
Refer to the figure for transfer control device removal and installation information.
CAUTION:
● Change vehicle state to 2WD or AUTO, and then remove and install transfer control device.
● Check 4WD shift indicator after installation. Refer to TF-12, "ALL-MODE 4WD TRANSFER BASIC
CONTROL" .
SDIA2654E
1. Shift lever 2. Actuator

AIR BREATHER HOSE
AIR BREATHER HOSE PFP:31098

A
Removal and Installation EDS0031U
Refer to the figure for air breather hose removal and installation information.
B
TF
SDIA2656E J
CAUTION:
● Make sure there are no pinched or restricted areas on the air breather hose caused by bending or
winding when installing it. K
● Install the air breather hose into the air breather (metal connector) and actuator (case connector)
until the hose end reaches the base of the tube.
● Install the air breather hose into the breather tube (metal connector) and transfer motor (case con- L
nector) until the hose end reaches the end of the curved section.

TRANSFER MOTOR
TRANSFER MOTOR PFP:00000
Removal and Installation EDS0031V
REMOVAL
1. Disconnect the transfer motor connector.
2. Remove the air breather hose from the transfer motor. Refer to
TF-107, "Removal and Installation" .
3. Remove the transfer motor bolts.
4. Remove the transfer motor.
SDIA2133E
INSTALLATION
1. Apply ATF to the O-ring and install it to the transfer motor.
CAUTION:
Do not reuse O-rings.
2. Fit the double-flat end of the transfer motor shaft into the slot of
the sub-oil pump assembly. Then tighten to the specified torque.
Refer to TF-112, "Transfer Components" .
CAUTION:
Be sure to install connector bracket.
3. Install the air breather hose to the transfer motor. Refer to TF-
107, "Removal and Installation" . SDIA2787E
4. Connect the transfer motor connector.
5. Check the transfer fluid. Refer to MA-24, "FILLING" .
6. Start the engine for one minute. Then stop the engine and recheck the transfer fluid. Refer to MA-24,
"FLUID LEAKAGE AND FLUID LEVEL" .

TRANSFER OIL FILTER
TRANSFER OIL FILTER PFP:00000

A
Removal and Installation EDS0031W
REMOVAL
1. Remove the oil filter bolts and oil filter.
B
CAUTION:
● Do not damage center case and oil filter.
● Loosen bolts and detach oil filter evenly.

C
TF
SMT875C
E
2. Remove the O-rings from the oil filter.
H
SDIA2327E
3. Remove the oil filter stud from the oil filter. I

4. Remove the O-ring from the oil filter stud.
SDIA2784E
L
INSTALLATION
1. Apply ATF to the O-ring, and install it on the oil filter stud.
M
CAUTION:
Do not reuse O-ring.
2. Install the oil filter stud to the oil filter.
SDIA2784E

TRANSFER OIL FILTER
3. Apply ATF to the two O-rings, and install them on the oil filter.
CAUTION:
SDIA2327E
4. Install the oil filter to the transfer assembly. Tighten the bolts to
the specified torque. Refer to TF-112, "Transfer Components" .
CAUTION:
● Do not damage oil filter.
● Attach oil filter and tighten bolts evenly.
5. Check the transfer fluid. Refer to MA-24, "FILLING" .

6. Start the engine for one minute. Then stop the engine and
recheck the transfer fluid. Refer to MA-24, "FLUID LEAKAGE
AND FLUID LEVEL" .
SDIA2136E

REMOVAL AND INSTALLATION
REMOVAL AND INSTALLATION PFP:00000

A
Removal EDS001DV
1. Drain fluid from transfer case. Refer to MA-24, "Changing Transfer Fluid" .
2. Remove front propeller shaft. Refer to PR-5, "REMOVAL" . B
● Insert plug into rear oil seal after removing propeller shaft.
CAUTION:
Be careful not to damage spline, sleeve yoke and rear oil seal, when removing propeller shaft. C
3. Remove rear propeller shaft. Refer to PR-9, "REMOVAL" .
4. Remove center exhaust tube and muffler assembly. Refer to EX-4, "REMOVAL" .
5. Remove wire harness from retainers. TF
6. Disconnect the following connectors:
● ATP switch
E
● Neutral-4LO switch
● Wait detection switch
● Transfer terminal cord F

● Transfer control device
● Transfer motor
7. Remove air breather hoses from control device, rear case and transfer motor. G
8. Remove transfer control device lever from transfer control device.
9. Remove the transfer control device from extension housing.
H
10. Remove transmission mount.
11. Position suitable jack under transmission and transfer case.
12. Remove crossmember using power tool. Refer to AT-255, "COMPONENTS" .
I
13. Remove transfer case to A/T bolts.
WARNING:
Support transfer case assembly with suitable jack while removing it. J
14. Separate transfer from transmission and remove.
Installation EDS001DW
K
1. Installation is in the reverse order of removal.
Bolt length : 45 mm (1.17in)
Transfer bolt torque : 36 N·m (3.7kg-m, 26 lb-ft) L
SMT872C

OVERHAUL
OVERHAUL PFP:00000
Transfer Components EDS001E8
SDIA2090E
1. 2-4 sleeve 2. L-H sleeve 3. Snap ring

4. Internal gear 5. Planetary carrier assembly 6. Metal bushing
7. Needle bearing 8. Sun gear 9. Carrier bearing
10. Snap ring 11. Snap ring 12. Mainshaft front bearing
13. Wait detection switch 14. Check plug 15. Check spring
16. Check ball 17. Front case 18. Snap ring
19. Oil seal 20. Shift cross 21. Oil seal
22. Lock pin 23. Shift lever 24. Washer
25. Drain plug 26. Oil seal 27. Companion flange
28. Self-lock nut 29. Main shaft 30. Needle bearing
31. Front bearing 32. Front drive shaft 33. Rear bearing
34. Spacer 35. Drive chain 36. Clutch drum
37. Snap ring 38. Clutch hub 39. Snap ring
40. Retaining plate 41. Driven plate (10 sheet) 42. Drive plate (10 sheet)
43. Return spring assembly 44. Press flange 45. Thrust needle bearing

