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Toyota LAND CRUISER, Service Manual Supplement

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Toyota LAND CRUISER Service Manual Supplement Download Page 220

SA-6

SUSPENSION AND AXLE (STATION WAGON) - FRONT DIFFERENTIAL

FRONT DIFFERENTIAL

ASSEMBLY REMOVAL AND

INSTALLATION

COMPONENTS

Summary of Contents for LAND CRUISER

Page 1: ......

Page 2: ...air and service When performing the operations following the procedures using this manual be sure to use tools spe cified and recommended If using non specified or recommended tools and service method be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer s vehicle before starting the operation If part replacement is necessary must rep...

Page 3: ...For the service specifications and repair procedures of the above model other than those listed in this supplement refer to the following manuals 2004 TOYOTA MOTOR CORPORATION A i n f o r m a t j o n in t h i s m a n u a is b a s e d on the latest product in All rights reserved This book may not be formation at the time of publication However specifications reproduced or copied in whole or in part...

Page 4: ...INTRODUCTION CLUTCH MANUAL TRANSMISSION AUTOMATIC TRANSMISSION TRANSFER PROPELLER SHAFT SUSPENSION AND AXLE BRAKE SYSTEM BODY ELECTRICAL SYSTEM AIR CONDITIONING SYSTEM ELECTRICAL WIRING DIAGRAMS ...

Page 5: ...DENTIFICATION INFORMATION IN 5 GENERAL REPAIR INSTRUCTIONS IN 6 PRECAUTION IN 9 VEHICLE LIFT AND SUPPORT LOCATIONS IN 16 Hardtop Canvas Top IN 16 Station Wagon IN 18 ABBREVIATIONS USED IN THIS MANUAL IN 1 9 STANDARD BOLT TORQUE SPECIFICATIONS IN 20 ...

Page 6: ...ting any repair task TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause PREPARATION Preparation lists the SST Special Service Tools recommended tools equipment lubricant and SSM Special Service Materials which should be prepared before beginning the operation and explains the purpose of each one REPAIR PROCEDURES Most repair oper...

Page 7: ...T TRACK to the information needed The upper case task heading can be read at a glance when necessary and the text below it provides detailed information Important specifications and warnings always stand out in bold type REFERENCES References have been kept to a minimum However when they are required you are given the page to refer to SPECIFICATIONS Specifications are presented in bold type throug...

Page 8: ...m Example Torque 30 Nm 310 kgf cm 22 ftlbf CAUTIONS NOTICES HINTS CAUTIONS are presented in bold type and indicate there is a possibility of injury to you or other people NOTICES are also presented in bold type and indicate the possibility of damage to the components being repaired HINTS are separated from the text but do not appear in bold They provide additional information to help you perform t...

Page 9: ...ehicle identification number is stamped on the outer sur face of the front right side frame This number is also stamped on the manufacturer s name plate A Vehicle Identification Number B Manufacturer s Name Plate ENGINE SERIAL NUMBER The engine serial number is stamped on the right side of the cylinder block ...

Page 10: ...t d Clean the battery terminal posts and cable ter minals with a clean shop rag Do not scrape them with a file or other abrasive objects e Install the cable terminal to the battery post with the nut loose and tighten the nut after installa tion Do not use a hammer to tap the terminal onto the post f Be sure the cover for the positive terminal is properly in place 4 Check hose and wiring connectors...

Page 11: ... torque wrench 9 Use of special service tools SST and special service materials SSM may be required depending on the nature of the repair Be sure to use SST and SSM where specified and follow the proper work proce dure A list of SST and SSM can be found in the preparation part at the front of each section in this manual 10 When replacing fuses be sure the new fuse has the correct amperage rating D...

Page 12: ...t the middle of the hose c To pull apart electrical connectors pull on the connector itself not the wires d Be careful not to drop electrical components such as sensors or relays If they are dropped on a hard floor they should be replaced and not reused e When steam cleaning an engine protect the distributor air filter and VCV from water f Never use an impact wrench to remove or install temperatur...

Page 13: ...with ignition turned off and prolonged braking 7 Do not dispose of used catalyst along with parts contaminated with gasoline or oil FOR VEHICLES WITH AN AUDIO SYSTEM WITH BUILT IN ANTI THEFT SYSTEM Audio System displaying the sign ANTI THEFT SYSTEM shown on the left has a built in anti theft system which makes the audio system soundless if stolen If the power source for the audio system is cut eve...

Page 14: ...ial mode position FREE or LOCK 3 Whether wheels should be touching ground or jacked up 4 Transmission gear position 5 Transfer gear position H or L 6 Maximum testing vehicle speed 7 Maximum testing time Also be sure to observe the following cautions 1 Never accelerate or decelerate the vehicle sud denly 2 Observe the other cautions given for each indi vidual test Before Beginning Test During tests...

Page 15: ...e In other ranges the gears of the transfer clash and swi tching cannot occur w o ABS CAUTIONS WHEN CENTER DIFFERENTIAL CON TROL SWITCH IS TURNED ON Operate the switch only when all four wheels are stopped or when driving with the wheels in a straight line Never operate the switch under the following conditions 1 When any tire is slipping 2 When any tire is spinning freely 3 When swerving or corne...

Page 16: ...elect lever to H position w o ABS Turn the center differential lock switch to OFF and check that the center differential lock indi cator light goes off 2 Shift the transmission shift lever to N range 3 Idle the engine operate the brake booster and perform the test Center Differential Lock Transfer Select Lever Wheel Control Switch Indicator Light ON OFF ON ON H L A lifted wheel cannot be ro tated ...

Page 17: ...perform the test 3 When performing tests observe the following precautions w o ABS Check that the center differential is securely in LOCK condition Confirm that the vehicle is securely immobilised Never operate the brakes suddenly suddenly drive the wheels or suddenly decelerate On Vehicle Wheel Balancing When doing on vehicle wheel balancing on a full time 4WD vehicle to prevent the wheels from r...

Page 18: ...e transfer select lever to H position 4 The parking brake lever should be fully released 5 None of the brakes should be allowed to drag 6 The wheels should be driven with both the engine and the wheel balancer HINT When doing this be careful of the other wheels which will rotate at the same time 7 Avoid sudden acceleration deceleration and bra king 8 Carry out the wheel balancing with the transmis...

Page 19: ...ion Parking Brake Transmission Shift Lever Position Transfer Shift Lever Position w o ABS Center Differential Lock Switch Center Differential FREE Normal Driving OFF H Position Applied P Range Released N Range N Position OFF OFF N Position N Range Released Towing with Rope Sling Type Tow Truck Front wheels must be able to rotate freely Sling Type Tow Truck with Dollies Flat Bed Truck HINT Do not t...

Page 20: ...IN 16 INTRODUCTION VEHICLE LIFT AND SUPPORT LOCATIONS Hardtop Canvas Top VEHICLE LIFT AND SUPPORT LOCATIONS Hardtop Canvas Top ...

Page 21: ...INTRODUCTION VEHICLE LIFT AND SUPPORT LOCATIONS Hardtop Canvas Top IN 17 ...

Page 22: ...IIM 18 INTRODUCTION VEHICLE LIFT AND SUPPORT LOCATIONS Station Wagon VEHICLE LIFT AND SUPPORT LOCATIONS Station Wagon ...

