Transfer Case: Diagnosis Nissan Juke I

SELF DIAGNOSTIC RESULT

Refer to " DTC INDEX ".

When "PRSNT" is displayed on self-diagnosis result.

1. The system is presently malfunctioning.

When "PAST" is displayed on self-diagnosis result.

1. System malfunction in the past is detected, but the system is presently normal.

ACTIVE TEST

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

VALUES ON THE DIAGNOSIS TOOL

Scheme 2

DTC Inspection Priority Chart

If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart.

DTC Index

Note. If some DTCs are displayed at the same time, refer to " DTC INSPECTION PRIORITY CHART ".

DTC INDEX

DTC DETECTION LOGIC

DTC CONFIRMATION PROCEDURE

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Turn the ignition switch OFF to ON. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1804 or P1809" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S08251800742012120600000) ". NO: INSPECTION END

Diagnosis Procedure

1. PERFORM SELF-DIAGNOSIS AGAIN With CONSULT Perform "DTC CONFIRMATION PROCEDURE" (self-diagnosis) again. Refer to " «DTC LOGIC»(ref-516403-S27204045502012120600000) ". Is DTC "P1804 or 1809" detected? YES: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Check AWD control module pin terminals for damage or loose connection with harness connector. If any items are damaged, repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1808" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S20059490832012120600000) ". NO: INSPECTION END

1. PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ABS". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516419-S30121076622012120600000) ". NO: GO TO 2.
2. ERASE SELF-DIAGNOSTIC RESULT With CONSULT Erase self-diagnostic results for "ALL MODE AWD/4WD". Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Check that ABS warning lamp turns OFF. Does ABS warning lamp turn OFF? YES: GO TO 3. NO: Refer to " «COMPONENT FUNCTION CHECK»(ref-516419-S34786286822012120600000) ".
3. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P1808" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Turn the ignition switch OFF to ON. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1811" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S01585791842012120600000) ". NO: INSPECTION END

1. CHECK AWD CONTROL MODULE POWER SUPPLY (1) Turn the ignition switch OFF. Disconnect AWD control module harness connector. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 1 Ground 11 - 13 V Turn the ignition switch ON. CAUTION: Never start the engine. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 1 Ground 11 - 13 V Is the inspection result normal? YES: GO TO 3 . NO: GO TO 2.
2. CHECK AWD CONTROL MODULE POWER SUPPLY (2) Turn the ignition switch OFF. Check the 10A fuse (#33). Check the harness for open or short between AWD control module harness connector No. 1 terminal and 10A (#33). Is the inspection result normal? YES: Perform the trouble diagnosis for power supply circuit. Refer to " «WIRING DIAGRAM - BATTERY POWER SUPPLY»(ref-516406-S29806471722012120600000) ". NO: Repair or replace error-detected parts.
3. CHECK AWD CONTROL MODULE POWER SUPPLY (3) Turn the ignition switch OFF. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 3 Ground 0 V Turn the ignition switch ON. CAUTION: Never start the engine. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 3 Ground 11 - 13 V Is the inspection result normal? YES: GO TO 5 . NO: GO TO 4.
4. CHECK AWD CONTROL MODULE POWER SUPPLY (4) Turn the ignition switch OFF. Check the 10A fuse (#3). Check the harness for open or short between AWD control module harness connector No. 3 terminal and 10A (#3). Is the inspection result normal? YES: Perform the trouble diagnosis for ignition power supply circuit. Refer to " «WIRING DIAGRAM - IGNITION POWER SUPPLY»(ref-516406-S10757167402012120600000) ". NO: Repair or replace error-detected parts.
5. CHECK AWD CONTROL MODULE GROUND Turn the ignition switch OFF. Check the continuity between AWD control module harness connector and ground. AWD control module - Continuity Connector Terminal B47 10 Ground Existed 11 Is the inspection result normal? YES: GO TO 6. NO: Repair or replace error-detected parts.
6. CHECK TERMINALS AND HARNESS CONNECTORS Check the AWD control module pin terminals for damage or loose connection with harness connector. Is the inspection result normal? YES: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Turn the ignition switch OFF to ON. Change AWD mode switch following order. Changing order: 2WD-->AWD-V-->AWD-->AWD-V-->2WD Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1813" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S13602388702012120600000) ". NO: INSPECTION END

1. CHECK AWD MODE SWITCH Check AWD mode switch. Refer to " «COMPONENT INSPECTION»(ref-516403-S20458223612012120600000) ". Is the inspection result normal? YES: GO TO 2. NO: Replace AWD mode switch. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S27165166082012120600000) ".
2. CHECK AWD MODE SWITCH CIRCUIT (1) Disconnect AWD control module harness connector. Check the continuity between AWD control module harness connector and AWD mode switch harness connector. AWD control module AWD mode switch Continuity Connector Terminal Connector Terminal B47 9 M48 1 Existed 5 Not existed 6 Not existed 13 1 Not existed 5 Existed 6 Not existed 21 1 Not existed 5 Not existed 6 Existed Is the inspection result normal? YES: GO TO 3. NO: Repair or replace error-detected parts.
3. CHECK AWD MODE SWITCH CIRCUIT (2) Check the continuity between AWD mode switch harness connector and ground. AWD mode switch - Continuity Connector Terminal M48 3 Ground Not existed Is the inspection result normal? YES: GO TO 4. NO: Repair or replace error-detected parts.
4. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Check AWD mode switch pin terminals for damage or loose connection with harness connector. Is the inspection result normal? YES: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

Component Inspection

1. CHECK AWD MODE SWITCH Turn the ignition switch OFF. Remove AWD mode switch. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S27165166082012120600000) ". Check the continuity between AWD mode switch harness connector terminals. AWD switch assembly Condition Continuity Terminal 1 3 AWD mode switch: 2WD Not existed AWD mode switch: AWD-V or AWD Existed 5 3 AWD mode switch: 2WD Existed AWD mode switch: AWD-V or AWD Not existed 6 3 AWD mode switch: 2WD or AWD-V Not existed AWD mode switch: AWD Existed Is the inspection result normal? YES: INSPECTION END NO: Replace AWD mode switch. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S27165166082012120600000) ".

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Turn the ignition switch OFF, and wait for several seconds. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P181B" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S40463606962012120600000) ". NO: INSPECTION END

1. CHECK AWD CONTROL MODULE POWER SUPPLY (1) Turn the ignition switch OFF. Disconnect AWD control module harness connector. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 1 Ground 11 - 13 V Turn the ignition switch ON. CAUTION: Never start the engine. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 1 Ground 11 - 13 V Is the inspection result normal? YES: GO TO 3 . NO: GO TO 2.
2. CHECK AWD CONTROL MODULE POWER SUPPLY (2) Turn the ignition switch OFF. Check the 10A fuse (#33). Check the harness for open or short between AWD control module harness connector No. 1 terminal and 10A (#33). Is the inspection result normal? YES: Perform the trouble diagnosis for power supply circuit. Refer to " «WIRING DIAGRAM - BATTERY POWER SUPPLY»(ref-516406-S29806471722012120600000) ". NO: Repair or replace error-detected parts.
3. CHECK AWD CONTROL MODULE GROUND Turn the ignition switch OFF. Check the continuity between AWD control module harness connector and ground. AWD control module - Continuity Connector Terminal B47 10 Ground Existed 11 Is the inspection result normal? YES: GO TO 4. NO: Repair or replace error-detected parts.
4. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P181B" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P181D" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S32004643022012120600000) ". NO: INSPECTION END