OVERHAUL
46. Snap ring 47. Retaining pin 48. L-H fork

49. 2-4 fork 50. Shift fork spring 51. Fork guide A
52. Retainer pin 53. Shift rod
TF
M
SDIA2091E
1. Dust cover 2. Oil seal 3. Rear case

4. Air breather 5. Seal ring 6. Main oil pump cover
7. Inner gear 8. Outer gear 9. Main oil pump housing
10. D-ring 11. D-ring 12. Clutch piston
13. Thrust needle bearing race 14. Oil strainer 15. O-ring
16. Snap ring 17. Control valve assembly 18. Lip seal (7 pieces)
19. Washer 20. Filler plug 21. Oil filter stud
22. O-ring 23. Oil filter 24. ATP switch
25 Neutral-4LO switch 26. Oil pressure check plug 27. Harness bracket
28. Stem bleeder 29. Harness bracket 30. Center case
31. Mainshaft rear bearing 32. C-ring 33. Washer holder
34. Snap ring 35. Sub oil pump housing 36. Outer gear
37. Inner gear 38. Sub oil pump cover 39. O-ring
40. Transfer motor 41. Connector bracket

REAR CASE
REAR CASE PFP:33102
Disassembly EDS001E9
1. Remove bolts.
SDIA2092E
2. Remove rear case from center case, using suitable tool.
SDIA2093E
3. Remove the dust cover, using suitable tool.
SDIA2094E
4. Remove the oil seal, using suitable tool.

CAUTION:
Be careful not to damage the rear case.
SDIA2095E
5. Remove the air breather.

CENTER CASE
CENTER CASE PFP:33105

A
Disassembly EDS001EA
1. Remove the rear case. Refer to TF-114, "Disassembly" .

a. Remove neutral-4LO and ATP switches. B
b. Remove main oil pump from the center case. Refer to TF-124,
"MAIN OIL PUMP" .
C
TF
SDIA2096E E
2. Remove the stem bleeder from the bleed hole.

F
SDIA2097E
I
3. Remove self-lock nut from companion flange.
L
SDIA2098E
4. Put a matchmark on top of front drive shaft thread. The match-

mark should be in line with the mark on the companion flange. M
CAUTION:
Always match to the top of the front drive shaft thread
using paint.
SDIA2214E

CENTER CASE
5. Remove companion flange, using suitable tool.
SDIA2099E
6. Remove the center case bolts.
SDIA2100E
7. Remove harness bracket.

8. Remove filler plug and washer.
9. Separate center case from front case, using suitable tool, then
remove center case by prying it up.
CAUTION:
Be careful not to damage the mating surface.
SDIA2101E
10. Remove snap ring and washer holder from the mainshaft.
SDIA2104E

CENTER CASE
11. Remove C-rings from mainshaft bearing, using suitable tool.

A
SDIA2105E
TF
FRONT DRIVE SHAFT AND DRIVE CHAIN
1. With front drive shaft held by one hand as shown, remove using
E
a suitable tool, remove front drive shaft with drive chain.
CAUTION:
Do not tap drive chain with a plastic hammer.
F
SMT900C
H
2. Remove the front drive shaft front bearing using Tool.
Tool number
I
A : ST33052000 ( — )
B : ST30031000 ( — )
J
K
SDIA2106E
3. Remove the front drive shaft rear bearing using Tool. L

Tool number
A : ST33052000 ( — )
M
B : ST30031000 ( — )
SDIA2107E

CENTER CASE
MAINSHAFT AND CLUTCH DRUM

1. Set center case on press stand. Remove mainshaft from center
case.
SDIA2108E
2. Remove thrust needle bearing from press flange.
SDIA2109E
3. Remove snap ring from mainshaft, using suitable tool.
SDIA2110E
4. Press flange as shown, using Tool. Press drift until snap ring is
out of place.
Tool number
A : ST22452000 (J-34335)
B : ST30911000 ( — )
C : KV31103300 ( — )
SDIA2111E

CENTER CASE
5. Remove snap ring from mainshaft, using suitable tool.

A
SDIA2112E
TF
6. Remove press flange from mainshaft.
G
SMT910C
7. Remove return spring assembly from clutch hub.

H
SMT911C
K
8. Remove each plate from clutch drum.
SMT912C
9. Remove snap ring from mainshaft.
SDIA2113E

CENTER CASE
10. Tap mainshaft, using suitable tool to remove it from clutch drum
and clutch hub.
11. Remove needle bearing and spacer from the mainshaft.
SMT914C
12. Remove the snap ring from the clutch hub.
WDIA0101E
CLUTCH PISTON
1. Remove oil pressure check plug from oil pressure check port.
SDIA2115E
2. Apply air gradually from oil pressure check port, and remove
clutch piston from center case.
SDIA2116E

CENTER CASE
3. Remove the two D-rings from clutch piston.

