Component Tests and General Diagnostics

INSPECTION





1. INSPECT A.D.D. ACTUATOR
a. Disconnect the actuator connector.
b. Measure the resistance between the terminals 2 and 6.
Standard resistance: 0.3-100 Ohms
c. Measure the resistance between the terminals 2 or 6 and body ground.
Standard resistance: More than 0.5 M Ohms
If the resistance value is not as specified, replace the actuator assembly.





2. INSPECT A.D.D. ACTUATOR OPERATION
Apply battery positive voltage between the terminal 2 or 6, and check the actuator operation by sound, A.D.D. status and continuity between the terminal 3 and 4.
If the operation is not as specified, replace the actuator assembly.
3. INSPECT LIMIT SWITCH CONTINUITY
a. Connect the actuator connector.





b. Shift the transfer shift lever or switch the transfer operation switch to "H2" position.
c. Check the A.D.D. actuator operation by sound.
d. Disconnect the actuator connector.





e. Check the continuity between each terminal, as shown in the chart.
f. Connect the actuator connector.





g. Shift the transfer shift lever or switch the transfer operation switch to "H4" position.
h. Check the A.D.D. actuator operation by sound.
i. Disconnect the actuator connector.





j. Check the continuity between each terminal, as shown in the chart.
k. Connect the actuator connector.

4. INSPECT A.D.D. RELAY








a. Check the continuity between each terminal, as shown in the chart.





b. Apply battery positive voltage between each terminal and check the continuity between each terminal, as shown in the chart.
If continuity is not as specified, replace the relay.
5. INSPECT TRANSFER 4WD POSITION SWITCH
6. REMOVE A.D.D. ACTUATOR





7. INSPECT CLUTCH HUB AND CLUTCH SLEEVE
a. Check the clutch hub and clutch sleeve for wear and damage.
If necessary, replace them.
b. Check that clutch sleeve slides smoothly on the clutch hub.





8. MEASURE SLEEVE FORK AND CLUTCH SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve.
Maximum clearance: 0.35 mm (0.0138 inch)
If the clearance exceeds the maximum, replace the fork or sleeve.