1. PERFORM ECM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ENGINE". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516395-S21635750032012120600000) ". NO: GO TO 2.
2. ERASE SELF-DIAGNOSTIC RESULT With CONSULT Erase self-diagnostic results for "ALL MODE AWD/4WD". Turn the ignition switch OFF. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Check that malfunction indicator lamp (MIL) turns OFF. Does malfunction indicator lamp (MIL) turn OFF? YES: GO TO 3. NO: Refer to " «DIAGNOSIS DESCRIPTION: MALFUNCTION INDICATOR LAMP (MIL)»(ref-516395-S36411621772012120600000) ".
3. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P181D" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Turn the ignition switch OFF to ON. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P181E" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S18862230982012120600000) ". NO: INSPECTION END

1. PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ABS". Is DTC "C1143" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516419-S23828813232012120600000) ". NO: GO TO 2.
2. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P181E" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Turn the ignition switch OFF to ON. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P181F" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S06029838692012120600000) ". NO: INSPECTION END

1. PERFORM WRITING UNIT CHARACTERISTICS Erase self-diagnostic result for "ALL MODE AWD/4WD". Perform writing unit characteristics. Refer to " «WORK PROCEDURE»(ref-516403-S15713168772012120600000) ". Perform self-diagnosis for "ALL MODE AWD/4WD". Is any DTC except "P181F" detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516403-S03600643992012120600000) ". NO: GO TO 2.
2. PERFORM SELF-DIAGNOSIS AGAIN With CONSULT Perform "DTC CONFIRMATION PROCEDURE" (self-diagnosis) again. Refer to " «DTC LOGIC»(ref-516403-S07030112282012120600000) ". Is DTC "P181F" detected? YES: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Check AWD control module pin terminals for damage or loose connection with harness connector. If any items are damaged, repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1820" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S26953694542012120600000) ". NO: INSPECTION END

1. PERFORM ECM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ENGINE". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516395-S21635750032012120600000) ". NO: GO TO 2.
2. ERASE SELF-DIAGNOSTIC RESULT With CONSULT Erase self-diagnostic results for "ALL MODE AWD/4WD". Turn the ignition switch OFF. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Check that malfunction indicator lamp (MIL) turns OFF. Does malfunction indicator lamp (MIL) turn OFF? YES: GO TO 3. NO: Refer to " «DIAGNOSIS DESCRIPTION: MALFUNCTION INDICATOR LAMP (MIL)»(ref-516395-S36411621772012120600000) ".
3. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P1820" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1829" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S21007555452012120600000) ". NO: INSPECTION END

1. PERFORM ECM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ENGINE". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516395-S21635750032012120600000) ". NO: GO TO 2.
2. ERASE SELF-DIAGNOSTIC RESULT With CONSULT Erase self-diagnostic results for "ALL MODE AWD/4WD". Turn the ignition switch OFF. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Check that malfunction indicator lamp (MIL) turns OFF. Does malfunction indicator lamp (MIL) turn OFF? YES: GO TO 3. NO: Refer to " «DIAGNOSIS DESCRIPTION: MALFUNCTION INDICATOR LAMP (MIL)»(ref-516395-S36411621772012120600000) ".
3. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P1829" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION (1) With CONSULT Turn the ignition switch OFF to ON, and then wait for 5 seconds or more. Turn the ignition switch OFF. Turn the ignition switch ON, and then wait for 5 seconds or more. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P182D" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S20415770532012120600000) ". NO: GO TO 3.
3. PERFORM DTC CONFIRMATION (2) With CONSULT Lift up the vehicle. Start the engine, and run at idle for 1 second. Stop the engine. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P182D" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S20415770532012120600000) ". NO: GO TO 4.
4. PERFORM DTC CONFIRMATION (3) With CONSULT Drive the vehicle at 30 km/h (19 MPH) or less for approximately 1 minute. Stop the vehicle. Drive the vehicle at 30 km/h (19 MPH) or less for approximately 1 minute again. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P182D" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S20415770532012120600000) ". NO: INSPECTION END

1. CHECK AWD SOLENOID CIRCUIT (1) Turn the ignition switch OFF. Disconnect AWD control module harness connector. Check the resistance between AWD control module harness connector. AWD control module Condition Resistance (Approx.) Connector Terminal B47 23 24 10°C (50°F) 2.55 ohms 20°C (68°F) 2.65 ohms 30°C (86°F) 2.76 ohms Is the inspection result normal? YES: GO TO 4 . NO: GO TO 2.
2. CHECK AWD SOLENOID CIRCUIT (2) Disconnect rear final drive assembly harness connector. Check the continuity between AWD control module harness connector and rear final drive assembly harness connector. AWD control module Rear final drive assembly Continuity Connector Terminal Connector Terminal B47 23 B64 4 Existed 24 8 Check the continuity between AWD control module harness connector and the ground. AWD control module - Continuity Connector Terminal B47 23 Ground Not existed 24 Is the inspection result normal? YES: GO TO 3. NO: Repair or replace the error-detected parts.
3. CHECK AWD SOLENOID Check AWD solenoid. Refer to " «COMPONENT INSPECTION»(ref-516403-S18902818342012120600000) ". Is the inspection result normal? YES: GO TO 4. NO: AWD solenoid (left) is malfunctioning. Replace electric controlled coupling (left). Refer to " «REMOVAL AND INSTALLATION»(ref-516430-S28408088262012120600000) ".
4. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Check rear final drive assembly pin terminals for damage or loose connection with harness connector. Is the inspection result normal? YES: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace the error-detected parts.

1. CHECK AWD SOLENOID Turn the ignition switch OFF. Disconnect rear final drive assembly harness connector. Check the resistance between rear final drive assembly connector terminals. Rear final drive assembly Condition Resistance (Approx.) Terminal 4 8 10°C (50°F) 2.55 ohms 20°C (68°F) 2.65 ohms 30°C (86°F) 2.76 ohms Is the inspection result normal? YES: INSPECTION END NO: AWD solenoid (left) is malfunctioning. Replace electric controlled coupling (left). Refer to " «REMOVAL AND INSTALLATION»(ref-516430-S28408088262012120600000) ".

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION (1) With CONSULT Turn the ignition switch OFF to ON, and then wait for 5 seconds or more. Turn the ignition switch OFF. Turn the ignition switch ON, and then wait for 5 seconds or more. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P182E" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S21376653612012120600000) ". NO: GO TO 3.
3. PERFORM DTC CONFIRMATION (2) With CONSULT Lift up the vehicle. Start the engine, and run at idle for 1 second. Stop the engine. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P182E" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S21376653612012120600000) ". NO: GO TO 4.
4. PERFORM DTC CONFIRMATION (3) With CONSULT Drive the vehicle at 30 km/h (19 MPH) or less for approximately 1 minute. Stop the vehicle. Drive the vehicle at 30 km/h (19 MPH) or less for approximately 1 minute again. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P182E" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S21376653612012120600000) ". NO: INSPECTION END

1. CHECK AWD SOLENOID CIRCUIT (1) Turn the ignition switch OFF. Disconnect AWD control module harness connector. Check the resistance between AWD control module harness connector. AWD control module Condition Resistance (Approx.) Connector Terminal B47 25 26 10°C (50°F) 2.55 ohms 20°C (68°F) 2.65 ohms 30°C (86°F) 2.76 ohms Is the inspection result normal? YES: GO TO 4 . NO: GO TO 2.
2. CHECK AWD SOLENOID CIRCUIT (2) Disconnect rear final drive assembly harness connector. Check the continuity between AWD control module harness connector and rear final drive assembly harness connector. AWD control module Rear final drive assembly Continuity Connector Terminal Connector Terminal B47 25 B64 2 Existed 26 6 Check the continuity between AWD control module harness connector and the ground. AWD control module - Continuity Connector Terminal B47 25 Ground Not existed 26 Is the inspection result normal? YES: GO TO 3. NO: Repair or replace the error-detected parts.
3. CHECK AWD SOLENOID Check AWD solenoid. Refer to " «COMPONENT INSPECTION»(ref-516403-S05294512142012120600000) ". Is the inspection result normal? YES: GO TO 4. NO: AWD solenoid (right) is malfunctioning. Replace electric controlled coupling (right). Refer to " «REMOVAL AND INSTALLATION»(ref-516430-S28408088262012120600000) ".
4. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Check rear final drive assembly pin terminals for damage or loose connection with harness connector. Is the inspection result normal? YES: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace the error-detected parts.