A
SDIA2117E
TF
4. Remove thrust needle bearing race from clutch piston, using
suitable tool by hooking a edge into 3 notches of thrust needle
bearing race. E
CAUTION:
Be careful not to damage the clutch piston.
F
G
SDIA2118E
CONTROL VALVE H
CAUTION:
● Do not reuse any part that has been dropped or damaged.
● Make sure valve is assembled in the proper direction. I
● Do not use a magnet because residual magnetism stays during disassembly.
1. Remove two bolts, and remove oil strainer.
J
SDIA2119E
M
2. Remove two O-rings from oil strainer.
SDIA2120E

CENTER CASE
3. Remove control valve assembly bolts.
SDIA2121E
4. Remove snap ring. Then push connector assembly into center

case to remove control valve assembly.
SDIA2122E
5. Remove lip seals from center case.

CAUTION:
There are two kinds of lip seals (lip seal of large inner diam-
eter: 5 pieces, lip seal of small inner diameter: 2 pieces).
Confirm the position before disassembly.
SDIA2123E
6. Remove all bolts except for the two as shown.
SDIA2124E
7. Remove 4WD solenoid valve, clutch pressure switch, 2-4WD

shift solenoid valve, line pressure switch, and transfer fluid tem-
perature sensor from control valve assembly.
PDIA0183E

CENTER CASE
8. Remove O-rings from each solenoid valve, switch and terminal body.
A
9. Place control valve with lower body facing up, remove two
mounting bolts, and then remove lower body and separator plate
from upper body. B
CAUTION:
Be careful not to drop relief balls. Detach lower body care-
fully.
C
TF
SDIA2125E
10. Make sure reverse balls, relief balls and relief springs, accumu- E
lator pistons and valve springs are securely installed as shown,
and remove them.
F
SDIA2126E H
11. Remove retainer plates.

I
SDIA2127E
12. Remove each control valve, spring and plug. L
SDIA2128E

CENTER CASE
MAINSHAFT REAR BEARING

1. Remove mainshaft rear bearing from center case, using Tool
Tool number : KV38100300 (J-25523)
SDIA2129E
MAIN OIL PUMP

1. Remove bolts as shown to detach main oil pump.
SDIA2130E
2. Remove outer gear, and inner gear, from main oil pump housing.
SDIA2131E
3. Remove seal ring from the main oil pump cover.
SDIA2132E

CENTER CASE
SUB OIL PUMP

1. Remove bolts to detach transfer motor from center case. Then A
remove O-ring from the transfer motor.
SDIA2133E
TF
2. Remove sub oil pump cover bolts.

E
SDIA2134E
H
3. Thread two bolts (M4 x 0.8) into the holes of sub oil pump cover
as shown, and pull out to remove sub oil pump assembly.
I
K
SMT934C
4. Remove sub oil pump cover, outer gear, inner gear, and O-ring
from sub oil pump housing. L
SDIA2135E

CENTER CASE
OIL FILTER
1. Remove bolts for oil filter.
SDIA2136E
2. Remove the oil filter using suitable tool as shown.
SDIA2137E
3. Remove O-rings from oil filter.
SMT939C
4. Remove the filter stud from oil filter.

5. Remove O-ring from the filter stud.
PDIA0184E

FRONT CASE
FRONT CASE PFP:33107

A
Disassembly EDS001EB
1. Remove rear case from center case. Refer to TF-114, "Disassembly" .

2. Remove the lock pin nut from the lock pin, using suitable tool. B
a. Remove the lock pin.
TF
SDIA2150E E
3. Remove the oil seal from the front case, using suitable tool.
CAUTION: F
Be careful not to damage the front case and shift cross.
SDIA2166E
I
4. Remove front case from center case.
L
SDIA2138E
SHIFT ROD COMPONENTS

1. Remove check plug, then check spring and check ball. M
a. Remove wait detection switch.
SDIA2139E

FRONT CASE
2. Remove shift rod components together with 2-4 sleeve and L-H
sleeve.
SDIA2140E
3. Remove the shift cross from the front case.

4. Remove 2-4 sleeve and L-H sleeve from 2-4 fork and L-H fork
respectively.
SMT992C
5. Drive out retaining pin from shift rod, using suitable pin punch.
SDIA2141E
6. Remove L-H fork, 2-4 fork, shift fork spring and fork guide from
shift rod.
SDIA2142E

FRONT CASE
PLANETARY CARRIER, SUN GEAR AND INTERNAL GEAR

1. Remove oil seal from the front case, using suitable tool. A
CAUTION:
Be careful not to damage the front case and sun gear.
B
SDIA2143E
TF
2. Remove the snap ring from the sun gear.

E
SDIA2144E
H
3. Remove the sun gear assembly from the front case, using Tool.
Tool number : ST35300000 ( — )
I
K
SDIA2145E
4. Remove snap ring from the planetary carrier assembly, using

suitable tool. L
SDIA2146E

FRONT CASE
5. Remove the sun gear assembly from the planetary carrier

assembly.
SDIA2147E
6. Remove the snap ring from the sun gear assembly, using suit-
able tool.
NOTE:
Do not reuse snap ring.
SDIA2148E
7. Remove the carrier bearing from the sun gear, using Tool.
Tool number
A : ST35300000 ( — )
B : ST30021000 ( — )
SDIA2149E
8. Remove the needle bearing from the sun gear, using Tool.
SDIA2354E

FRONT CASE
9. Remove the metal bushing from the sun gear, using suitable
Tool. A
Tool number
A : ST33710000 ( — )
B
B : ST35325000 ( — )
C : ST33290001 (J-34286)
C
SDIA2168E
TF
G
SDIA2169E
10. Remove snap ring, and remove internal gear.

H
SMT004D
K
11. Remove front oil seal, using suitable tool.
CAUTION:
Be careful not to damage the front case. L
SDIA2170E
12. Remove snap ring from the front case.