Page 23: ...med on Place Gasket FL Fusible Link IG Ignition LED Light Emitting Diode LH Left Hand LHD Left Hand Drive LSD Limited Slip Differential M T Manual Transmission MP Multipurpose PTO Power Take Off RH Right Hand RHD Right Hand Drive SSM Special Service Materials SST Special Service Tools STD Standard SW Switch VSV Vacuum Switching Valve w With w o Without 2WD Two Wheel Drive Vehicles 4 x 2 4WD Four W...

Page 24: ...IN 20 INTRODUCTION STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS HOW TO DETERMINE BOLT STRENGTH ...

Page 25: ...INTRODUCTION STANDARD BOLT TORQUE SPECIFICATIONS IN 21 SPECIFIED TORQUE FOR STANDARD BOLTS ...

Page 26: ...ly the points which differ from the above listed manuals STATION WAGON CLUTCH MASTER CYLINDER CL 2 Manual Name Pub No Land Cruiser Station Wagon Chassis and Body Repair Manual Land Cruiser Hardtop Can vas Top and Station Wagon Chassis and Body Repair Manual Supplement RM184E RM290E ...

Page 27: ...ring Clutch Accumulator Slotted Spring Pin Reservoir Tank Float Specified torque Non reusable part CLUTCH MASTER CYLINDER REMOVAL REMOVE MASTER CYLINDER a Draw out fluid with syringe b Using SST disconnect the clutch tube SST 09023 00100 c Remove the clip clevis pin and return spring d Remove the nut from the room side e Remove the nut from the engine room side f Pull out the master cylinder SST ...

Page 28: ...NT Clean the disassembled parts with compressed air 1 INSPECT MASTER CYLINDER BORE FOR SCORING OR CORROSION If a problem is found clean or replace the cylinder 2 INSPECT PISTON AND CUPS FOR WEAR SCORING CRACKS OR SWELLING If either one requires replacement use the parts from the cylinder kit 3 INSPECT PUSH ROD FOR WEAR OR DAMAGE If necessary replace the push rod MASTER CYLINDER ASSEMBLY 1 COAT PAR...

Page 29: ...mer drive in the slotted spr ing pin MASTER CYLINDER INSTALLATION 1 INSTALL MASTER CYLINDER Install the mounting nut and torque them Torque 7 8 Nm 80 kgfcm 69 in Ib 2 CONNECT CLUTCH LINE UNION Using SST connect the union SST 09023 00100 3 CONNECT PUSH ROD AND INSTALL PIN Install the clip in the push rod pin 4 BLEED SYSTEM AND ADJUST CLUTCH PEDAL ...

Page 30: ...y the points which differ from the above listed manu als HARDTOP CANVAS TOP DESCRIPTION MT 2 PREPARATION MT 3 TRANSMISSION REMOVAL AND INSTALLATION MT 4 OUTPUTSHAFT MT 13 SERVICE SPECIFICATIONS MT 24 STATION WAGON DESCRIPTION MT 26 PREPARATION MT 27 OUTPUTSHAFT MT 28 SERVICE SPECIFICATIONS MT 40 ...

Page 31: ...ong the sealing surface Parts must be assembled within 10 minutes of application Otherwise the sealant FIPG material must be removed and reapplied DESCRIPTION Transmission type H150F and H151F are constant mesh synchronizers for forward gears and a sliding mesh reverse gear A triple cone type synchromesh mechanism is used in the second gear to improve the shift feeling characteristics This helps t...

Page 32: ...NVAS TOP PREPARATION MT 3 PREPARATION SST SPECIAL SERVICE TOOLS Transmission Transfer Bearing Replacer Replacer Pipe Rear Axle Hub Guide Tool Differential Drive Pinion Bearing Replacer Output shaft rear ball bearing Bearing Remover ...

Page 33: ...L AND INSTALLATION COMPONENTS Shift Lever Knob Shift Lever Knob Shift Lever boot Release Cylinder Transfer Shift Lever Shift Lever boot Transmission Shift Lever Rear Propeller Shaft Washer Tank Bracket Front Propeller Shaft Starter Transmission with Transfer Engine Rear Mounting Crossmember Under Cover ...

Page 34: ...hift lever cap rotate it countercrockwise to remove f Remove the shift lever 3 REMOVE TRANSFER SHIFT LEVER a Remove the transfer shift lever knob b Remove the four screws and remove the boot c Remove the nut and washer and the link d Remove the three bolts and the transfer shift lever 4 LOOSEN FAN SHROUD OF COOLING FAN TO AVOID DAMAGE TO FAN 5 RAISE VEHICLE AND DRAIN TRANSMISSION OIL NOTICE Be sur...

Page 35: ...e the propeller shaft 9 REMOVE SPEEDOMETER CABLE Using pliers remove the speedometer cable 10 DISCONNECT BACK UP LIGHT SWITCH CONNECTOR 11 REMOVE CLUTCH RELEASE CYLINDER Remove the two bolts and release cylinder 12 REMOVE STARTER a Disconnect the connector and wire from the starter b Remove the two bolts and starter 13 REMOVE FRONT EXHAUST PIPE a Disconnect the oxygen sensor connector b Remove the...

Page 36: ...ABILIZER BRAKET SET BOLTS Remove four stabilizer bracket set bolts 15 SUPPORT TRANSMISSION Remove the transmission enough to remove the weight from the rear support 16 REMOVE CROSSMEMBER a Raise the transmission slightly with a jack b Remove the eight bolts two nuts and crossmember 17 REMOVE TRANSMISSION a Remove the transmission mounting bolts from the en gine b Pull out the transmission down and...

Page 37: ...Remove the four bolts and engine rear mounting from the transmission 19 REMOVE TRANSFER FROM TRANSMISSION a Remove the transfer adaptor rear mounting bolts b Pull the transfer straight up and remove it from the trans mission HINT Take care not to damage the adaptor rear oil seal with the transfer input gear spline ...

Page 38: ...orque 37 N m 380 kgf cm 27 ft lbf 2 INSTALL ENGINE REAR MOUNTING Install the engine rear mounting and torque the four bolts Torque 59 N m 600 kgf cm 43 ft lbf 3 INSTALL TRANSMISSION TO ENGINE a Align the input shaft spline with the clutch disc and in stall the transmission to the engine b Install and torque the ten bolts Torque 72 N m 730 kgf cm 53 ft lbf 4 INSTALL CROSSMEMBER a Raise the transmis...

Page 39: ...clutch housing Torque 39 Nm 400 kgfcm 29 ftlbf b Install the exhaust pipe clamp Torque 19 Nm 195 kgfcm 14 ftlbf c Install a new gasket bracket and torque the two bolts Torque 39 Nm 400 kgfcm 29 ftlbf d Connect the oxygen sensor connector 7 INSTALL STARTER a Install the starter with two bolts Torque 39 Nm 400 kgfcm 29 ftlbf b Connect the connector and wire to the starter 8 INSTALL CLUTCH RELEASE CY...