1. CHECK AWD SOLENOID Turn the ignition switch OFF. Disconnect rear final drive assembly harness connector. Check the resistance between rear final drive assembly connector terminals. Rear final drive assembly Condition Resistance (Approx.) Terminal 2 6 10°C (50°F) 2.55 ohms 20°C (68°F) 2.65 ohms 30°C (86°F) 2.75 ohms Is the inspection result normal? YES: INSPECTION END NO: AWD solenoid (right) is malfunctioning. Replace electric controlled coupling (right). Refer to " «REMOVAL AND INSTALLATION»(ref-516430-S28408088262012120600000) ".

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Turn the ignition switch OFF to ON. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P182F" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S34737551432012120600000) ". NO: INSPECTION END

1. CHECK ELECTRIC CONTROLLED COUPLING (LEFT) TEMPERATURE SENSOR POWER SUPPLY Turn the ignition switch OFF. Disconnect rear final drive assembly harness connector. Turn the ignition switch ON. CAUTION: Never start the engine. Check the voltage between rear final drive assembly harness connector terminals. + - Voltage Rear final drive assembly Connector Terminal B64 3 7 Approx. 5 V Is the inspection result normal? YES: GO TO 3 . NO: GO TO 2.
2. CHECK ELECTRIC CONTROLLED COUPLING (LEFT) TEMPERATURE SENSOR CIRCUIT Turn the ignition switch OFF. Disconnect AWD control module harness connector. Check the continuity between AWD control module harness connector and rear final drive assembly harness connector. AWD control module Rear final drive assembly Continuity Connector Terminal Connector Terminal B47 16 B64 7 Existed 17 3 Check the continuity between rear final drive assembly harness connector and ground. Rear final drive assembly - Continuity Connector Terminal B64 7 Ground Not existed Is the inspection result normal? YES: GO TO 4 . NO: Repair or replace error-detected parts.
3. CHECK ELECTRIC CONTROLLED COUPLING (LEFT) TEMPERATURE SENSOR Check the electric controlled coupling (left) temperature sensor. Refer to " «COMPONENT INSPECTION»(ref-516403-S20377706582012120600000) ". Is the inspection result normal? YES: GO TO 4. NO: Electric controlled coupling (left) temperature sensor is malfunctioning. Replace electric controlled coupling (left). Refer to " «REMOVAL AND INSTALLATION»(ref-516430-S28408088262012120600000) ".
4. CHECK TERMINALS AND HARNESS CONNECTORS Check the pin terminals for damage or loose connection with each harness connector. Is the inspection result normal? YES: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. CHECK ELECTRIC CONTROLLED COUPLING (LEFT) TEMPERATURE SENSOR Turn the ignition switch OFF. Disconnect rear final drive assembly harness connector. Check the resistance between transfer control fluid temperature sensor connector terminals. Rear final drive assembly Condition Resistance (Approx.) Terminal 3 7 10°C (50°F) 9.8 kohms 20°C (68°F) 6.5 kohms 30°C (86°F) 4.4 kohms Is the inspection result normal? YES: INSPECTION END NO: Electric controlled coupling (left) temperature sensor is malfunctioning. Replace electric controlled coupling (left). Refer to " «REMOVAL AND INSTALLATION»(ref-516430-S28408088262012120600000) ".

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 3 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1830" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S05669728392012120600000) ". NO: INSPECTION END

1. PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ABS". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516419-S30121076622012120600000) ". NO: GO TO 2.
2. ERASE SELF-DIAGNOSTIC RESULT With CONSULT Erase self-diagnostic results for "ALL MODE AWD/4WD". Start the engine and drive at 30 km/h (19 MPH) or more for approximately 3 minute. Stop the vehicle. Check that ABS warning lamp turns OFF. Does ABS warning lamp turn OFF? YES: GO TO 3. NO: Refer to " «COMPONENT FUNCTION CHECK»(ref-516419-S34786286822012120600000) ".
3. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P1830" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 3 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1831" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S34116414742012120600000) ". NO: INSPECTION END

1. PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ABS". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516419-S30121076622012120600000) ". NO: GO TO 2.
2. ERASE SELF-DIAGNOSTIC RESULT With CONSULT Erase self-diagnostic results for "ALL MODE AWD/4WD". Start the engine and drive at 30 km/h (19 MPH) or more for approximately 3 minute. Stop the vehicle. Check that ABS warning lamp turns OFF. Does ABS warning lamp turn OFF? YES: GO TO 3. NO: Refer to " «COMPONENT FUNCTION CHECK»(ref-516419-S34786286822012120600000) ".
3. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P1831" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 3 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1832" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S39079200542012120600000) ". NO: INSPECTION END

1. PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ABS". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516419-S30121076622012120600000) ". NO: GO TO 2.
2. ERASE SELF-DIAGNOSTIC RESULT With CONSULT Erase self-diagnostic results for "ALL MODE AWD/4WD". Start the engine and drive at 30 km/h (19 MPH) or more for approximately 3 minute. Stop the vehicle. Check that ABS warning lamp turns OFF. Does ABS warning lamp turn OFF? YES: GO TO 3. NO: Refer to " «COMPONENT FUNCTION CHECK»(ref-516419-S34786286822012120600000) ".
3. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P1832" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Turn the ignition switch OFF to ON. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P183A" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S16216970372012120600000) ". NO: INSPECTION END

1. CHECK ELECTRIC CONTROLLED COUPLING (RIGHT) TEMPERATURE SENSOR POWER SUPPLY Turn the ignition switch OFF. Disconnect rear final drive assembly harness connector. Turn the ignition switch ON. CAUTION: Never start the engine. Check the voltage between rear final drive assembly harness connector terminals. + - Voltage Rear final drive assembly Connector Terminal B64 1 5 Approx. 5 V Is the inspection result normal? YES: GO TO 3 . NO: GO TO 2.
2. CHECK ELECTRIC CONTROLLED COUPLING (RIGHT) TEMPERATURE SENSOR CIRCUIT Turn the ignition switch OFF. Disconnect AWD control module harness connector. Check the continuity between AWD control module harness connector and rear final drive assembly harness connector. AWD control module Rear final drive assembly Continuity Connector Terminal Connector Terminal B47 6 B64 1 Existed 7 5 Check the continuity between rear final drive assembly harness connector and ground. Rear final drive assembly - Continuity Connector Terminal B64 1 Ground Not existed Is the inspection result normal? YES: GO TO 4 . NO: Repair or replace error-detected parts.
3. CHECK ELECTRIC CONTROLLED COUPLING (RIGHT) TEMPERATURE SENSOR Check the electric controlled coupling (right) temperature sensor. Refer to " «COMPONENT INSPECTION»(ref-516403-S20020870672012120600000) ". Is the inspection result normal? YES: GO TO 4. NO: Electric controlled coupling (right) temperature sensor is malfunctioning. Replace electric controlled coupling (right). Refer to " «REMOVAL AND INSTALLATION»(ref-516430-S28408088262012120600000) ".
4. CHECK TERMINALS AND HARNESS CONNECTORS Check the pin terminals for damage or loose connection with each harness connector. Is the inspection result normal? YES: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. CHECK ELECTRIC CONTROLLED COUPLING (RIGHT) TEMPERATURE SENSOR Turn the ignition switch OFF. Disconnect rear final drive assembly harness connector. Check the resistance between transfer control fluid temperature sensor connector terminals. Rear final drive assembly Condition Resistance (Approx.) Terminal 1 5 10°C (50°F) 9.8 kohms 20°C (68°F) 6.5 kohms 30°C (86°F) 4.4 kohms Is the inspection result normal? YES: INSPECTION END NO: Electric controlled coupling (right) temperature sensor is malfunctioning. Replace electric controlled coupling (right). Refer to " «REMOVAL AND INSTALLATION»(ref-516430-S28408088262012120600000) ".