NOTE:
SDIA2171E

FRONT CASE
13. Remove the mainshaft front bearing from the front case, using
Tool.
Tool number : ST33200000 (J-26082)
SDIA2178E

FRONT CASE

A
Inspection EDS001EC
PLANETARY CARRIER
● Measure end play of each pinion gear, and make sure the mea- B
surement is within specification shown below. If out of specifica-
tion, replace planetary carrier assembly with new one.
Pinion gear end play : 0.1 - 0.7 mm (0.004 - 0.028 in) C
● Check working face of each gear, bearing and others for dam-
age, burrs, partial wear, dents and other abnormality. If any is
found, replace planetary carrier assembly with new one. TF
PDIA0185E
E
SUN GEAR
● Check if oil passage of sun gear assembly is clogged. For this,
try to pass a 3.6 mm (0.142 in) dia. wire through oil passage as F
shown.
● Check sliding/contact surface of each gear, bearing and others
for damage, burrs, partial wear, dents, and other abnormality. If G
any is found, replace sun gear assembly with new one.
PDIA0186E
I
INTERNAL GEAR
● Check internal gear teeth for damage, partial wear, dents and
other abnormality. If any is found, replace internal gear with new
J
one.
SMT008D
SHIFT ROD COMPONENTS M

● Check working face of shift rod and fork for wear, partial wear,
bending and other abnormality. If any is found, replace with new
one.
SMT009D

FRONT CASE
● Measure clearance between shift fork and sleeve. If it is out of

specification, replace it with new one.
Standard value : Less than 0.36 mm (0.0142 in)
SMT010D

CENTER CASE

A
Inspection EDS001ED
BEARINGS
1. Make sure bearings roll freely and are free from noise, pitting
B
and cracks.
TF
SDIA2175E
E
SUB-OIL PUMP
1. Check inner and outer circumference, tooth face, and side-face
of inner and outer gears for damage or abnormal wear. F
2. Measure side clearance between sub oil pump housing edge
and inner gear/outer gear.
3. Make sure side clearance is within specification. If the measure- G
ment is out of specification, replace inner and outer gears
together with new ones as a set.
Specification : 0.015 - 0.035 mm (0.0006 - 0.0014 in) H
SDIA2173E
I
MAIN OIL PUMP
1. Check inner and outer circumference, tooth face, and side-face
of inner and outer gears for damage or abnormal wear.
J
2. Measure side clearance between main oil pump housing edge
and inner gear/outer gear.
3. Make sure side clearance is within specification. If the measure-
ment is out of specification, replace inner and outer gears with K
new ones as a set.
Specification : 0.015 - 0.035 mm (0.0006 - 0.0014 in)
L
SDIA2174E
MAINSHAFT M
● Check surfaces which contact sun gear, clutch drum, clutch hub,
press flange, clutch piston, each bearing, etc. for damage, peel,
partial wear, dents, bending, or other abnormal damage. If any is
found, replace with new one.
SMT944C

CENTER CASE
CONTROL VALVE
● Check resistance between terminals of 4WD solenoid valve, 2-
4WD shift solenoid valve and transfer fluid temperature sensor.
Refer to TF-59, "4WD SOLENOID VALVE" and TF-61, "2-4WD
SHIFT SOLENOID VALVE AND 4WD SHIFT SWITCH" .
PDIA0183E
● Check sliding faces of control valves and plugs for abnormality.

If any is found, replace the control valve assembly with new one.
Refer to TF-121, "CONTROL VALVE" .
CAUTION:
Replace control valve body together with clutch return
spring as a set.
SMT947C
● Check each control valve spring for damage or distortion, and

also check its free length, outer diameter and wire diameter. If
any damage or fatigue is found, replace control valve body with
new one. Refer to TF-121, "CONTROL VALVE" .
CAUTION:
Replace control valve body together with clutch return spring
as a set.
SMT948C
CLUTCH
● Check drive plate facings and driven plate for damage, cracks or
other abnormality. If any abnormalities are found, replace with
new one.
● Check the thickness of drive plate facings and driven plate.
Refer to TF-155, "SERVICE DATA AND SPECIFICATIONS
(SDS)" .
CAUTION:
● Measure facing thickness at 3 points to take an average.
● Check all the drive and driven plates.
● Check return spring for damage or deformation.

SMT949C
● Do not remove spring from the plate

CENTER CASE
● Check stamped mark shown in the figure. Then, check that free
length, (include thickness of plate) are within specifications. If A
any abnormality is found, replace with new return spring assem-
bly of the same stamped number.
NOTE: B
Specifications, refer to TF-155, "SERVICE DATA AND SPECIFI-
CATIONS (SDS)" .
C
SDIA2176E
TF

FRONT CASE
Assembly EDS001EE
PLANETARY CARRIER, SUN GEAR AND INTERNAL GEAR

1. Install new oil seal until it is seated flush with end face of the
front case, using Tool.
NOTE:
● Before installing, apply ATF or petroleum jelly to new oil seal
lip.
SDIA2177E
2. Install internal gear with its groove facing snap ring into front
case. Then secure it with new snap ring.
NOTE:
WDIA0100E
3. Set mainshaft front bearing into front case and install, using
Tool.
Tool number : ST30720000 (J-25405)
SDIA2172E
4. Install new snap ring into front case.

NOTE:
SDIA2171E
5. Install shift cross to front case.

FRONT CASE
6. Install oil new seal in front case, using Tool.