Page 40: ...s b Torque the nuts Torque Front Propeller Shaft 74 Nm 750 kgf cm 54 ft lb Rear Propeller Shaft 88 Nm 900 kgfcm 65 ft lb HINT When installing the washers put them properly in place 12 CONNECT PROPELLER SHAFT FLANGE ON DIFFEREN TIAL a Align the matchmarks on the flanges and connect the flanges with four bolts and nuts b Torque the bolts and nuts Torque Front Propeller Shaft 74 Nm 750 kgfcm 54 ft lb...

Page 41: ... the three bolts c Install the boot and four screws d Install the transfer shift lever knob 17 INSTALL TRANSMISSION SHIFT LEVER a Apply MP grease to the transmission shift lever b Align the groove of the shift lever cap and the pin part of the case cover c Cover the shift lever cap with a cloth d Then pressing down on the shift lever cap rotate it clockwise to install e Install the shift lever boo...

Page 42: ...MANUAL TRANSMISSION HARDTOP CANVAS TOP OUTPUT SHAFT MT 13 OUTPUT SHAFT COMPONENTS ...

Page 43: ... GEAR OIL CLEARANCE Using a dial indicator measure the oil clearance of each gear Standard clearance 1st and 3rd gear 0 020 0 073 mm 0 0008 0 0029 in 2nd and 5th gear 0 015 0 068 mm 0 0006 0 0027 in Maximum clearance 1st and 3rd gear 0 073 mm 0 0029 in 2nd and 5th gear 0 068 mm 0 0027 in 3 REMOVE BALL BEARING AND FIRST GEAR a Using two screwdrivers and a hammer drive out the snap ring b Remove the...

Page 44: ...ve No 1 assembly synchronizer rings and second gear c Remove the needle roller bearing 5 REMOVE HUB SLEEVE NO 1 SHIFTING KEYS AND SPRING FROM CLUTCH HUB NO 1 Using a screwdriver remove the three shifting keys and two springs from the clutch hub No 1 6 REMOVE HUB SLEEVE NO 2 ASSEMBLY SYNCHRO NIZER RINGS THIRD GEAR AND NEEDLE ROLLER BEAR ING a Remove two screwdrivers and a hammer drive out the snap ...

Page 45: ...hree shifting keys and two springs from the clutch hub No 2 8 REMOVE HUB SLEEVE NO 3 ASSEMBLY SYNCHRO NIZER RING FIFTH GEAR AND NEEDLE ROLLER BEAR ING a Using two screwdriver and a hammer drive out the snap ring b Using SST and a press remove the hub sleeve No 3 as sembly and synchronizer ring SST 09950 00020 c Remove the needle roller bearing 9 REMOVE HUB SLEEVE NO 3 SHIFTING KEYS AND SPRINGS FRO...

Page 46: ...ter 1st 49 979 mm 1 9677 in 2nd 57 984 mm 2 2828 in 3rd 37 979 mm 1 4952 in 5rh 45 984 mm 1 8104 in If the outer diameter is less than the minimum replace the output shaft OUTPUT SHAFT COMPONENT PARTS INSPECTION 1 INSPECT SYNCHRONIZER RINGS FOR 1st AND 3rd GEAR a Check for wear or damage b Check the braking effect of the synchronizer ring Turn the synchronizer ring in one direction while pushing i...

Page 47: ...E Wash off completely the fine lapping com pound after rubbing 2 INSPECT SYNCHRONIZER RING FOR 2nd GEAR a Check for wear or damage b Check the braking effect of the synchronizer direction while pushing it to the gear cone and check that the ring is locked If the braking effect is insufficient replace the synchronizer ring c Measure the clearance between the synchronizer ring back and gear spline e...

Page 48: ...oned so that their end gaps are not in line 2 INSTALL FIFTH GEAR AND HUB SLEEVE NO 3 ASSEM BLY ON OUTPUT SHAFT a Apply gear oil to the shaft and needle roller bearing b Place the synchronizer ring on the gear and align the ring slots with the shifting keys c Install the needle roller bearing in the fifth gear d Using SST and a press install the fifth gear and hub sleeve No 3 SST 09316 60010 09316 ...

Page 49: ...mm 0 0039 0 0138 in 5 INSTALL THIRD GEAR AND HUB SLEEVE NO 2 ASSEM BLY a Apply gear oil to the shaft and needle roller bearing b Place the synchronizer ring on the gear and align the ring slots with the shifting keys c Install the needle roller bearing in the third gear d Using SST and a press install the third gear and hub sleeve No 2 SST 09316 60010 09316 00010 6 INSTALL SNAP RING a Select a sna...

Page 50: ...r ance Standard clearance 0 1 0 45 mm 0 0039 0 0138 in 8 INSTALL SECOND GEAR AND HUB SLEEVE NO 1 AS SEMBLY a Place the synchronizer rings on the 2nd gear b Apply gear oil to the shaft and needle roller bearing c Install the needle roller bearing in the second gear d Using a press install the second gear and hub sleeve No 1 assembly 9 INSTALL SNAP RING a Select a snap ring that will allow minimum a...

Page 51: ...Standard clearance 0 1 0 35 mm 0 0039 0 0138 in 11 INSTALL FIRST GEAR a Apply gear oil to the shaft and needle roller bearing b Place the synchronizer ring on the gear and align the ring slots with the shifting keys c Install the needle roller bearing in the first gear 12 INSTALL BALL BEARING a Install the pin and thrust washer b Using SST and a press install the ball bearing SST 09316 60010 09316...

Page 52: ...TRANSMISSION HARDTOP CANVAS TOP OUTPUT SHAFT c Install the pin and thrust washer 13 INSTALL SNAP RING a Select a snap ring that will allow minimum axial play b Using a brass bar and a hammer drive in a new snap ring ...

Page 53: ...MT 24 MANUAL TRANSMISSION HARDTOP CANVAS TOP SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA ...

Page 54: ...MT 25 MANUAL TRANSMISSION HARDTOP CANVAS TOP SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS ...

Page 55: ... material must be removed and reapplied DESCRIPTION Transmission type H150F and H151F are constant mesh synchronizers for forward gears and a sliding mesh reverse gear H1 50F A triple cone type synchromesh mechanism is used in the second gear to improve the shift feeling characteristics This helps to reduce the shifting effort provide smoothly shifting H1 51F A triple cone type synchromesh mechani...

Page 56: ...ATION SST SPECIAL SERVICE TOOLS Transmission Transfer Bearing Replacer Replacer Pipe Rear Axle Hub Guide Tool Differential Drive Pinion Bearing Replacer Bearing Remover Output shaft rear ball bearing 09316 60010 09316 00010 09523 36010 09555 55010 09950 00020 ...

Page 57: ...MT 28 MANUAL TRANSMISSION STATION WAGON OUTPUT SHAFT OUTPUT SHAFT COMPONENTS ...

Page 58: ...MANUAL TRANSMISSION STATION WAGON OUTPUT SHAFT MT 29 ...

Page 59: ...ndicator measure the oil clearance of each gear Standard clearance 1st and 3rd gear 0 020 0 073 mm 0 0008 0 0029 in 2nd and 5th gear 0 015 0 068 mm 0 0006 0 0027 in Maximum clearance 1st and 3rd gear 0 073 mm 0 0029 in 2nd and 5th gear 0 068 mm 0 0027 in 3 REMOVE BALL BEARING AND FIRST GEAR a Using two screwdrivers and a hammer drive out the snap ring b Remove the thrust washer and pin c Using SST...