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Turn the ignition switch OFF to ON. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P183B" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S28823883622012120600000) ". NO: INSPECTION END

1. CHECK AWD SOLENOID POWER SUPPLY (1) Turn the ignition switch OFF. Disconnect AWD control module harness connector. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 12 Ground 11 - 13 V Turn the ignition switch OFF to ON. CAUTION: Never start the engine. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 12 Ground 11 - 13 V Is the inspection result normal? YES: GO TO 3 . NO: GO TO 2.
2. CHECK AWD SOLENOID POWER SUPPLY (2) Turn the ignition switch OFF. Check the 10A fuse (#12). Check the harness for open or short between AWD control module harness connector No. 12 and the 10A fuse (#12). Is the inspection result normal? YES: Perform the trouble the diagnosis for power supply circuit. Refer to " «WIRING DIAGRAM - BATTERY POWER SUPPLY»(ref-516406-S29806471722012120600000) ". NO: Repair or replace error-detected parts.
3. CHECK AWD CONTROL MODULE POWER SUPPLY (1) Turn the ignition switch OFF. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 3 Ground 0 V Turn the ignition switch ON. CAUTION: Never start the engine. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 3 Ground 11 - 13 V Is the inspection result normal? YES: GO TO 5 . NO: GO TO 4.
4. CHECK AWD CONTROL MODULE POWER SUPPLY (2) Turn the ignition switch OFF. Check the 10A fuse (#3). Check the harness for open or short between AWD control module harness connector No. 3 terminal and 10A (#3). Is the inspection result normal? YES: Perform the trouble diagnosis for ignition power supply circuit. Refer to " «WIRING DIAGRAM - IGNITION POWER SUPPLY»(ref-516406-S10757167402012120600000) ". NO: Repair or replace error-detected parts.
5. CHECK AWD SOLENOID GROUND Check the continuity between AWD control module harness connector and ground. AWD control module - Continuity Connector Terminal B47 10 Ground Existed 11 Is the inspection result normal? YES: GO TO 6. NO: Repair or replace the error-detected parts.
6. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Check AWD solenoid pin terminals for damage or loose connection with harness connector. Is the inspection result normal? YES: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace the error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P183C" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S09378078612012120600000) ". NO: INSPECTION END

1. PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ABS". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516419-S30121076622012120600000) ". NO: GO TO 2.
2. ERASE SELF-DIAGNOSTIC RESULT With CONSULT Erase self-diagnostic results for "ALL MODE AWD/4WD". Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Check that ABS warning lamp turns OFF. Does ABS warning lamp turn OFF? YES: GO TO 3. NO: Refer to " «COMPONENT FUNCTION CHECK»(ref-516419-S34786286822012120600000) ".
3. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P183C" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P183D" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S07402333272012120600000) ". NO: INSPECTION END

1. PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ABS". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516419-S30121076622012120600000) ". NO: GO TO 2.
2. ERASE SELF-DIAGNOSTIC RESULT With CONSULT Erase self-diagnostic results for "ALL MODE AWD/4WD". Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Check that ABS warning lamp turns OFF. Does ABS warning lamp turn OFF? YES: GO TO 3. NO: Refer to " «COMPONENT FUNCTION CHECK»(ref-516419-S34786286822012120600000) ".
3. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P183D" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P183E" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S36945179522012120600000) ". NO: INSPECTION END

1. PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ABS". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516419-S30121076622012120600000) ". NO: GO TO 2.
2. ERASE SELF-DIAGNOSTIC RESULT With CONSULT Erase self-diagnostic results for "ALL MODE AWD/4WD". Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Check that ABS warning lamp turns OFF. Does ABS warning lamp turn OFF? YES: GO TO 3. NO: Refer to " «COMPONENT FUNCTION CHECK»(ref-516419-S34786286822012120600000) ".
3. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P183E" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine. CAUTION: Never drive the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P183F" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S12748703862012120600000) ". NO: INSPECTION END

1. PERFORM TCM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "TRANSMISSION". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516407-S30961944862012120600000) ". NO: GO TO 2.
2. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P183F" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1840" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S05630724262012120600000) ". NO: INSPECTION END

1. PERFORM TCM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "TRANSMISSION". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516407-S30961944862012120600000) ". NO: GO TO 2.
2. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P1840" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1864" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S37154672232012120600000) ". NO: INSPECTION END

1. PERFORM TCM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "TRANSMISSION". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516407-S30961944862012120600000) ". NO: GO TO 2.
2. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P1864" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "P1865" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S29457851582012120600000) ". NO: INSPECTION END

1. PERFORM TCM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "TRANSMISSION". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516407-S30961944862012120600000) ". NO: GO TO 2.
2. CHECK TERMINALS AND HARNESS CONNECTORS Check AWD control module pin terminals for damage or loose connection with harness connector. Is inspection result normal? YES: After turning the ignition switch OFF, perform DTC confirmation procedure again. If DTC "P1865" is detected, Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Turn the ignition switch OFF to ON. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "U1000" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S39791232732012120600000) ". NO: INSPECTION END

Proceed to " TROUBLE DIAGNOSIS FLOW CHART ".

1. PRECONDITIONING If "DTC CONFIRMATION PROCEDURE" has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. GO TO 2.
2. PERFORM DTC CONFIRMATION With CONSULT Turn the ignition switch OFF to ON. Perform self-diagnosis for "ALL MODE AWD/4WD". Is DTC "U1010" detected? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S28365236532012120600000) ". NO: INSPECTION END

1. CHECK AWD CONTROL MODULE Check AWD control module harness connector for disconnection and deformation. Is the inspection result normal? YES: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace error-detected parts.

1. CHECK AWD CONTROL MODULE POWER SUPPLY (1) Turn the ignition switch OFF. Disconnect AWD control module harness connector. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 1 Ground 11 - 13 V Turn the ignition switch ON. CAUTION: Never start the engine. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 1 Ground 11 - 13 V Is the inspection result normal? YES: GO TO 3 . NO: GO TO 2.
2. CHECK AWD CONTROL MODULE POWER SUPPLY (2) Turn the ignition switch OFF. Check the 10A fuse (#33). Check the harness for open or short between AWD control module harness connector No. 1 terminal and 10A (#33). Is the inspection result normal? YES: Perform the trouble diagnosis for power supply circuit. Refer to " «WIRING DIAGRAM - BATTERY POWER SUPPLY»(ref-516406-S29806471722012120600000) ". NO: Repair or replace error-detected parts.
3. CHECK AWD CONTROL MODULE POWER SUPPLY (3) Turn the ignition switch OFF. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 3 Ground 0 V CAUTION: Never start the engine. Turn the ignition switch ON. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 3 Ground 11 - 13 V Is the inspection result normal? YES: GO TO 5 . NO: GO TO 4.
4. CHECK AWD CONTROL MODULE POWER SUPPLY (4) Turn the ignition switch OFF. Check the 10A fuse (#3). Check the harness for open or short between AWD control module harness connector No. 3 terminal and 10A (#3). Is the inspection result normal? YES: Perform the trouble diagnosis for ignition power supply circuit. Refer to " «WIRING DIAGRAM - IGNITION POWER SUPPLY»(ref-516406-S10757167402012120600000) ". NO: Repair or replace error-detected parts.
5. CHECK AWD SOLENOID POWER SUPPLY (1) Turn the ignition switch OFF. Disconnect AWD control module harness connector. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 12 Ground 11 - 13 V Turn the ignition switch OFF to ON. CAUTION: Never start the engine. Check the voltage between AWD control module harness connector and ground. AWD control module - Voltage Connector Terminal B47 12 Ground 11 - 13 V Is the inspection result normal? YES: GO TO 7 . NO: GO TO 6.
6. CHECK AWD SOLENOID POWER SUPPLY (2) Turn the ignition switch OFF. Check the 10A fuse (#12). Check the harness for open or short between AWD control module harness connector No. 12 and the 10A fuse (#12). Is the inspection result normal? YES: Perform the trouble the diagnosis for power supply circuit. Refer to " «WIRING DIAGRAM - BATTERY POWER SUPPLY»(ref-516406-S29806471722012120600000) ". NO: Repair or replace error-detected parts.
7. CHECK AWD CONTROL MODULE GROUND Turn the ignition switch OFF. Check the continuity between AWD control module harness connector and ground. AWD control module - Continuity Connector Terminal B47 10 Ground Existed 11 Is the inspection result normal? YES: INSPECTION END NO: Repair or replace error-detected parts.

