1. Regarding parts that should not be reused
Do not reuse the following parts.
- Packing
- Gasket
- Oil seal
- O-ring
- Lock nut
- Lock washer
2. About LOCTITE 242 (moderate strength, blue color liquid)
1) Application area
- Various bolts, connectors, and plugs
- Oil seal fixing section
2) Instructions for use
- Wipe both of the joint sections with a shop cloth, etc., and remove oil and grease.
- Apply LOCTITE to threaded portions of the bolts, connectors, or plugs.
- Tighten the bolts, connectors, or plugs to the specified torque.
3. About LOCTITE 263 (high strength, red color liquid)
1) Application area
2) Instructions for use
- Wipe the joint sections sufficiently using a cleaning agent such as brake cleaner.
- Let the cleaning agent dry naturally.
- Apply LOCTITE to the threaded portion of the bolt.
- Tighten the bolts to the specified torque.
- A strong force should not be applied for at least 1 hour.
4. About LOCTITE FMD127 (sealant, blue color liquid)
1) Instructions for use
- Wipe the joint sections sufficiently using a cleaning agent such as brake cleaner.
- Let the cleaning agent dry naturally.
- Apply LOCTITE thoroughly to the entire circumference with a bead width of 2.0 to 2.5 mm {0.08 to 0.10 in}. In this case, push out the bead directly from the tube.
- Tighten the bolts to the specified torque.
- Let it dry naturally for a minimum of 30 minutes or more.
5. About liquid gasket
LOCTITE 518 (red) and FMD-127 (blue) are liquids in paste form, and are liquid anaerobic sealants that harden at room temperature. These sealants begin to harden when the flange is bonded. After the sealants are completely hardened, they have a flexibility that responds in accordance with the displacement of the flange bonding surface generated due to vibrations, internal pressure, changes in temperature, etc.
1) Pretreatment
- Remove dust, dirt, moisture, oil, etc. that have adhered to the bonding surfaces, and dry the surfaces completely.
- When reassembling, remove any residual sealing agent on the bonding surfaces using the LOCTITE gasket remover, etc. Be careful when using only a spatula, etc. to remove, this may damage the seal surface.
2) Application and assembly
As the liquid gasket is an anaerobic sealant, it hardens only when air is shut off. However, since it begins to harden gradually upon contact with metal contact surfaces, it must be applied just before assembly.
- Press the tip of the nozzle against the cover mounting surface of the gear case and apply it in the form of bead with a diameter of approximately 1 to 3 mm {0.04 to 0.12 in} thoroughly to the entire circumference.
- After the bead application, thoroughly spread the liquid gasket across the entire circumference of the seal surface with your fingers, etc., and then tighten it to the specified torque.
3) Starting operation
After assembly, wait for 20 minutes or more before conducting the air check and motoring.
It takes 1 to 3 hours until practical hardness is attained.
6. Precautions when applying LOCTITE and liquid gasket
Caution
- Be careful not to let foreign matters such as dust and chips adhere to the tip of the nozzle.
- Be careful not to let foreign matters adhere to the seal surface.
- If the nozzle is clogged, unclog it using a wire, etc.
- When applying, do not use a hardening accelerator at the same time, as this may cause clogging of the nozzle.
- LOCTITE 518 and FMD-127 harden by using metal as a catalyst, so use a container made of polyethylene when storing those that have been squeezed out of the tubes.
- LOCTITE 518 and FMD-127 should not be refilled back into their tubes.
- When applying the gasket to the transfer, wipe off the liquid gasket that protrudes from the gasket surface, as a paint cannot be applied until the gasket gets hardened.
- When washing cases, a water-soluble alkaline detergent may be used occasionally. This may form a coating of water-soluble alkaline detergent on the seal surface, resulting in interference with hardening of the anaerobic sealant. Therefore, use a degreasing agent, etc. for complete removal of the coating.
7. Using circuit test tools
Unless instructed in the diagnostic procedure, do not use a test lamp. When a probe connector is required in the diagnostic procedure, use connector test adapter kit 5-8840-2835-0.
8. Commercial electronic equipment
Aftermarket electronic equipment refers to commercially available electronic equipment installed to the vehicle after it has been shipped from the factory. Be careful, as such accessories are not taken into particular consideration at the vehicle design stage.
Aftermarket electronic equipment may cause malfunctions in the electronic control system, even if the equipment is usually installed. Aftermarket electronic equipment includes devices not connected to the electrical system of the vehicle, such as mobile phones or radios.
Therefore when diagnosing electronic system problems, first confirm whether such aftermarket electronic equipment is installed, and remove it from the vehicle.
If the problem has not been resolved after removing the equipment, perform the diagnosis using the regular procedure.
Caution
- Make sure that both the power supply and ground of aftermarket electronic equipment are connected to a circuit that is not related to the circuits of the electronic control system.
9. Damage caused by electrostatic discharge
Because the electronic components used in the electronic control system are designed to operate at extremely low voltages, they can be easily damaged by electrostatic discharge, and some types of electronic components can be damaged by static electricity of 100 V or less, which cannot be felt by a person. A voltage of 4,000 V is required for a person to be able to detect an electrostatic discharge.
There are various ways a person can build up an electrostatic charge. The most common way to build up an electrostatic charge is through friction or induction.
An example of when a person builds an electrostatic charge by friction is when they slide across the seat of the vehicle.
A person wearing insulated shoes can build an electrostatic charge by induction if they momentarily touch the ground while standing near a highly charged object. A charge of the same polarity flows out, and with a highly opposing polarity, that person becomes charged. Because static electricity can be damaging, be careful when handling or testing electronic components.
Caution
- To prevent damage caused by electrostatic discharge, do not touch the connector pins of the control unit or the electronic components soldered onto the circuit board of the control unit.
- To prevent damage caused by electrostatic discharges, do not open the packaging of a replacement part until preparations for installation of the replacement part are completed.
- To prevent damage caused by electrostatic discharge, connect the package to a properly working vehicle ground before removing the part from the package.
- To prevent damage caused by electrostatic discharge, touch a properly working ground before installing the part when handling it while sliding across the seat, while sitting down from a standing position, or while walking a certain distance.
10. Control unit maintenance precautions
The control unit is designed to withstand the regular current load associated with vehicle operation. Take care to prevent the circuit from overloading. When testing for an open circuit and short circuit, do not ground or apply voltage to the control unit circuit unless instructed to do so. When performing these circuit tests, make sure to use a DMM (5-8840-0285-3) with a large input impedance.
Even when it is clear that there is a failure in the control unit, make sure to verify that there are no abnormal conditions outside of the control unit before replacing it. Failure to do so, for example in cases where the control unit is damaged due to a short circuit in the output circuit, will lead to the new control unit also being damaged.
11. Description of diagnosis
The transfer control failure symptoms are divided into symptoms that can be detected by the DTCs via illumination of the check 4WD warning light, and symptoms that the driver can detect as vehicle problems.
Continue the diagnosis in accordance with the diagnostic system check-transfer case controls.
12. About self-diagnosis
The TCCM has a self-diagnosis function and performs the check operation at the time of system start-up to determine the presence of system malfunctions and failed sections. If a malfunction is detected, the check 4WD warning light is illuminated and the DTC is stored.
Caution
- The illuminated warning lights turn OFF every time the ignition switch is turned OFF but the DTCs continue to be stored unless the clearing procedure is performed. While driving or for intermittent failures etc., even when the ignition switch is turned from OFF to ON, the control unit determines if the systems are normal at that point, and because the normal illumination pattern may displayed, inspect and repair following the trouble diagnostic flow.