Page 60: ...No 1 assembly synchronizer rings and second gear c Remove the needle roller bearing 5 REMOVE HUB SLEEVE NO 1 SHIFTING KEYS AND SPRINGS FROM CLUTCH HUB NO 1 Using a screwdriver remove the three shifting keys and two springs from the clutch hub No 1 6 REMOVE HUB SLEEVE NO 2 ASSEMBLY SYNCHRO NIZER RING THIRD GEAR AND NEEDLE ROLLER BEAR ING a Remove two screwdrivers and a hammer drive out the snap rin...

Page 61: ...ng a screwdriver remove the three shifting keys and two springs from the clutch hub No 2 8 REMOVE HUB SLEEVE NO 3 ASSEMBLY SYNCHRO NIZER RING FIFTH GEAR AND NEEDLE ROLLER BEAR ING a Using two screwdriver and a hammer drive out the snap ring b Using SST and a press remove the hub sleeve No 3 as sembly and synchronizer ring SST 09950 00020 c Remove the needle roller bearing 9 REMOVE HUB SLEEVE NO 3 ...

Page 62: ...r 1st 49 979 mm 1 9677 in 2nd 57 984 mm 2 2828 in 3rd 37 979 mm 1 4952 in 5th 45 984 mm 1 8104 in If the outer diameter is less than the minimum replace the output shaft 2 INSPECT SYNCHRONIZER RINGS H150F FOR FIRST THIRD AND FIFTH GEARS H151F FOR FIFTH GEARS a Check for wear or damage b Check the braking effect of the synchronizer ring Turn the synchronizer ring in one direction while pushing it t...

Page 63: ...nd after rubbing 3 INSPECT SYNCHRONIZER RING H150F FOR SECOND GEARS H1 51F FOR FIRST SECOND AND THIRD GEARS a Check for wear or damage b Check the braking effect of the synchronizer direction while pushing it to the gear cone and check that the ring is locked If the braking effect is insufficient replace the synchronizer ring c Measure the clearance between the synchronizer ring back and gear spli...

Page 64: ...ed so that their end gaps are not in line 2 INSTALL FIFTH GEAR AND HUB SLEEVE NO 3 ASSEM BLY ON OUTPUT SHAFT a Apply gear oil to the shaft and needle roller bearing b Place the synchronizer ring on the gear and align the ring slots with the shifting keys c Install the needle roller bearing in the fifth gear d Using SST and a press install the fifth gear and hub sleeve No 3 SST 09316 60010 09316 00...

Page 65: ... 0 35 mm 0 0039 0 0138 in 5 INSTALL THIRD GEAR AND HUB SLEEVE NO 2 ASSEM BLY H151F a Place the synchronizer rings on the 3rd gear b Apply gear oil to the shaft and needle roller bearing H150F c Place the synchronizer ring on the gear and align the ring slots with the shifting keys d Install the needle roller bearing in the third gear e Using SST and a press install the third gear and hub sleeve No...

Page 66: ...ar thrust clear ance Standard clearance 0 1 0 45 mm 0 0039 0 0138 in 8 INSTALL SECOND GEAR AND HUB SLEEVE NO 1 AS SEMBLY a Apply gear oil to the shaft and needle roller bearing b Place the synchronizer rings on the gear and align the ring slots with the shifting keys c Install the needle roller bearing in the second gear d Using a press install the second gear and hub sleeve No 1 assembly 9 INSTAL...

Page 67: ...st clearance Standard clearance 0 1 0 35 mm 0 0039 0 0138 in 11 INSTALL FIRST GEAR H151F a Place the synchronizer rings on the 1st gear b Apply gear oil to the shaft and needle roller bearing H150F c Place the synchronizer ring on the gear and align the ring slots with the shifting keys d Install the needle roller bearing in the first gear 12 INSTALL BALL BEARING a Install the pin and thrust washe...

Page 68: ...Using a brass bar and a hammer drive in a new snap ring 13 INSTALL SNAP RING a Select a snap ring that will allow minimum axial play c Install the pin and thrust washer b Using SST and a press install the ball bearing SST 09316 60010 09316 00010 09523 36010 ...

Page 69: ...MT 40 MANUAL TRANSMISSION STATION WAGON SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA ...

Page 70: ...MT 41 MANUAL TRANSMISSION STATION WAGON SERVICE SPECIFICATIONS ...

Page 71: ... Pub No RM184E NOTE The following pages contain only the points which differ from the above listed man ual STATION WAGON DESCRIPTION AT 2 OPERATION AT 4 PREPARATION AT 12 TROUBLESHOOTING AT 14 VALVE BODY AT 58 THROTTLE CABLE AT 63 ASSEMBLY REMOVAL AND INSTALLATION AT 66 SERVICE SPECIFICATIONS AT 86 ...

Page 72: ...a four speed transfer developed with the aim of producing an easy driving 4WD vehicle A lock up mechanism is built into the torque converter The A442F transmission is mainly composed of the torque converter the overdrive hereafter called O D planetary gear unit 3 speed planetary gear unit 4 speed transfer hydraulic control system and an electronic control system ...

Page 73: ...AUTOMATIC TRANSMISSION STATION WAGON DESCRIPTION AT 3 GENERAL SPECIFICATIONS ...

Page 74: ...AT 4 AUTOMATIC TRANSMISSION STATION WAGON OPERATION OPERATION OPERATION ...

Page 75: ...AUTOMATIC TRANSMISSION STATION WAGON OPERATION AT 5 1 FUNCTION OF COMPONENTS ...

Page 76: ...AT 6 AUTOMATIC TRANSMISSION STATION WAGON OPERATION The conditions of operation for each gear position are shown on the following illustration ...

Page 77: ...AT 7 AUTOMATIC TRANSMISSION STATION WAGON OPERATION ...

Page 78: ...acting on the torque converter clutches and brakes in accordance with the vehicle driving condition There are four solenoid valves on the valve body These solenoid valves are turned on and off by signals from ECU to operate the shift valves These shift valves then switch the fluid passages so that fluid goes to the torque converter and plan etary gear units Except for the solenoid valves the hydra...

Page 79: ...uces vehicle squat when the vehicle starts out and gear shift shock The electronic control system for controlling the shift timing and the operation of the lock up clutch is composed of the following three parts a Sensors These sense the vehicle speed and throttle position and send this data to the ECT ECU in the form of electronic signals b ECT ECU This determines the shift and lock up timing bas...

Page 80: ...ure falls below 55 C 131 F the engine ECU sends a signal to the ECT ECU preventing the transmission from up shifting into overdrive Control of Lock Up System The ECT ECU has programmed in its memory a lock up clutch operation pattern for each driving mode Normal or Power Based on this lock up pattern the ECU turns lock up solenoid valve on or off in ac cordance with the vehicle speed signals recei...

Page 81: ...0 C 302 F the ECT ECU lights the warning light located in the combination meter The light goes off when temperature falls below 120 C 248 F AT6023 V01585 6 A T P Automatic Transmission Parking INDICATOR The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in neutral position The A T P indicator lights up to warn the drive...

Page 82: ...AT 12 AUTOMATIC TRANSMISSION STATION WAGON PREPARATION PREPARATION SST SPECIAL SERVICE TOOLS EQUIPMENT ...