Tool number : ST22360002 (J25679-01) A
NOTE:
● Before installing, apply ATF or petroleum jelly to seal lip.
B
7. Install the shift lever to the shift cross, and lock pin and tighten to
specified torque. Refer to TF-112, "Transfer Components" .
C
SDIA2182E
TF
8. Install the carrier bearing to the sun gear assembly, using Tool.
Tool number
A : ST30911000 ( — ) E
B : KV31103300 ( — )
G
SDIA2179E
9. Install new snap ring to sun gear assembly, using suitable tool.
H
NOTE:
SDIA2148E
K
10. Apply ATF to the circumference of the new metal busing prior to
installing it to the sun gear assembly, using Tool.
Dimension A : 7.7 - 8.3 mm (0.303 - 0.327 in) L

NOTE: M
Do not reuse old metal bushing.
SDIA2187E
11. Install the needle bearing to the sun gear assembly, using Tool.
Dimension B : 62.5 - 63.1 mm (2.461 - 2.484 in)

NOTE:
● Before installing, apply ATF to needle bearing.
● Do not reuse old needle bearing.
SDIA2478E

FRONT CASE
12. Install the sun gear assembly to the planetary carrier assembly.
SDIA2180E
13. Install new snap ring to planetary carrier assembly.

NOTE:
SDIA2181E
14. Install front case to planetary carrier assembly, using Tool.

Tool number : ST33200000 (J-26082)
SDIA2183E
15. Install new snap ring to the sun gear assembly.

NOTE:
SDIA2144E
16. Apply ATF or petroleum jelly to the circumference of the new oil
seal, and install it to the front case using Tool.
NOTE:
Do not reuse oil seal.
Tool number
A : ST30720000 (J-25405)
B : ST33200000 (J-26082)
Dimension : 4.0 - 4.6 mm (0.157 - 0.181 mm)

SDIA2184E

FRONT CASE
17. Install shift rod assembly to front case assembly. Refer to TF-141, "SHIFT ROD ASSEMBLY" .
A
SHIFT ROD ASSEMBLY
1. Install fork guide, shift fork spring, 2-4 fork, and L-H fork to shift
rod, and secure them with new retaining pins.
B
NOTE:
Do not reuse retaining pins.
TF
SDIA2142E
2. Install 2-4 sleeve and L-H sleeve to each fork. E
SMT992C
H
3. While aligning L-H sleeve with planetary carrier, install shift rod
assembly to front case. I
SDIA2140E
L
4. Remove all the liquid gasket on check plug and front case, and
install check ball and check spring to front case. Apply specified
sealant or equivalent, to check plug. Install it to front case, and
tighten to specified torque. Refer to GI-45, "Recommended M
Chemical Products and Sealants" .
Front case check plug : 22 N·m (2.2 kg-m, 16 ft-lb)
5. Remove all the liquid gasket on the switch fitting and inner side
of front case, and with wait detection switch threaded one pitch
into the hole. Apply specified sealant or equivalent, to the
thread. Install it, and tighten to specified torque. Refer to GI-45, SDIA2139E
"Recommended Chemical Products and Sealants" .
Wait detection switch : 28 N·m (2.9 kg-m, 21 ft-lb)
NOTE:
Wait detection switch harness connector is black.
6. Install center case assembly to front case assembly. Refer to TF-151, "Final Assembly" .
7. Install rear case assembly to center case. Refer to TF-151, "Final Assembly" .

CENTER CASE
Assembly EDS001EF
OIL FILTER
1. Apply ATF or petroleum jelly to two new O-rings, and install
them on oil filter.
NOTE:
SDIA2327E
2. Apply ATF or petroleum jelly to the new O-ring, and install them
on filter stud.
NOTE:
3. Install filter stud to oil filter.
PDIA0184E
4. Install oil filter to center case and tighten bolts to specifications.

Oil filter bolts : 7.9 N·m (0.81 kg-m, 70 in-lb)
CAUTION:
Do not knock oil filter with a tool such as a hammer.
SUB OIL PUMP

1. Install outer gear and inner gear in to sub oil pump housing, and
measure side clearance. Refer to TF-135, "SUB-OIL PUMP" .
SDIA2135E
2. Align dowel pin hole and mounting bolt hole of sub oil pump
assembly with center case. Install sub oil pump cover then
tighten bolts.
Sub oil pump bolts : 7.9 N·m (0.81 kg-m, 70 in-lb)
SDIA2328E

CENTER CASE
3. Apply ATF or petroleum jelly to new O-ring and install it to trans-

fer motor. A
NOTE:
4. Fit double-flat end of transfer motor shaft into slot of sub-oil B
pump assembly. Then tighten bolts.
Transfer motor bolts : 45 N·m (4.6 kg-m, 33 ft-lb)
C
CAUTION:
Be sure to install connector bracket.
SDIA2185E
TF
MAIN OIL PUMP
1. Install inner gear and outer gear in the main oil pump housing.
Then, measure the side clearance. Refer to TF-135, "MAIN OIL
PUMP" . E
SDIA2174E
2. Install main oil pump housing, outer gear and inner gear to cen- H
ter case.
Main oil pump bolts : 7.8 N·m (0.8 kg-m, 69 in-lb)
I
SDIA2188E
K
3. Apply ATF or petroleum jelly to the new seal ring and install it to
main oil pump cover. L
NOTE:
Do not reuse seal ring.
M
SDIA2132E
4. Install main oil pump cover to the center case, and install bolts.
Main oil pump cover bolts : 7.8 N·m (0.8 kg-m, 69 in-lb)
SDIA2130E

CENTER CASE
CONTROL VALVE
1. Clean upper body, control valves and springs with cleaning
agent, and dry compressed air.
2. Dip control valves in ATF, and apply ATF to the valve-mounting
area of upper body.
3. Install each control valve, spring, and plug to upper body, and
install retainer plates to hold them in place.
CAUTION:
● To insert control valves into upper body, place upper
body on a level surface in order to prevent flaw or dam-
age.
SDIA2128E
● Make sure each control valve is smoothly inserted.
SDIA2127E
4. Install reverse balls, relief balls and relief springs, accumulator

pistons and valve springs to upper body.
SDIA2126E
5. Install lower body and separator plate to upper body.