1. CHECK POWER SUPPLY AND GROUND CIRCUIT Perform the trouble diagnosis for power supply and ground circuit. Refer to " «DIAGNOSIS PROCEDURE»(ref-516403-S12095498352012120600000) ". Is the inspection result normal? YES: GO TO 2. NO: Repair or replace the error-detected parts.
2. PERFORM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ALL MODE AWD/4WD". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516403-S03600643992012120600000) ". NO: GO TO 3.
3. CHECK AWD WARNING LAMP SIGNAL With CONSULT Turn the ignition switch ON. CAUTION: Never start the engine. Check "WARNING LAMP" in "DATA MONITOR" for "ALL MODE AWD/4WD". Does the item on "DATA MONITOR" indicate "On"? YES: Perform the trouble diagnosis for combination meter power supply circuit. Refer to " «COMBINATION METER: DIAGNOSIS PROCEDURE»(ref-516415-S17725457572012120600000) ". NO: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ".

1. CHECK AWD WARNING LAMP Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Does AWD warning lamp turn ON? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S27453818832012120600000) ". NO: GO TO 2.
2. CHECK AWD MODE SWITCH Perform the trouble diagnosis for AWD mode switch. Refer to " «DIAGNOSIS PROCEDURE»(ref-516403-S13602388702012120600000) ". Is the inspection result normal? YES: GO TO 3. NO: Repair or replace the error-detected parts.
3. CHECK AWD MODE INDICATOR LAMP SIGNAL With CONSULT Start the engine. CAUTION: Never drive the vehicle. Change AWD mode switch to "AWD-V" from "2WD". Check "INDICATOR" in "DATA MONITOR" for "ALL MODE AWD/4WD". Does the item on "DATA MONITOR" indicate "AWD-V"? YES: GO TO 4. NO: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ".
4. CHECK COMBINATION METER POWER SUPPLY CIRCUIT Perform the trouble diagnosis for combination meter power supply circuit. Refer to " «COMBINATION METER: DIAGNOSIS PROCEDURE»(ref-516415-S17725457572012120600000) ". Is the inspection result normal? YES: INSPECTION END NO: Repair or replace the error-detected parts.

1. CHECK AWD WARNING LAMP Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute. Stop the vehicle. Does AWD warning lamp turn ON? YES: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S27453818832012120600000) ". NO: GO TO 2.
2. CHECK AWD MODE SWITCH Perform the trouble diagnosis for AWD mode switch. Refer to " «DIAGNOSIS PROCEDURE»(ref-516403-S13602388702012120600000) ". Is the inspection result normal? YES: GO TO 3. NO: Repair or replace the error-detected parts.
3. CHECK AWD MODE INDICATOR LAMP SIGNAL With CONSULT Start the engine. CAUTION: Stop the vehicle. Change AWD mode switch to "AWD" from "AWD-V". Check "INDICATOR" in "DATA MONITOR" for "ALL MODE AWD/4WD". Does the item on "DATA MONITOR" indicate "AWD"? YES: GO TO 4. NO: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ".
4. CHECK COMBINATION METER POWER SUPPLY CIRCUIT Perform the trouble diagnosis for combination meter power supply circuit. Refer to " «COMBINATION METER: DIAGNOSIS PROCEDURE»(ref-516415-S17725457572012120600000) ". Is the inspection result normal? YES: INSPECTION END NO: Repair or replace the error-detected parts.

1. CHECK AWD WARNING LAMP Perform the trouble diagnosis for AWD warning lamp. Refer to " «DIAGNOSIS PROCEDURE»(ref-516403-S27453818832012120600000) ". Is the inspection result normal? YES: Check each harness connector pin terminal for malfunction or disconnection. NO: Repair or replace the error-detected parts.

1. PERFORM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ALL MODE AWD/4WD". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516403-S03600643992012120600000) ". NO: GO TO 2.
2. CHECK AWD WARNING LAMP Perform the trouble diagnosis of the AWD warning lamp. Refer to " «DIAGNOSIS PROCEDURE»(ref-516403-S27453818832012120600000) ". Is the inspection result normal? YES: GO TO 3. NO: Repair or replace the error-detected parts.
3. CHECK AWD CONTROL MODULE POWER SUPPLY AND GRAND CIRCUIT Perform the trouble diagnosis of power supply and ground circuit. Refer to " «DIAGNOSIS PROCEDURE»(ref-516403-S12095498352012120600000) ". Is the inspection result normal? YES: Check each harness connector pin terminal for malfunction or disconnection. NO: Repair or replace the error-detected parts.

1. PERFORM ECM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ENGINE". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516395-S21635750032012120600000) ". NO: GO TO 2.
2. PERFORM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ALL MODE AWD/4WD". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516403-S03600643992012120600000) ". NO: GO TO 3.
3. CHECK AWD SOLENOID Perform the trouble diagnosis of the AWD solenoid. Refer to " «DIAGNOSIS PROCEDURE»(ref-516403-S20415770532012120600000) " (Left side), " «DIAGNOSIS PROCEDURE»(ref-516403-S21376653612012120600000) " (Right side). Is the inspection result normal? YES: GO TO 4. NO: Repair or replace the error-detected parts.
4. CHECK ELECTRIC CONTROLLED COUPLING Turn the ignition switch OFF. Set the transaxle to neutral. Release the parking brake. Lift up the vehicle. Rotate the propeller shaft by hand. Hold rear wheel of right and left lightly. Does rear wheel rotate? YES: Replace electric controlled coupling for mechanical malfunction (clutch sticking etc.). Refer to " «REMOVAL AND INSTALLATION»(ref-516430-S28408088262012120600000) ". NO: Check each harness connector pin terminal for disconnection.

1. CHECK AWD WARNING LAMP Turn the ignition switch ON. CAUTION: Never start the engine. Does AWD warning lamp turn ON? YES: GO TO 2. NO: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S27453818832012120600000) ".
2. CHECK PARKING BRAKE SWITCH SIGNAL With CONSULT Check "PKB SW" in "DATA MONITOR" for "ALL MODE AWD/4WD". Monitor Item Condition Status PKB SW When the parking brake switch is operation. On When the parking brake switch is not operation. Off Is the inspection result normal? YES: GO TO 3. NO: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516419-S23239854002012120600000) ".
3. CRUISE TEST Drive the vehicle for a period of time. Does any symptom occur? YES: Replace electric controlled coupling for mechanical malfunction (mechanical engagement of clutch is not possible). Refer to " «REMOVAL AND INSTALLATION»(ref-516430-S28408088262012120600000) ". NO: Check each harness connector pin terminal for disconnection.