Page 83: ...AUTOMATIC TRANSMISSION STATION WAGON PERPARATION AT 13 LUBRICANT SSM SPECIAL SERVICE MATERIALS ...

Page 84: ...e problem lies and begin troubleshooting with the simplest operation gradually working up in order or difficulty BASIC TROUBLESHOOTING Before troubleshooting an ECT first determine whether the problem is electrical or mechanical To do this just refer to the basic troubleshooting flow chart provided below If the cause is already known using the basic troubleshooting chart below a long with the gene...

Page 85: ...AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING AT 15 NOTICE Refer to A442F Automatic Transmission Repair Manual Pub No RM314E when mark appears in the column for page numbers ...

Page 86: ...AT 16 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING NOTICE Refer to A442F Automatic Transmission Repair Manual Pub No RM314E when mark appears in the column for page numbers ...

Page 87: ...ed but inspection can be made by checking the volt age at terminal TT of the check connector d The signals to each gear can be checked by measuring the voltage at terminal TT of the check connector while driving 2 The diagnostic code is retained in memory by the ECT ECU and due to back up voltage is not canceled out when the engine is turned off Consequently after repair it is necessary to turn th...

Page 88: ...D DIAGNOSTIC CODE Read the diagnostic code as indicated by the number of times the O D OFF light flashes Diagnostic Code Indication If the system is operating normally the light will flash 2 times par second In the event of a malfunction the light will flash 1 time par second The number of blinks will equal the first number and after 1 5 seconds pause the second number of the two digit diagnostic ...

Page 89: ...AT 19 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING DIAGNOSTIC CODES ...

Page 90: ... fuse must be left out with the ig nition switch OFF HINT Cancellation can be also done by removing the battery negative terminal but in this case other memory systems will be also canceled out The diagnostic code can be also canceled out by dis connecting the ECT ECU connector If the diagnostic trouble is not canceled out it will be retained by the ECT ECU and appear along with a new code in even...

Page 91: ...use the blinking to stop but the code will still be retained in the ECT ECU memory until canceled out There is no warning for diagnostic code No 64 and 65 In the event of a simultaneous malfunction of both No 1 and No 2 speed sensors no diagnostic code will appear and the fail safe system will not function However when driving in the D range the transmission will not up shift from first gear regar...

Page 92: ...AT 22 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING Diagnostic Code 61 No 2 speed sensor circuitry ...

Page 93: ...AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING AT 23 Diagnostic Code 64 Lock up solenoid valve circuitry ...

Page 94: ...AT 24 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING Diagnostic Code 86 Engine speed sensor circuitry 1HD T engine ...

Page 95: ...tube e Pull it out and check that the fluid level is on the HOT range If the level is at the low side add fluid Fluid type NOTICE Do not overfill 2 CHECK FLUID CONDITION If the fluid smells burnt or is black replace it in the fol lowing procedure a Remove the drain plug and drain the fluid b Reinstall the drain plug securely Torque 27 N m 280 kgf cm 20 ft lbf c With the engine OFF add new fluid th...

Page 96: ...MISSION SHIFT LEVER RANGE When shifting the shift lever from the N range to other ranges check that the lever can be shifted smoothly and accurately to each range and that the position indicator correctly indicates the position If the indicator is not aligned with the correct position carry out the following adjustment procedures a Loosen the nut on the control rod b Push the control shaft lever f...

Page 97: ...If not as started above carry out the following adjust ment procedures a Loosen the neutral start switch bolts and set the shift lever to the N range b Align the groove and neutral basic line c Hold in position and tighten the bolts Torque 13 Nm 130 kgfcm 9 ftlbf 6 INSPECT IDLE SPEED N RANGE Connect tachometer test probe to the check connector terminal IG inspect the idle speed Idle speed 650 rpm ...

Page 98: ...ANUAL DRIVING OPERATION Check that the shift and gear position correspond with the table below HINT If the L 2 and D range gear position are difficult to distinguish perform the following road test While driving shift through the L 2 and D ranges Check that the gear change corresponds to the shift position If any abnormality is found in the above test the prob lem lies in transmission ifself 3 CON...

Page 99: ...OTING AT 29 ELECTRONIC CONTROL SYSTEM PRECAUTION Do not open the cover or the case of the TCM and vari ous computer unless absolutely necessary If the IC ter minals are touched the IC may be destroyed by static electricity ELECTRONIC CONTROL CIRCUIT ...

Page 100: ...AT 30 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING ...

Page 101: ...AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING AT 31 ELECTRONIC CONTROL COMPONENTS ...

Page 102: ...AT 32 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING TROUBLESHOOTING FLOW CHART Trouble No 1 No Shifting ...

Page 103: ...AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING AT 33 Trouble No 2 Shift point too high or too low ...

Page 104: ...AT 34 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING Trouble No 3 No up shift to overdrive After warm up ...

Page 105: ...AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING AT 35 Trouble No 4 No lock up After warm up ...

Page 106: ...8 V If not as indicated there is a malfunction in either the stop light switch or circuit 3 INSPECT EACH UPSHIFT POSITION a Warm up the engine Coolant temperature 80 C 176 F b Turn the O D switch to ON c Place the pattern select switch in Normal and the shift lever into the D range d During a road test about 10 km h or 6 mph check that voltage at the TT terminal is as indicated below for each up s...

Page 107: ...AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING AT 37 ELECTRONIC CONTROL COMPONENETS INSPECTION 1 INSPECT VOLTAGE OF ECT ECU a Turn on the ignition switch b Measure the voltage at each terminal ...

Page 108: ...AT 38 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING ...

Page 109: ...UBLESHOOTING AT 39 2 INSPECT SOLENOID a Disconnect the connector from ECT ECU b Measure the resistance between and ground Resistance 11 15 c Apply battery voltage to each terminal Check that an op eration noise can be heard from the solenoid ...

Page 110: ... that the solenoid valves open b Check the lock up solenoid valve Apply 490 kPa 5 kgf cm2 71 psi of compressed air check that the solenoid valve opens When supply battery voltage to the solenoid check that the solenoid valve does not leak the air If malfunction is found during voltage inspection step 1 inspect the components listed below 4 INSPECT THROTTLE POSITION SENSOR a Using an ohmmeter check...

Page 111: ...H Using an ohmmeter check the continuity of terminals for each switch position HINT As there are diodes inside be careful of the tester probe polarity 8 INSPECT O D SWITCH Using an ohmmeter check the continuity of the terminals for each switch position 9 INSPECT NEUTRAL START SWITCH Check that there is continuity between terminals 10 1HD T engine INSPECT WATER TEMPERATURE SWITCH Check that there i...

Page 112: ...059 11 INSPECT A T FLUID TEMPERATURE WARNING LIGHT a Disconnect the connector from the temperature sensor Connecct terminal of the wire harness side connector and body ground b Turn the ignition switch ON check that the light go on If warning light does not light test the bulb 12 INSPECT A T FLUID TEMPERATURE SENSOR Check that there is continuity at the temperature of 145 C 155 C 325 F 343 F If co...