NOTE:
Do not reuse separator plates.
SDIA2125E

CENTER CASE
6. With lower body down, tighten two bolts in the position shown.
7. Apply ATF or petroleum jelly to new O-ring, and install it to 2- A
4WD shift solenoid valve, line pressure switch and 4WD sole-
noid valve. Install them to control valve assembly.
NOTE: B
SDIA2124E
TF
8. Apply ATF or petroleum jelly to lip seals, and install them to cen-
ter case.
CAUTION: E
There are 2 kinds of lip seals (lip seal of large inner diame-
ter: 5 pieces, lip seal of small inner diameter: 2 pieces).
Confirm their position for installation.
F
NOTE:
Do not reuse lip seals.
G
SDIA2123E
9. Install the other 13 bolts and tighten them to specified torque.

H
Control valve case bolts : 7.9 N·m (0.81 mm, 70 in-lb)
SDIA2100E
K
10. Install control valve assembly to center case, and tighten bolts.
Control valve bolts : 7.9 N·m (0.81 kg-m, 70 in-lb)
L
SDIA2121E
11. Install connector assembly into center case installation hole, and
secure terminal body with snap ring.
SDIA2122E

CENTER CASE
12. Apply ATF or petroleum jelly to new O-rings, and install them on
oil strainer.
NOTE:
13. Install oil strainer to control valve assembly.
SDIA2120E
CLUTCH PISTON
1. Apply ATF or petroleum jelly to new D-rings, and install them to
clutch piston.
NOTE:
Do not reuse D-rings.
SDIA2117E
2. Install thrust needle bearing race to clutch piston.
SDIA2189E
3. Install clutch piston to the center case as shown.

CAUTION:
Install so the fitting protrusion of the clutch piston with
aligns the dent of the center case.
SDIA2190E

CENTER CASE
4. Remove all the liquid gasket from oil pressure check port and
inside center case. With the new oil pressure check plug A
threaded in 1 or 2 pitches, apply specified sealant or equivalent,
to the oil pressure check plug thread of plug, and tighten. Refer
to GI-45, "Recommended Chemical Products and Sealants" .
B
Oil pressure check plug : 15 N·m (1.5 kg-m, 11 in-lb)
NOTE:
Do not reuse oil pressure check plug. C
5. Install mainshaft and clutch drum. Refer to TF-147, "MAIN-
SHAFT AND CLUTCH DRUM" . SMT915C
TF
MAINSHAFT AND CLUTCH DRUM
1. Apply ATF or petroleum jelly to needle bearing, and install nee-
dle bearing, clutch drum, clutch hub and new snap ring to main- E
shaft.
SMT974C
H
2. Install new snap ring to the clutch hub, using suitable tool.
NOTE:
Do not reuse snap ring. I
K
WDIA0101E
3. Install new snap ring to clutch hub from clutch hub to mainshaft, L
and secure them with snap rings.
NOTE:
Do not reuse snap rings.
M
SDIA2192E

CENTER CASE
4. Install each plate into clutch drum as shown.
SDIA2193E
5. Install the return spring assembly into clutch hub.
SMT911C
6. Install press flange by aligning notches to the clutch hub as

shown.
SDIA2194E
7. Install the snap ring to the main shaft snap ring groove on main-
shaft, using Tool.
Tool number
A : ST22452000 (J-34335)
B : ST30911000 ( — )
C : KV31103300 ( — )
NOTE:
SDIA2111E
8. Install new snap ring to mainshaft using suitable tool.

NOTE:
SDIA2112E

CENTER CASE
9. Apply ATF or petroleum jelly to thrust needle bearing and install

it on press flange. A
SDIA2109E
TF
10. Install the new snap ring to main shaft.
NOTE:
E
SDIA2195E
H
11. Install mainshaft rear bearing to center case, using Tool.
Tool number : ST1531000 (J-25640-B)
I
K
SDIA2196E
12. Install mainshaft assembly, and set it to press stand.

● Place to the tip of mainshaft, and press mainshaft into center L
case, using Tool.
Tool number
M
A : ST30911000 ( — )
B : ST33052000 ( — )
SDIA2197E
13. Install front drive shaft and drive chain. Refer to TF-150, "FRONT DRIVE SHAFT AND DRIVE CHAIN" .
14. Install front case assembly and rear case assembly.
Refer to TF-151, "Final Assembly" .

CENTER CASE
FRONT DRIVE SHAFT AND DRIVE CHAIN

1. Install front drive shaft rear bearing, using Tool.
Tool number
A : KV40100621 (J-25273)
B : ST30032000 (J-26010-01)
SDIA2198E
a. Install front drive shaft to front bearing, using Tool.

Tool number
A : KV40100621 (J-25273)
B : ST30032000 (J-26010-01)
SDIA2199E
2. Install drive chain temporarily to front drive shaft and clutch

drum.
CAUTION:
Install drive chain by aligning identification marks to the
rear as shown.
SDIA2200E
3. Tap front drive shaft while keeping it upright and press-fit front
drive shaft rear bearing, using suitable tool.
CAUTION:
Be careful not to tap drive chain with tool.
SMT988C
4. Install front case assembly and rear case assembly. Refer to TF-151, "Final Assembly" .

ASSEMBLY
ASSEMBLY PFP:00030
A
Final Assembly EDS001EG
1. Install C-rings to mainshaft.