1. CHECK VEHICLE SPEED SIGNAL With CONSULT Turn the ignition switch ON. Check that each value of "WHEEL SPD SEN FR", "WHEEL SPD SEN FL", "WHEEL SPD SEN RR", and "WHEEL SPD SEN RL" in "DATA MONITOR" for "ALL MODE AWD/4WD" is almost equal. Is the inspection result normal? YES: GO TO 2. NO: Proceed to " «DIAGNOSIS PROCEDURE»(ref-516403-S20059490832012120600000) ".
2. CHECK TIRE Check the following. Tire pressure Tire wear condition Front and rear tire size (There is no difference between front and rear tires.) Is the inspection result normal? YES: GO TO 3. NO: Repair or replace error-detected parts.
3. TERMINAL INSPECTION Check AWD control module harness connector for disconnection. Is the inspection result normal? YES: Replace AWD control module. Refer to " «REMOVAL AND INSTALLATION»(ref-516403-S19392911702012120600000) ". NO: Repair or replace the error-detected parts.

1. PERFORM EPS CONTROL UNIT SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "EPS". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516435-S42203261652012120600000) ". NO: GO TO 2.
2. PERFORM SELF-DIAGNOSIS With CONSULT Perform self-diagnosis for "ALL MODE AWD/4WD". Is any DTC detected? YES: Perform trouble diagnosis for detected DTC. Refer to " «DTC INDEX»(ref-516403-S03600643992012120600000) ". NO: GO TO 3.
3. CHECK AWD SOLENOID Perform the trouble diagnosis of the AWD solenoid. Refer to " «DIAGNOSIS PROCEDURE»(ref-516403-S20415770532012120600000) " (Left side), " «DIAGNOSIS PROCEDURE»(ref-516403-S21376653612012120600000) " (Right side). Is the inspection result normal? YES: GO TO 4. NO: Repair or replace the error-detected parts.
4. CHECK ELECTRIC CONTROLLED COUPLING Turn the ignition switch OFF. Set the transaxle to neutral. Release the parking brake. Lift up the vehicle. Rotate the propeller shaft. Hold the rear wheel of right and left lightly. Does the rear wheel rotate? YES: Replace electric controlled coupling for mechanical malfunction (clutch sticking etc.). Refer to " «REMOVAL AND INSTALLATION»(ref-516430-S28408088262012120600000) ". NO: Check each harness connector pin terminal for disconnection.

NVH Troubleshooting Chart

Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts.

Scheme 3

INSPECTION AFTER INSTALLATION

Check oil level and check for oil leakage. Refer to " INSPECTION ".

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

1. Remove transfer cover. Refer to " «DISASSEMBLY»(ref-516403-S00831843522012120600000) ".
2. Remove transfer case oil seal (right and left).
3. Remove ring gear shaft assembly from transfer case. If ring gear shaft cannot be removed, remove as follows. CAUTION: Never damage transfer case. Set the drifts (A and B) to right and left spacers individually. Compress ring gear shaft assembly with ring gear bearing to remove ring gear shaft assembly from transfer case. CAUTION: The drift shall be placed on the center of the spacers. The pressure shall be as low as to remove ring gear shaft assembly from transfer case. The maximum pressure shall be 10 kN (1 ton, 1.0 Imp ton). If the adjusting shims and spacers are installed by tapping, the transfer case may be damaged. Avoid tapping.
4. Remove spacer (right and left) from ring gear shaft assembly.
5. Remove ring gear bearing adjusting shim (right and left) from ring gear shaft assembly.
6. Remove outer races of ring gear bearing (right and left) from ring gear shaft assembly.
7. Remove inner race of ring gear bearing (right) from ring gear shaft with the drift (A) and the replacer (B).
8. Remove inner race of ring gear bearing (left) from ring gear shaft with the replacer (A) (Commercial service tool).
9. Remove the ring gear mounting bolts.
10. Lightly tap ring gear with a plastic hammer to remove ring gear from ring gear shaft.
11. Remove drive shaft oil seal from the ring gear shaft with the puller (A) [SST: KV381054S0 (J-34286)].
12. Perform inspection after disassembly. Refer to " «INSPECTION»(ref-516403-S33286117482012120600000) ".

Scheme 10

Scheme 11

Scheme 12

Scheme 13

1. Select ring gear bearing adjusting shim (right and left). Refer to " «ADJUSTMENT»(ref-516403-S13372530722012120600000) ".
2. Using the drift (A) [SST: ST33230000 (J-25805-01)], install drive shaft oil seal (1) within the dimension (L) shown as follows. CAUTION: Never reuse the oil seal. When installing, never incline oil seal. Apply multi-purpose grease to oil seal lip, and gear oil onto the circumference.
3. Install the ring gear to ring gear shaft.
4. Install the inner race of ring gear bearing (left) to ring gear shaft with the drift (A) (Commercial service tool). CAUTION: Never reuse the ring gear bearing. Apply gear oil to ring gear bearing.
5. Install the inner race of ring gear bearing (right) to ring gear shaft with the drift (A) (Commercial service tool). CAUTION: Never reuse the ring gear bearing. Apply gear oil to ring gear bearing.
6. Install outer races of ring gear bearing (right and left) to ring gear shaft assembly. CAUTION: Never reuse the ring gear bearing. Apply gear oil to ring gear bearing.
7. Install selected ring gear bearing adjusting shim (right and left) to ring gear shaft assembly.
8. Install spacer (right and left) to ring gear shaft assembly.
9. Set the drifts (A and B) to right and left spacers individually. Compress ring gear shaft assembly with ring gear bearing to install ring gear shaft assembly to transfer case. CAUTION: The drift shall be placed on the center of the spacers. The pressure shall be as low as to install ring gear shaft assembly into transfer case. The maximum pressure shall be 10 kN (1 ton, 1.0 Imp ton). If the adjusting shims and spacers are installed by tapping, the transfer case may be damaged. Avoid tapping.
10. Install transfer cover to check and adjust each part. Refer to " «ASSEMBLY»(ref-516403-S05259250412012120600000) ". CAUTION: Never apply liquid gasket.
11. Check backlash, tooth contact, and total preload. Refer to " «ADJUSTMENT»(ref-516403-S13372530722012120600000) ". CAUTION: Measure the total preload without the transfer case oil seal.
12. Reinstall transfer cover for applying liquid gasket. Refer to " «ASSEMBLY»(ref-516403-S05259250412012120600000) ".
13. Install the transfer case oil seal (left and right). Refer to " «ASSEMBLY»(ref-516403-S05259250412012120600000) ".

Scheme 14

Ring gear bearing adjusting shim (left)

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

1. Measure the dimensions of each measuring point with the following procedure: Dimension "A" measurement Measure dimension (A) of transfer case with a pair of vernier calipers. Refer to "Measuring point". CAUTION: Never damage transfer case. Dimension "X" measurement Measure the diameter (X) of transfer case with a pair of vernier calipers. Refer to "Measuring point". CAUTION: Never damage transfer case. Dimension "Y" measurement Measure dimension (Y') of transfer case (including the thickness of straightedge) with a pair of vernier calipers and straightedge. Refer to "Measuring point". CAUTION: Never damage transfer case. Measure the thickness of straightedge. Calculate the dimension "Y" by formula below. Y = Y' - "Thickness of straightedge" Dimension "Z" measurement Measure dimension (Z) of transfer case with a pair of vernier calipers and straightedge. Refer to "Measuring point". CAUTION: Never damage transfer case. Dimension "V" measurement Measure dimension (V) of ring gear shaft with a pair of vernier calipers. Refer to "Measuring point". Dimension "W" measurement Measure dimension (W) of ring gear shaft with a pair of vernier calipers. Refer to "Measuring point". Dimension "E" measurement Measure dimension (E) of ring gear shaft with a pair of vernier calipers. Refer to "Measuring point". Dimension "F" measurement Measure dimension (F) from outer race edge surface of ring gear bearing (left) to inner race edge surface with depth gauge. Refer to "Measuring point". Dimension "G" measurement Measure thickness (G) of spacer (left) with a pair of vernier calipers. Refer to "Measuring point".
2. Calculate dimension "B" by the formula below. B = Z - Y - (X x 0.5)
3. Calculate dimension "D" by the formula below. D = E - V + W
4. Check dimension (M) on the ring gear side face. NOTE: Dimension "M" indicates the difference between the optimum engagement and standard dimensions in increments of 0.01 mm (0.0004 in) written on the ring gear side face.
5. Calculate the thickness of the ring gear bearing adjusting shim (left) "T1" by the formula below. T1 = A - B + C + D - E - F - G - (M / 100) + 0.045 mm (0.0018 in) NOTE: Calculate dimension "C" as 56.0 mm (2.20 in)
6. Select ring gear bearing adjusting shim (left). For selection adjusting shim, refer to the latest parts information . CAUTION: Only one adjusting shim can be selected. Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with the calculated value is available.