Page 113: ...elerator pedal with your right foot Quickly read the stall speed at this time NOTICE Release the accelerator pedal and stop test if the rear wheels begin to rotate before the en gine speed reaches specified stall speed Stall speed 1FZ FE engine 2 150 150rpm 1HD T engine 1 950 150rpm h Perform the same test in R range EVALUATION a If the stall speed is the same for both positions but lower than spe...

Page 114: ...AT 44 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING ...

Page 115: ...s and take the average value MEASURE TIME LAG a Fully apply the parking brake b Start the engine and check the idle speed Idle speed 650 rpm N range c Shift the shift lever from N to D range Using a stop watch measure the time it takes from shifting the lever until the shock is felt Time lag Less than 1 0 seconds d In same manner measure the time lag for N R Time lag Less than 1 5 seconds EVALUATI...

Page 116: ...AT 46 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING ...

Page 117: ...E PRESSURE a Fully apply the parking brake and chock the four wheels b Start the engine and check idling rpm c Keep your left foot pressed firmly on the brake pedal and shift into D range d Measure the line pressure when the engine is idling e Press the accelerator pedal all the way down Quickly read the highest line pressure when engine speed reaches stall speed NOTICE Release the accelerator ped...

Page 118: ... b If the measured values at all positions are lower than specified Throttle cable out of adjustment Throttle valve defective Regulator valve defetive Oil pump defective O D direct clutch defective c If pressure is low in the D range only D range circuit fluid leakage Forward clutch defective d If pressure is low in the R range only R range circuit fluid leakage Direct clutch defective First and r...

Page 119: ... HINT There is no O D up shift or lock up when the coolant temperature is below 55 C 131 F EVALUATION 1 If there is no 1 2 up shift No 2 solenoid is stuck 1 2 shift valve is stuck 2 If there is no 2 3 up shift No 1 solenoid is stuck 2 3 shift valve is stuck 3 If there is no 3 O D up shift 3 4 shift valve is stuck 4 If the shift point is defective Throttle valve 1 2 shift valve 2 3 shift valve 3 4 ...

Page 120: ...1 Drive in D position O D gear at a steady speed lock up ON of about 95 km h 59 mph 2 Lightly depress the accelerator pedal and check that the engine rpm does not change abruptly If there is a big jump in engine rpm there is no lock up 2 2 RANGE TEST Shift into the 2 range and while driving with the acceler ator pedal held constantly at the full throttle valve open ing position push in one of the ...

Page 121: ... L range check to see that there is no up shift to 2nd gear b While running in the L range release the accelerator pedal and check the engine braking effect EVALUATION If there is no engine braking effect First and reverse brake is defective c Check for abnormal noise during acceleration and decel eration 4 R RANGE TEST Shift into the R range and while starting at full throttle check for slipping ...

Page 122: ...SION STATION WAGON TROUBLESHOOTING 5 P RANGE TEST Stop the vehicle on a gradient more than 5 and after shifting into the P range release the parking brake Then check to see that the parking lock pawl holds the vehicle in place ...

Page 123: ...AT 53 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING km h mph Engine 1FZ FE Tire size 215 80 R16 AUTOMATIC SHIFT SCHEDULE Engine 1FZ FE Tire size 7 50R16 6 km h mph ...

Page 124: ...AT 54 AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING Engine 1HD T Tire size 245 85 R16 km h mph Engine 1HD T Tire size 7 50R16 6 km h mph Engine 1FZ FE Tire size 275 70 R16 km h mph ...

Page 125: ...AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING AT 55 Engine 1HD T Tire size 275 70 R16 km h mph km h mph Engine 1HD T Tire size 215 80 R16 ...

Page 126: ...ROUBLESHOOTING TROUBLESHOOTING MATRIX CHART You will find the troubles easier using the table will shown below In this table each number shows the priority of cause in troubles Check each part in order If necessary replace these parts ON VEHICLE ...

Page 127: ...AUTOMATIC TRANSMISSION STATION WAGON TROUBLESHOOTING AT 57 Remark Refer to A442F Automatic Transmission Repair Manual Pub No RM314E OFF VEHICLE Trouble Parts Name See Page ...

Page 128: ... FLUID Remove the drain plug and drain fluid into a suitable con tainer 4 REMOVE OIL PAN PROTECTOR Remove the four bolts and the oil pan protector 5 REMOVE OIL PAN AND GASKET NOTICE Some fluid will remain in the oil pan Be careful not to damage the filler tube a Remove the twenty bolts b Install the blade off SST between the transmission and oil pan cut off applied sealer SST 09302 00100 NOTICE Be...

Page 129: ...d oil strainer 7 REMOVE VALVE BODY a Remove the twenty one bolts b Disconnect the four connectors from the solenoids c Remove the throttle cable the cam and remove the valve body VALVE BODY INSTALLATION 1 INSTALL VALVE BODY a Align the groove of the manual valve with the pin of the manual valve lever ...

Page 130: ... mm 1 26 in E 28 mm 1 10 in F 52 mm 2 05 in G 40 mm 1 57 in H 22 mm 0 87 in I 42 mm 1 65 in d Check that the manual valve lever contacts the center of the roller at the tip of the detente spring e Tighten the bolts Torque 10 Nm 100 kgf cm 7 ft lbf 2 CONNECT FOUR SOLENOID CONNECTORS 3 INSTALL OIL STRAINER Install a new gasket and the oil strainer with the four bolts Torque 10 Nm 100 kgf cm 7 ft lbf...

Page 131: ...the transmission case and oil pan b Apply seal packing to the oil pan Seal packing Part No 08826 00090 THREE BOND 1281B or equivalent c Install and tighten the twenty bolts Torque 6 9 N m 70 kgfcm 61 in lbf 6 INSTALL OIL PAN PROTECTOR Install the protector with the four bolts 7 INSTALL DRAIN PLUG a Install the drain plug with a new gasket b Torque the drain plug Torque 27 Nm 280 kgfcm 20 ftlbf 8 I...

Page 132: ...2 AUTOMATIC TRANSMISSION STATION WAGON VALVE BODY 9 FILL TRANSMISSION WITH ATF Capacity 6 0 liters 6 3 US qts 5 3 Imp qts NOTICE Do not overfill Fluid type ATF DEXRON II 10 CHECK FLUID LEVEL See page AT 25 ...

Page 133: ...ge c Disconnect the cable from the torque converter housing 3 REMOVE VALVE BODY See page AT 58 4 REMOVE FOUR CENTER SUPPORT APPLY GASKETS 5 REMOVE FRAME CROSSMEMBER SET BOLTS a Support the frame crossmember with a jack b Remove the eight set bolts 6 REMOVE THROTTLE CABLE CLAMP a Lower the jack b Remove the cable clamp from the transmission housing 7 REMOVE THROTTLE CABLE Using 10 mm socket driver ...

Page 134: ... INSTALL VALVE BODY See page AT 59 6 INSTALL FRONT PROPELLER SHAFT See Pub No RM184E page PR 8 7 IF THROTTLE CABLE IS NEW PAINT MARK ON INNER CABLE HINT New cable do not have a cable stopper installed Therefore to mark adjustment possible paint a mark as described below a Connect the throttle cable to the throttle cam of valve body b Pull the inner cable lightly until resistance is felt and hold i...

