Transfer Case: Testing and Inspection

INSPECTION





1. INSPECT 2WD <--> 4HI SHIFT
a. Ignition switch ON.
b. Check that the 4HI indicator lights come on when the touch select 2-4 switch is in ON position.
c. Check that the 4HI indicator lights go off when the touch select 2-4 switch is in OFF position.

HINT:
- If the light does not light up, even though the switch has been turned ON, the vehicle should be moved back and forth.
- If switching is not completed after 3 seconds of shift operation, the 4HI indicator light will flash.





2. INSPECT 4HI <--> 4LO SHIFT
a. Ignition switch ON.
b. Shift the transmission shift lever in N position.
c. Turn the touch select 2-4 switch ON.
d. Check that the 4LO indicator lights come on and the 4HI indicator lights go off when the touch select high-low switch is in ON position.
e. Check that the 4LO indicator lights go off and the 4HI indicator lights come on when the touch select high-low switch is in OFF position.

HINT:
- Inspection should be performed with the vehicle stopped, and transmission shift lever in N position.
- If switching is not completed after 3 seconds of shift operation, the 4LO indicator light will flash.





3. INSPECT TOUCH SELECT 2-4 AND HIGH-LOW SWITCH CONTINUITY
a. Remove center integration panel assembly.
b. Inspect the continuity between the each terminals.





Touch select 2-4 switch:





Touch select high-low switch:

If continuity is not as specified, replace the center integration panel assembly.





4. INSPECT ACTUATOR RESISTANCE
a. Using an ohmmeter, measure the resistance between terminals 1 and 2.
Standard resistance: 0.3 - 100 Ohms
b. Using an ohmmeter, measure the resistance between terminals 1 or 2 and body ground.
Standard resistance: More than 0.5 M Ohms
If resistance value is not as specified, replace the actuator assembly.
5. INSPECT ACTUATOR OPERATION





a. 2WD -> 4HI shift: Connect lines via a relay as shown in the illustration, then check that the actuator fork shaft moves to 2WD -> 4HI position.





b. 4HI -> 2WD shift: Connect lines via a relay as shown in the illustration, then check that the actuator fork. shaft moves to 4HI -> 2WD position.





c. 4HI -> 4LO shift: Connect lines via a relay as shown in the illustration, then check that the actuator fork shaft moves to 4HI -> 4LO position.





d. 4LO -> 4HI shift: Connect lines via a relay as shown in the illustration, then check that the actuator fork shaft moves to 4LO -> 4HI position.





HINT: When inspecting the operation described above, use a heater main relay.

NOTICE: Connect the terminals being careful not to touch the neighboring terminals or metallic parts of relay housing.








6. INSPECT LIMIT SWITCH CONTINUITY
a. Start the engine and raise the vehicle.
b. With the actuator connector connected, shift the transfer shift lever and after checking the operating sound, disconnect the connector and inspect the continuity between each terminal.

HINT: When shifting the actuator fork shaft, connect the connectors.

7. INSPECT VEHICLE SPEED SENSOR
8. INSPECT 4HI AND 4LO INDICATOR LIGHT
Check the combination meter.





9. INSPECT 4WD CONTROL ECU
Connect the wire harness side connector to the 4WD control ECU and inspect wire harness side connector from the back side, as shown.





STANDARD VALUE OF ECU TERMINAL