Rear Differential Fluid Pressure Sensor Test

Rear Differential Fluid Pressure Sensor Test (KA, KC Models AWD)













Removal

1. Vehicle Lift

1. Raise the vehicle on a lift, and make sure it is securely supported.

2. Rear Differential Sensor Cover





1. Remove the rear differential sensor cover (A).

3. Rear Differential Fluid Pressure Sensor Connector





1. Disconnect the connector (A).

4. Rear Differential Fluid Pressure Sensor





1. Remove the rear differential fluid pressure sensor (A) and the O-ring (B).

Test

NOTE: Check that the real time AWD indicator does not come on. If it does, check for real time AWD system DTC's.

1. HDS DLC - Connection





1. Connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard.

2. Turn the ignition switch to ON (II).

3. Make sure the HDS communicates with the vehicle. If it does not communicate, go to the DLC circuit troubleshooting.

2. Rear Differential Fluid Pressure Sensor - Test





1. Turn the ignition switch to LOCK (0).

2. Reconnect the rear differential fluid pressure sensor connector (A) to the rear differential pressure sensor (B).

3. Turn the ignition switch to ON (II).

4. Select the DATA LIST in the REAL TIME AWD SYSTEM with the HDS.

5. Check the ACTUAL OIL PRESSURE OF THE OIL PRESSURE SENSOR FOR REAR DIFFERENTIAL in the DATA LIST with the HDS.

* If the fluid pressure is higher than 0-77 kPa (0.0-0.8 kgf/cm2 , 0-11 psi), replace the rear differential fluid pressure sensor.
* If the fluid pressure is within the range of 0-77 kPa (0.0-0.8 kgf/cm2, 0-11 psi), go to step 6.

6. Turn the ignition switch to LOCK (0).





7. Attach the A/T pressure test hose, the A/T pressure adapter, the pressure gauge adapter, and the oil pressure hose as shown, then attach the rear differential fluid pressure sensor (A) to the pressure gauge adapter (B).

8. Place the end of the A/T pressure test hose into a drain pan (C).

9. Start the engine, the real time AWD pump will do a brief low pressure purge of the system, this will cause air and fluid to flow out of the test hose.

10. Turn the ignition switch to LOCK (0).

11. Repeat step 9 again to assure the A/T pressure test hose is full of fluid without air bubbles

12. Turn the ignition switch to LOCK (0).





13. Attach the A/T low pressure gauge w/panel (A) onto the end of the A/T pressure test hose (B).

14. Turn the ignition switch to ON (II).

15. Select the ADJUSTMENT in the REAL TIME AWD SYSTEM with the HDS.

16. Select the AIR BLEEDING in the ADJUSTMENT with the HDS.

NOTE: See the HDS Help menu for specific instructions.

17. Select the FUNCTIONAL TEST in the REAL TIME AWD SYSTEM with the HDS.

18. Select the SOLENOID TEST in the FUNCTIONAL TEST with the HDS.

19. Do LEVEL 7 of the SOLENOID TEST with the HDS.

20. Check the differential fluid pressure value of the pressure gauge.

* If the fluid pressure is not within the range of 280-560 kPa (2.86-5.71 kgf/cm2 , 40.6-81.2 psi), replace the rear differential pump motor.
* If the fluid pressure is within the range of 280-560 kPa (2.86-5.71 kgf/cm2 , 40.6-81.2 psi), go to step 21.

21. Check the ACTUAL OIL PRESSURE OF THE OIL PRESSURE SENSOR FOR REAR DIFFERENTIAL in the DATA LIST with the HDS.

* If the fluid pressure is not within the range of 280-560 kPa (2.86-5.71 kgf/cm2 , 40.6-81.2 psi), replace the rear differential fluid pressure sensor.
* If the fluid pressure is within the range of 280-560 kPa (2.86-5.71 kgf/cm2 , 40.6-81.2 psi), differential fluid pressure sensor is OK, and the test is complete.

Installation

1. Rear Differential Fluid Pressure Sensor





1. Install the rear differential fluid pressure sensor (A) with a new O-ring (B).

2. Rear Differential Fluid Pressure Sensor Connector





1. Connect the connector (A).

3. Rear Differential Sensor Cover





1. Install the rear differential sensor cover (A).

2. Connect the breather hoses (B) to the clamps (C).

4. Rear Differential Fluid - Inspection





1. Use solvent and a brush to wash any oil and dirt off the oil filler plug, and dry them with compressed air.

2. Remove the oil filler plug (A) and the sealing washer (B).

3. Check the condition of the rear differential fluid, if the fluid is dirty or burnt, replace it.

4. Make sure the rear differential fluid is at the proper level (C).

* If the level is below the proper level, check for rear differential fluid leaks at the differential.
* If a problem is found, fix it before filling the differential with fluid.

5. The fluid level must reach up to the bottom of the oil filler plug hole.

6. If necessary, add the rear differential fluid until it runs out, then reinstall the oil filler plug with a new sealing washer.

5. Rear Differential Fluid After Replacement - Check (Real Time AWD System)

1. Apply the parking brake, and block all four wheels.

2. Start the engine, and let it idle more than 6 seconds, then turn the engine off. Repeat this step three more times.

3. Shift to D while pressing the brake pedal firmly. Press the accelerator pedal for 2 seconds, then let it idle. Repeat this three more times.

4. Check that the real time AWD indicator does not come on. If it does, check for real time AWD system DTC's.

6. Maintenance Minder Reset

1. Reset the Maintenance Minder. Description and Operation