Page 135: ...ATION WAGON THROTTLE CABLE AT 65 9 ADJUST THROTTLE CABLE See page AT 26 10 FILL TRANSMISSION WITH ATF Capacity 6 0 liters 6 3 US qts 5 3 Imp qts NOTICE Do not overfill Fluid type ATF DEXRON H 11 CHECK FLUID LEVEL See page AT 25 ...

Page 136: ...wn Clamp Battery Cover Fan Shroud Starter Oil Cooler Pipe Wire Harness Vacuum Hose Oil Filler Tube Level Gauge Shift Control Rod 1HD T Only Shiffener Plate IHD T Only Engine Under Cover w Mechanical Winch Drive Shaft Torque Converter Cover Speedometer Cable Transfer Under Cover Frame Crossmember w Mechanical Winch Specified torque ...

Page 137: ...ISSION STATION WAGON ASSEMBLY REMOVAL AND INSTALLATION AT 67 TRANSMISSION REMOVAL 1 DISCONNECT BATTERY CABLE FROM NEGATIVE TER MINAL 2 REMOVE BATTERY AND COVER 3 LOOSEN FAN SHROUD OF COOLING FAN TO AVOID DAMAGE TO FAN ...

Page 138: ...e adjusting nut and disconnect the cable hous ing from the bracket b Disconnect the cable from the linkage 5 1HD T REMOVE STARTER MOUNTING BOLT 6 REMOVE TRANSMISSION SELECT LEVER AND TRANS FER SHIFT LEVER a Remove the clip washer and wave washer and discon nect the link b Remove the nut and washer disconnect the link ...

Page 139: ...he transfer shift lever knob d Remove the four screws and the console e Remove the four bolts and transfer shift lever bolt f Remove the three bolts and the console box g Remove the six bolts and the transmission shift lever as sembly h Remove the four screws and the transfer shift lever ...

Page 140: ...OVE POWER TAKE OF SHIFT CABLE a Pull out the pin and disconnect the cable b Remove the two bolts and the cable bracket c Remove the engine under cover d Place matchmarks on the yoke and flange e Remove the bolts and nuts disconnect the drive shaft from the PTO f Remove the front and rear bracket set bolts and then re move the drive shaft 10 REMOVE OIL FILLER TUBE a Remove the level gauge b Remove ...

Page 141: ... WAGON ASSEMBLY REMOVAL AND INSTALLATION AT 71 c Remove the bolt and the filler tube 11 DISCONNECT TWO OIL COOLER TUBES a Remove the bolt and clamp b Disconnect the temperature sensor connector c Disconnect the two oil cooler tubes ...

Page 142: ...MBLY REMOVAL AND INSTALLATION 12 REMOVE ENGINE UNDER COVER Remove the four bolts and the cover 13 DISCONNECT NO 2 SPEED SENSOR CONNECTOR 14 DISCONNECT SOLENOID CONNECTOR 15 REMOVE SIX TORQUE CONVERTER MOUNTING BOLTS a Remove the converter hole plug ...

Page 143: ...ix bolt 16 REMOVE CROSSMEMBER a Support the transmission with the transmission jack b Remove the eight bolts and then remove the frame cross member 17 REMOVE TRANSMISSION ASSEMBLY a Be sure to out a wooden block or equivalent between the jack and oil pan to prevent damage Support the oil pan with a jack b Lower the rear end of transmission ...

Page 144: ...bolt and disconnect the oil cooler tube clamp from the converter housing g Disconnect the connectors from the transfer h Remove the clamp and disconnect the wire harness from the transmission and transfer i Remove the two bolts and disconnect the exhaust pipe bracket from the converter housing j 1HD T Remove the four bolts and the stiffener plate k 1HD T Remove the nut and disconnect the connector...

Page 145: ...AUTOMATIC TRANSMISSION STATION WAGON ASSEMBLY REMOVAL AND INSTALLATION AT 75 m Remove the bolts and the transmission ...

Page 146: ...ub and outer race of the one way clutch SST 09350 30020 09351 32010 c With the torque converter made stand the clutch should lock when turned counterclockwise and rotate freely and smoothly clockwise If necessary clean the converter and retest the clutch Replace the converter if the clutch still fails the test 2 MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR Set up a dial indicator and measure t...

Page 147: ...1 INSTALL TORQUE CONVERTER IN TRANSMISSION If the torque converter clutch has been drained and washed refill with new ATF Fluid type AFT DEXR0N n 2 CHECK TORQUE CONVERTER INSTALLATION Using calipers and a straight edge measure from the in stalled surface to the front surface of the transmission Correct distance 1FZ FE More than 37 2 mm 1 465 in 1HD T More than 43 8 mm 1 724 in 3 PLACE TRANSMISSION...

Page 148: ...the converter hous ing with the bolt f Connect the park neutral position switch g 1FZ FE Install the starter with the two bolts Torque 72 Nm 730 kgf cm 53 ftlbf h 1FZ FE Connect the connectors i Install the nut j 1HD T Install the starter with the bolt Torque 72 N m 730 kgf cm 53 ft lbf k 1HD T Connect the connectors I 1HD T Install the nut m Connect the exhaust pipe bracket to the converter hous ...

Page 149: ... Install the crossmember with eight bolts and two nuts Torque 61 N m 620 kgf cm 45 ft lbf 6 INSTALL TORQUE CONVERTER MOUNTING BOLTS a Install the six bolts while turning the crankshaft Torque 55 N m 550 kgf cm 40 ft lbf b Seal the converter hole plug with adhesive c Install the converter hole plug ...

Page 150: ...OR 8 CONNECT NO 2 SPEED SENSOR CONNECTOR 9 INSTALL ENGINE UNDER COVER Install the cover with the four bolts Torque 28 Nm 290 kgf cm 21 ftlbf 10 CONNECT TWO OIL COOLER TUBES a Connect the two oil cooler tubes Torque 34 Nm 350 kgf cm 25 ftlbf b Install the cooler tube clamp Torque 10 Nm 100 kgf cm 7 ft lbf ...

Page 151: ...LER TUBE a Install the filler tubes with the bolt b Install the bolt c Install the level gauge 12 w MECHANICAL WINCH INSTALL POWER TAKE OFF DRIVE SHAFT a Align the matchmarks on the joint flange yoke and drive shaft b Install the drive shaft c Align the matchmarks on the drive shaft and PTO d Torque the nuts Torque 20 Nm 200 kgfcm 14 ft lbf ...

Page 152: ...Install the two bolts and the cable bracket b Connect the cable and insert the pin 14 CONNECT NO 1 SPEED SENSOR CONNECTOR 15 INSTALL FRONT AND REAR PROPELLER SHAFTS See Pub No RM184E page PR 8 16 INSTALL TRANSMISSION SELECT LEVER AND TRANS FER SHIFT LEVER a Remove the four bolts and the transfer shift lever b Install the transmission shift lever assembly with the six bolts ...

Page 153: ...stall the console box with the three bolts d Install the transfer shift lever boot with the four bolts e Install the four screws and the console f Install the transfer shift lever knob g Connect the link with the washer and nut h Connect the link with the wave washer washer and clip ...