B
TF
SDIA2201E
E
2. Set washer holder on mainshaft, and secure it with new snap
ring.
NOTE:
F
H
SDIA2104E
3. Apply specified Anaerobic Liquid Gasket or equivalent to the

entire center case mounting surface of front case assembly as I
shown. Refer to GI-45, "Recommended Chemical Products and
Sealants" .
NOTE: J
Remove all foreign materials such as water, oil and grease from
center case and front case mating surfaces.
K
SDIA2202E

ASSEMBLY
4. Install center case assembly to front case assembly.

CAUTION:
Pay careful attention so that mainshaft end is not damaged.
5. Tap center case lightly press-fit front drive shaft bearing into
front case, using suitable tool.
SDIA2138E
6. Tighten front case bolts to specified torque.

Front case bolts : 45 N·m (4.6 kg-m, 33 ft-lb)
NOTE:
Be sure to install air breather hose clamp, connector bracket
and harness clip.
SDIA2100E
7. Remove all the gasket fluid from switch mounting area and
inside center case. With ATP switch and neutral-4LO switch
threaded in 1 to 2 pitches, apply specified sealant or equivalent
to the thread of the switches and tighten to specified torque.
Refer to GI-45, "Recommended Chemical Products and Seal-
ants" .
ATP and Neutral- 4LO : 28 N·m (2.9 kg-m, 21 ft-lb)
switches
SDIA2096E
8. Apply ATF or petroleum jelly to stem bleeder and install to center

case.
SDIA2097E
9. Install main oil pump assembly to the center case assembly and tighten bolts. Refer to TF-112, "Transfer
Components" .

ASSEMBLY
10. Align the matchmark on front drive shaft with the mark on the
companion flange, then install the companion flange. A
SDIA2214E
TF
11. Install new companion flange self-lock nut, and tighten to specifi-
cation using suitable tool.
Companion flange self- : 275 N·m (28 kg-m, 203 ft-lb) E
lock nut
NOTE:
Do not reuse self-lock nut. F
G
SDIA2203E
12. Apply ATF or petroleum jelly to the circumference of new rear oil
H
seal, and install using Tool as shown so that it is flush with case
tip face.
Tool number : ST30720000 (J-25405)
I
NOTE:
● Apply multi-purpose grease to oil seal lip.
● Do not reuse oil seal. J
SDIA2204E
K
13. Apply ATF or petroleum jelly to the circumference of the new
dust cover. Position the dust cover using the identification mark
as shown. L
NOTE:
● Do not reuse the dust cover.
● Identification mark should be set at the position shown. M
SDIA2208E
14. Install new dust cover using Tool.

SDIA2205E

ASSEMBLY
15. Install air breather into rear case.
16. Apply specified Anaerobic Liquid Gasket or equivalent to entire

rear case mounting surface of center case as shown. Refer to
GI-45, "Recommended Chemical Products and Sealants" .
CAUTION:
Be careful not to allow Liquid Gasket to the stem bleeder
hole.
NOTE:
Remove all foreign materials such as water, oil, and grease from
center case and rear case mating surfaces.
SDIA2206E
17. Install rear case to center case, and tighten bolts to specified
torque.
Center case bolts : 45 N·m 4.6 kg-m, 33 ft-lb)
SDIA2100E
18. Installation of the remaining components is in the reverse order of removal.

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
General Specifications EDS0031X
Applied model VK56DE

Transfer model ATX14B B
Fluid capacity (Approx.) (US qt, lmp qt) 3.0 (3-1/8, 2-5/8)
High 1.000 C
Gear ratio
Low 2.596
Planetary Sun gear 57

gear Internal gear 91 TF
Number of teeth
Front drive sprocket 38
Front drive shaft 38
E
Inspection and Adjustment EDS0031Y
CLEARANCE BETWEEN INNER GEAR AND OUTER GEAR

Unit: mm (in) F
Item Specification
Sub-oil pump 0.015 - 0.035 (0.0006 - 0.0014)
G
Main oil pump 0.015 - 0.035 (0.0006 - 0.0014)
CLUTCH
Unit: mm (in) H
Item Limit value
Drive plate 1.4 (0.055)
I
PINION GEAR END PLAY
Unit: mm (in)
Item Standard
J
Pinion gear end play 0.1 - 0.7 (0.004 - 0.028)
CLEARANCE BETWEEN SHIFT FORK AND SLEEVE

Unit: mm (in) K
Item Standard
Shift fork and sleeve Less than 0.36 (0.0142)
L
SELECTIVE PARTS
Sub-oil Pump
Unit: mm (in) M
Part number*
Gear thickness
Inner gear Outer gear
9.27 - 9.28 (0.3650 - 0.3654) 31346 0W462 31347 0W462
9.28 - 9.29 (0.3654 - 0.3657) 31346 0W461 31347 0W461
9.29 - 9.30 (0.3657 - 0.3661) 31346 0W460 31347 0W460
*: Always check with the Parts Department for the latest parts information.
Main Oil Pump

Unit: mm (in)
Part number*
Gear thickness
Inner gear Outer gear
8.27 - 8.28 (0.3256 - 0.3260) 31346 7S112 31347 7S112
8.28 - 8.29 (0.3260 - 0.3264) 31346 7S111 31347 7S111
8.29 - 8.30 (0.3264 - 0.3268) 31346 7S110 31347 7S110

SERVICE DATA AND SPECIFICATIONS (SDS)
Control Valve
Unit: mm (in)
Mounting position
Part number* Outer dia. Overall length
(Part name)
L1
31772 21X00 8.0 (0.315) 38.5 (1.516)
(2-4 shift valve)
L2
31772 80X11 10.0 (0.394) 40.0 (1.575)
(Clutch valve)
L4
31772 80X11 10.0 (0.394) 40.0 (1.575)
(Pilot valve)
L5
31741 0W410 12.0 (0.472) 68.0 (2.677)
(Regulator valve)
Control Valve Spring