Ring gear bearing adjusting shim (right)

Scheme 26

Scheme 27

1. Measure the dimensions of each measuring point with the following procedure: Dimension "X" measurement Measure the diameter (X) of transfer case with a pair of vernier calipers. Refer to "Measuring point". CAUTION: Never damage transfer case. Dimension "Y" measurement Measure dimension (Y') of transfer case (including the thickness of straightedge) with a pair of vernier calipers and straightedge. Refer to "Measuring point". CAUTION: Never damage transfer case. Measure the thickness of straightedge. Calculate the dimension "Y" by formula below. Y = Y' - "Thickness of straight" Dimension "Z" measurement Measure dimension (Z) of transfer case with a pair of vernier calipers and straightedge. Refer to "Measuring point". CAUTION: Never damage transfer case. Dimension "H" measurement Measure dimension (H) from outer race edge surface of ring gear bearing (right) to inner race edge surface with depth gauge. Refer to "Measuring point". Dimension "I" measurement Measure thickness (I) of spacer (right) with a pair of vernier calipers. Refer to "Measuring point".
2. Calculate dimension "B" by the formula below. B = Z - Y - (X x 0.5)
3. Calculate dimension "D" by the formula below. D = E - V + W
4. Check dimension (M) on the ring gear side face. NOTE: Dimension "M" indicates the difference between the optimum engagement and standard dimensions in increments of 0.01 mm (0.0004 in) written on the ring gear side face.
5. Calculate the thickness of the ring gear bearing adjusting shim (right) "T2" by the formula below. T2 = B - C - D - H - I + (M / 100) + 0.045 mm (0.0018 in) NOTE: Calculate dimension "C" as 56.0 mm (2.20 in)
6. Select ring gear bearing adjusting shim (right). For selection adjusting shim, refer to the latest parts information . CAUTION: Only one adjusting shim can be selected. Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with the calculated value is available.

Drive pinion adjusting shim

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

1. Measure the dimensions of each measuring point with the following procedure: Dimension "L" measurement Measure dimension (L) from outer race edge surface of pinion bearing (front) to inner race edge surface with depth gauge. Refer to "Measuring point". Dimension "Q" measurement Measure dimension (Q) of transfer case with depth gauge and straightedge. Refer to "Measuring point". CAUTION: Never damage transfer case. Dimension "R" measurement Measure dimension (R-) of transfer case (including the thickness of straightedge) with a pair of vernier calipers and straightedge. Refer to "Measuring point". CAUTION: Never damage transfer case. Measure the thickness of straightedge. Calculate the dimension "R" by formula below. R = R' - "Thickness of straightedge" Dimension "S" measurement Measure the diameter (S) of transfer case with a pair of vernier calipers. Refer to "Measuring point". CAUTION: Never damage transfer case.
2. Calculate dimension "J" by the formula below. J = R - Q + (S x 0.5)
3. Check dimension (O) on the gear end of drive pinion. NOTE: Dimension "O" indicates the difference between the optimum engagement and the standard dimensions in increments of 0.01 mm (0.0004 in) written on the gear end of drive pinion.
4. Calculate the thickness of the drive pinion adjusting shim "T3" by the formula below. T3 = J - K - L + (O / 100) NOTE: Calculate dimension "K" as 70.85 mm (2.7894 in)
5. Select drive pinion adjusting shim. For selection adjusting shim, refer to the latest parts information . CAUTION: Only one adjusting shim can be selected. Select the closest one, favoring thicker over thinner when necessary if no adjusting shim with the calculated value is available.

Scheme 33

1. Remove ring gear shaft assembly from the transfer case. Refer to " «DISASSEMBLY»(ref-516403-S34329499182012120600000) ".
2. Rotate the companion flange back and forth from 2 to 3 times to check for unusual noise, binding, sticking, and so on.
3. Rotate the companion flange at least 20 times to check for smooth operation of the bearing.
4. Measure the drive pinion bearing preload with the preload gauge (A) [SST: ST3127S000 (J-25765-A)]. Drive pinion bearing preload: Refer to " «PRELOAD TORQUE»(ref-516403-S30740193342012120600000) ". CAUTION: Each rotational part should rotate smoothly with the specified gear oil. If outside the standard, disassemble the drive pinion assembly to check and adjust each part.

INSPECTION AFTER DISASSEMBLY

Check items below. If necessary, replace them with new ones.

Gear and Shaft

Check gear face and shaft for wear, cracks, damage, and seizure.

Bearing

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other damage.

Shim

Check for seizure, damage, and unusual wear.

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

1. Remove transfer cover. Refer to " «DISASSEMBLY»(ref-516403-S00831843522012120600000) ".
2. Remove ring gear shaft assembly. Refer to " «DISASSEMBLY»(ref-516403-S34329499182012120600000) ".
3. Remove pinion lock nut from the drive pinion.
4. Put matching marks (A) on screw ends of drive pinion and companion flange. CAUTION: Use paint to avoid scratching the surface.
5. Remove companion flange from drive pinion with the puller (A) (Commercial service tool).
6. Remove drive pinion oil seal from the transfer case with the puller (A) [SST: KV381054S0 (J-34286)]. CAUTION: Never damage transfer case.
7. Remove drive pinion assembly (1) from transfer case while tapping the drive pinion lightly with a plastic hammer. CAUTION: Never drop the drive pinion assembly.
8. Remove collapsible spacer from the drive pinion.
9. Remove inner race of pinion bearing (rear) from transfer case.
10. Remove inner race of pinion bearing (front) from drive pinion with the replacer (A) (Commercial service tool).
11. Tap the outer race of pinion bearing (rear) from transfer case with a brass rod to remove outer race of pinion bearing (rear). CAUTION: Never damage transfer case.
12. Remove drive pinion adjusting shim.
13. Perform inspection after disassembly. Refer to " «INSPECTION»(ref-516403-S06561061922012120600000) ".

Scheme 41

Scheme 42

Scheme 43

Scheme 44

1. Select drive pinion adjusting shim. Refer to " «ADJUSTMENT»(ref-516403-S13372530722012120600000) ".
2. Install selected drive pinion adjusting shim to transfer case.
3. Install outer race of pinion bearing (rear) to the transfer case with the drift (A) [SST: ST37830000 (-)]. CAUTION: Never reuse pinion bearing. Apply gear oil to the pinion bearing.
4. Install inner race of pinion bearing (front) to drive pinion with the drift (A) [SST: ST35272000 (J-26092)]. CAUTION: Never reuse pinion bearing. Apply gear oil to the pinion bearing.
5. Assemble inner race of pinion bearing (rear) into the transfer case. CAUTION: Never reuse pinion bearing. Apply gear oil to the pinion bearing.
6. Using the drifts (A) (Commercial service tool), install drive pinion oil seal (1) to transfer case within the dimension (L) shown as follows. L: 0 - 0.6 mm (0 - 0.024 in) CAUTION: Never reuse oil seal. When installing, never incline oil seal. Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference.
7. Assemble a collapsible spacer onto the drive pinion. CAUTION: Never reuse the collapsible spacer.
8. Assemble drive pinion assembly into the transfer case, and then install companion flange to drive pinion. NOTE: Align matching marks (A) on the thread edge of drive pinion and companion flange, and install companion flange if drive pinion is reused.
9. Tap the companion flange (1) with a plastic hammer as far as the pinion lock nut can be tightened. CAUTION: Never damage drive pinion oil seal.
10. Apply anti-corrosive oil to the thread and seat of the pinion lock nut, and temporarily tighten pinion lock nut to the drive pinion. CAUTION: Never reuse pinion lock nut.
11. Tighten pinion lock nut within the specified torque range with the preload gauge (A) [SST: ST3127S000 (J-25765-A)] so that the drive pinion bearing preload is within standard. Drive pinion bearing preload: Refer to " «PRELOAD TORQUE»(ref-516403-S30740193342012120600000) ". CAUTION: Start the tightening of pinion lock nut from lower limit of the specified torque. Check the preload every 5° to 10° while tightening the pinion lock nut. Replace the collapsible spacer and tighten it again to adjust if preload exceeds the specified value. Never loosen pinion lock nut to adjust preload. After adjustment, rotate the drive pinion back and forth from 2 to 3 times to check for unusual noise, sticking, binding, and so on.
12. Install ring gear shaft assembly. Refer to " «ASSEMBLY»(ref-516403-S37446471372012120600000) ".
13. Install transfer cover to check and adjust each part. Refer to " «ASSEMBLY»(ref-516403-S05259250412012120600000) ". CAUTION: Never apply liquid gasket.
14. Check backlash, tooth contact, total preload and companion flange runout. Refer to " «ADJUSTMENT»(ref-516403-S13372530722012120600000) ". CAUTION: Measure the total preload without the transfer case oil seal.
15. Reinstall transfer cover for applying liquid gasket. Refer to " «ASSEMBLY»(ref-516403-S05259250412012120600000) ".
16. Install the transfer case oil seal (left and right). Refer to " «ASSEMBLY»(ref-516403-S05259250412012120600000) ".

Check items below. If necessary, replace them with new ones.

Gear and Shaft

Check gear face and shaft for wear, cracks, damage, and seizure.

Bearing

Check for seizure, peeling, wear, corrosion, sticking, unusual noise, roughness in hand turning, and other damage.

Shim

Check for seizure, damage, and unusual wear.

Scheme 45

Scheme 46

1. Remove transfer cover mounting bolts.
2. Lightly tap position (A) of transfer cover with a plastic hammer to remove transfer cover. CAUTION: When tapping of transfer cover, be sure to tap the back of cover.
3. Remove transfer case oil seal (right and left).
4. Remove ring gear shaft assembly. Refer to " «DISASSEMBLY»(ref-516403-S34329499182012120600000) ". NOTE: When the ring gear shaft removed, the following parts are simultaneously removed: Spacer (right and left) Ring gear bearing adjusting shim (right and left) Outer race of ring gear bearing (right and left)
5. Remove drive pinion assembly from transfer case. Refer to " «DISASSEMBLY»(ref-516403-S20979731002012120600000) ".
6. Tap the outer races of pinion bearing (front and rear) from transfer case with a brass rod to remove outer races of pinion bearing (front and rear). CAUTION: Never damage transfer case.
7. Remove drive pinion adjusting shim.
8. Remove dowel pin. CAUTION: Never remove dowel pin, if it is not necessary to replace.
9. Remove the filler plug and drain plug from the transfer case, and then remove each gasket.
10. Remove oil defense from transfer cover.
11. Perform inspection after disassembly. Refer to " «INSPECTION»(ref-516403-S06274501552012120600000) ".

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

1. Install the oil defense to transfer cover.
2. Install gaskets onto filler plug and drain plug and install them into transfer case. CAUTION: Never reuse gasket. Install filler plug after oil is filled.
3. Install the dowel pin to transfer case. CAUTION: Never reuse the dowel pin.
4. Select drive pinion adjusting shim, and install it to transfer case. Refer to " «ADJUSTMENT»(ref-516403-S13372530722012120600000) ".
5. Install outer race of pinion bearing (front) to the transfer case with the drift (A) [SST: ST37830000 (-)]. CAUTION: Never reuse pinion bearing. Apply gear oil to the pinion bearing.
6. Install outer race of pinion bearing (rear) to transfer case with the drift (A) [SST: ST33230000 (J-25805-01)]. CAUTION: Never reuse pinion bearing. Apply gear oil to the pinion bearing.
7. Install drive pinion assembly to transfer case. Refer to " «ASSEMBLY»(ref-516403-S17666658162012120600000) ".
8. Install ring gear shaft assembly to transfer case. Refer to " «ASSEMBLY»(ref-516403-S37446471372012120600000) ".
9. Set the drifts (A and B) to right and left side spacers individually. Compress ring gear shaft assembly with ring gear bearing to install transfer cover to transfer case. CAUTION: Never apply gasket fluid on the mounting surface. Clean the mounting surface of transfer case and transfer cover to degrease sufficiently. The drift shall be placed on the center of the spacers. The pressure shall be as low as to install ring gear shaft assembly into transfer case. The maximum pressure shall be 10 kN (1 ton, 1.0 Imp ton). If the adjusting shims and spacers are installed by tapping, the transfer cover may be damaged. Avoid tapping.
10. Check backlash, tooth contact, and total preload. Refer to " «ADJUSTMENT»(ref-516403-S13372530722012120600000) ". CAUTION: Measure the total preload without the transfer case oil seals.
11. Remove transfer cover. Refer to " «DISASSEMBLY»(ref-516403-S00831843522012120600000) ".
12. Apply liquid gasket (1) to mating surface of transfer cover. Use Genuine Silicone RTV or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-516389-S27688368402012120600000) ". CAUTION: Remove old gasket adhering to the mounting surfaces. Also remove any moisture, oil, or foreign material adhering to the mounting surfaces. The width of sealant bend is 2 - 3 mm (0.08 - 0.012 in). Overlap both ends of the bead for at least 3 mm (0.012 in). Immediately install transfer cover after installing applying gasket.
13. Set the drifts (A and B) to right and left side spacers individually. Compress ring gear shaft assembly with ring gear bearing to install transfer cover to transfer case. CAUTION: Immediately install after applying gasket. The drift shall be placed on the center of the spacers. The pressure shall be as low as to install ring gear shaft assembly into transfer case. The maximum pressure shall be 10 kN (1 ton, 1.0 Imp ton). If the adjusting shims and spacers are installed by tapping, the transfer cover may be damaged. Avoid tapping.
14. Tighten transfer cover mounting bolts to the specified torque.
15. Using the drifts (A and B), install transfer case oil seal (left) (1) within the dimension (L) shown as follows. L: 1.0 - 1.6 mm (0.040 - 0.063 in) CAUTION: Never reuse oil seals. When installing, never incline oil seals. Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal. Immediately install after installing transfer cover. After installing oil seal, immediately wipe out gasket squeezed out inward of transfer case.
16. Using the drifts (A) [SST: ST35271000 (J-26091)], install transfer case oil seal (right) (1) within the dimension (L) shown as follows. L: 0 - 0.6 mm (0 - 0.024 in) CAUTION: Never reuse oil seals. When installing, never incline oil seals. Apply multi-purpose grease onto oil seal lips, and gear oil onto the circumference of oil seal. Immediately install after installing transfer cover. After installing oil seal, immediately wipe out gasket squeezed out inward of transfer case.

Check items below. If necessary, replace them with new ones.

Case and Cover

Check the cracks, damages, and bearing mounting surface for wear.