Unit: mm (in)
Mounting position
Part number* Free length Outer dia. Overall length
(Part name)
L1
31742 2W500 31.85 (1.2539) 7.0 (0.276) 0.6 (0.024)
(2-4 shift valve spring)
L2
31742 2W505 40.6 (1.598) 8.9 (0.350) 0.7 (0.028)
(Clutch valve spring)
L4
31742 0W410 28.1 (1.106) 9.0 (0.354) 1.2 (0.047)
(Pilot valve spring)
L5
31742 2W515 39.7 (1.563) 11.0 (0.433) 1.3 (0.051)
(Regulator valve spring)
Return Spring
Unit: mm (in)
Stamped mark Part number* Free length
1 31521 7S111 42.7 (1.168)
2 31521 7S112 43.1 (1.697)
3 31521 7S113 43.6 (1.717)
4 31521 7S114 44.0 (1.731)
Unit: mm (in)
Stamped mark Part number* Free length Outer dia. Overall length
L1
31742 2W500 31.85 (1.2539) 7.0 (0.276) 0.6 (0.024)
(2-4 shift valve spring)
L2
31742 2W505 40.6 (1.598) 8.9 (0.350) 0.7 (0.028)
(Clutch valve spring)
L4
31742 0W410 28.1 (1.106) 9.0 (0.354) 1.2 (0.047)
(Pilot valve spring)
L5
31742 2W515 39.7 (1.563) 11.0 (0.433) 1.3 (0.051)
(Regulator valve spring)

Transfer: Section

Uploaded by

Transfer: Section

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D DRIVELINE/AXLE

Revision: January 2005 TF-1 2004 Pathfinder Armada

Revision: January 2005 TF-2 2004 Pathfinder Armada

Revision: January 2005 TF-3 2004 Pathfinder Armada

● Before connecting or disconnecting the transfer control

Revision: January 2005 TF-4 2004 Pathfinder Armada

● When connecting or disconnecting pin connectors into or

Service Notice EDS000Z0

When you read wiring diagrams, refer to the following:

Revision: January 2005 TF-5 2004 Pathfinder Armada

Special Service Tools EDS001DX

ST30031000 Removing front driveshaft bearing

ST30720000 Installing mainshaft front bearing and oil seal

ST33220000 Installation needle bearings

KV40100621 Installing front drive shaft front and rear bear-

ST30032000 Installing front drive shaft bearing

ST33052000 Removing front drive shaft bearing

Revision: January 2005 TF-6 2004 Pathfinder Armada

Tool number Description

ST3532500 Removing metal bushing TF

KV38100500 Installing front oil seal

ST33290001 Removing metal bushing and oil seal

ST22452000 Removing and installing press flange snap

KV38100300 Removing mainshaft rear bearing

Revision: January 2005 TF-7 2004 Pathfinder Armada

Tool number Description

ST33710000 Removing needle bearing

ST22360002 Installing oil seal

ST15310000 Installing mainshaft rear bearing

KV40105310 Installing dust cover

KV31103300 Removing and installing press flange snap

Revision: January 2005 TF-8 2004 Pathfinder Armada

Commercial Service Tools EDS001DY

Puller Removing companion flange

Pin punch Removing and installing retainer pin F

Revision: January 2005 TF-9 2004 Pathfinder Armada

ALL-MODE 4WD SYSTEM PFP:00000

Cross-sectional View EDS001DZ

1. Center case 2. Chain 3. Multiple disc clutch

Revision: January 2005 TF-10 2004 Pathfinder Armada

Control System EDS000Z3

Revision: January 2005 TF-11 2004 Pathfinder Armada

ALL-MODE 4WD TRANSFER BASIC CONTROL

HYDRAULIC CONTROL CIRCUITS

Revision: January 2005 TF-12 2004 Pathfinder Armada

CONTROL SYSTEM DIAGRAM

INDICATIONS OF 4WD WARNING LAMP G

Revision: January 2005 TF-13 2004 Pathfinder Armada

Location of Electrical Parts EDS000Z5

Revision: January 2005 TF-14 2004 Pathfinder Armada

Description of Electrical Parts EDS000Z6

Revision: January 2005 TF-15 2004 Pathfinder Armada

LINE PRESSURE SWITCH

Revision: January 2005 TF-16 2004 Pathfinder Armada

Circuit Diagram for Quick Pinpoint Check EDS000Z7

Revision: January 2005 TF-17 2004 Pathfinder Armada

Wiring Diagram — TF — EDS000Z8

Revision: January 2005 TF-18 2004 Pathfinder Armada

Revision: January 2005 TF-19 2004 Pathfinder Armada

Revision: January 2005 TF-20 2004 Pathfinder Armada

Revision: January 2005 TF-21 2004 Pathfinder Armada

Revision: January 2005 TF-22 2004 Pathfinder Armada

Revision: January 2005 TF-23 2004 Pathfinder Armada

Revision: January 2005 TF-24 2004 Pathfinder Armada

Revision: January 2005 TF-25 2004 Pathfinder Armada

Revision: January 2005 TF-26 2004 Pathfinder Armada

ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION PFP:00000

Revision: January 2005 TF-27 2004 Pathfinder Armada

*1: TF-87 *2: TF-29

Revision: January 2005 TF-28 2004 Pathfinder Armada

INDICATIONS OF 4WD WARNING LAMP

Revision: January 2005 TF-29 2004 Pathfinder Armada

Flickering pattern or flick-

Trouble Diagnosis with CONSULT-II EDS000ZA

2. Connect CONSULT-II and CONSULT-II CONVERTER to data

Revision: January 2005 TF-30 2004 Pathfinder Armada

1: TF-87 2: TF-29