Page 154: ...e throttle linkage b Tighten the adjusting nuts and connect the cable housing to the bracket 19 TIGHTEN FAN SHROUD OF COOLING FAN TO AVOID DAMAGE TO FAN 20 INSTALL BATTERY AND COVER 21 CONNECT BATTERY CABLE FROM NEGATIVE TERMI NAL 22 ADJUST SHIFT CONTROL ROD See page AT 26 23 FILL SHIFT CONTROL ROD Fluid type ATF DEXRON H Capacity 6 0 liters 6 3 US qts 5 3 Imp qts ...

Page 155: ...AUTOMATIC TRANSMISSION STATION WAGON ASSEMBLY REMOVAL AND INSALLATION AT 85 24 CHECK FLUID LEVEL See page AT 25 ...

Page 156: ...AT 86 AUTOMATIC TRANSMISSION STATION WAGON SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATE Shift point schedule km h mph ...

Page 157: ...AUTOMATIC TRANSMISSION STATION WAGON SERVICE SPECIFICATIONS AT 87 ...

Page 158: ...AT 88 AUTOMATIC TRANSMISSION STATION WAGON SERVICE SPECIFICATIONS TORQUE SPECIFICATION ...

Page 159: ... FOR STATION WAGON WITH ABS DESCRIPTION TR 2 PRECAUTIONS TR 3 TROUBLESHOOTING TR 3 COMPONENTS TR 4 TRANSFER DISASSEMBLY TR 5 COMPONENT PARTS TR 12 Input Shaft Assembly TR 12 Idler Gear Assembly TR 16 Center Differential Assembly TR 19 Front Extension Housing Assembly TR 28 Rear Extension Housing Assembly TR 32 TRANSFER ASSEMBLY TR 41 MOTOR SHIFT CONTROL SYSTEM TR 49 SERVICE SPECIFICATIONS TR 51 ...

Page 160: ...ER DESCRIPTION DESCRIPTION The transfer transmits the drive force from the transmission to the front and rear wheels The specifications and cross section diagrams are as shown HF2AV TRANSFER V01733 Specifications ...

Page 161: ...s of application Otherwise the packing FIPG material must be removed and reapplied TROUBLESHOOTING Hard to shift or will not shift Problem Possible cause Transfer faulty Transfer faulty Transfer jumps out of gear Noise Transfer faulty Wrong oil grade Oil level low Oil leakage Oil level too high Oil seal O ring or gasket worn or damaged Tight corner braking Center differential or transfer faulty Re...

Page 162: ...TR 4 TRANSFER COMPONENTS COMPONENTS ...

Page 163: ... ACTUATOR Remove the four bolts and motor actuator HINT Remove the motor actuator in differential lock condition 3 REMOVE OUTPUT GEAR 4 REMOVE SCREW PLUG SPRING AND BALL a Using a torx socket wrench remove the screw plug Torx socket wrench T40 09042 00020 b Using a magnetic finger remove the spring and ball ...

Page 164: ...POWER TAKE OFF REMOVE POWER TAKE OFF COVER Remove the ten bolts power take off cover and gasket 7 w POWER TAKE OFF REMOVE POWER TAKE OFF CASE Remove the ten bolts power take off case and gasket 8 REMOVE FRONT EXTENSION HOUSING a Remove the six bolts b If necessary tap the front extension housing with a plas tic hammer 9 REMOVE CLUTCH SLEEVE SHIFT FORK NO 2 AND FORK SHAFT ...

Page 165: ...rate the shift fork No 2 and fork shaft 11 REMOVE REAR EXTENSION HOUSING Remove the nine bolts and rear extension housing HINT If necessary tap the rear extension housing with a plastic hammer 12 REMOVE RETAINER Remove the five bolts and retainer 13 REMOVE ADJUSTING SHIMS 14 REMOVE OIL STRAINER FROM REAR CASE Remove the two set bolts and oil strainer ...

Page 166: ...Remove the five bolts b Using a brass bar and hammer tap the case cover and re move it 16 SEPARATE FRONT CASE AND REAR CASE a Using snap ring pliers remove the snap ring b Remove the eight bolts c Using a brass bar and hammer tap the rear case and sep arate it ...

Page 167: ... input shaft assem bly 19 REMOVE IDLE GEAR ASSEMBLY CENTER DIFFEREN TIAL ASSEMBLY AND HIGH AND LOW SHIFT FORK AS SEMBLY 20 SEPARATE SHIFT FORK N0 1 AND FORK SHAFT a Using a pin punch and hammer drive out the slotted spring pin b Separate the shift fork No 1 and fork shaft 21 REMOVE SHIFT OUTER LEVER AND INNER LEVER a Remove the nut and washer ...

Page 168: ...t outer lever and inner lever 22 IF NECESSARY REPLACE SHIFT LEVER OIL SEAL a Using a screwdriver pry out the oil seal b Using SST and a hammer drive in a new oil seal SST 09608 20012 09608 00080 09608 03020 23 IF NECESSARY REPLACE INPUT SHAFT OIL SEAL a Using SST and a hammer drive out the oil seal SST 09316 60010 09316 00010 ...

Page 169: ... 09316 00010 09316 00030 24 REMOVE OIL RECEIVER FROM FRONT CASE Remove the set bolt and oil receiver 25 REMOVE TWO BEARING RACES FROM FRONT CASE a Using SST remove the bearing race SST 09950 20017 b Using a brass bar and hammer remove the bearing race 26 INSPECTION OF TRANSFER INDICATOR SWITCHES Check that there is continuity between terminals as shown ...

Page 170: ...T SHAFT ASSEMBLY COMPONENT PARTS Input Shaft Assembly COMPONENTS DISASSEMBLY OF INPUT SHAFT ASSEMBLY 1 REMOVE REAR BALL BEARING a Using snap ring pliers remove the snap ring b Using a press and socket wrench remove the rear ball bearing ...

Page 171: ... GEAR a Using snap ring pliers remove the snap ring b Using a press remove the power take off drive gear 3 REMOVE INPUT GEAR a w o Power take off Using snap ring pliers remove the snap ring b Using a press remove the input gear 4 REMOVE FRONT BALL BEARING Using a press remove the front ball bearing ...

Page 172: ...EARING Using a press install the front ball bearing 2 INSTALL INPUT GEAR a Using a press install the input gear b w o Power take off Select a snap ring that will allow minimum axial play and install it on the shaft 3 w POWER TAKE OFF INSTALL POWER TAKE OFF GEAR a Using a press install the power take off gear ...

Page 173: ...ers install the snap ring b Select a snap ring that will allow minimum axial play and install it on the shaft 4 INSTALL REAR BALL BEARING a Using SST and a press install the rear ball bearing SST 09316 60010 09316 00030 b Select a snap ring that will allow minimum axial play ...

Page 174: ...THRUST CLEARANCE OF IDLER LOW GEAR a Using a feeler gauge measure the idler low gear thrust clearance Standard clearance 0 125 0 275 mm 0 0049 0 0108 in Maximum clearance 0 275 mm 0 0108 in b Using a dial indicator measure the idler low gear oil clear ance Standard clearance 0 015 0 068 mm 0 0006 0 0027 in Maximum clearance 0 068 mm 0 0027 in ...

Page 175: ... TAPER ROLLER BEARING Using SST press and socket wrench remove the rear taper roller bearing SST 09950 00020 4 REMOVE IDLER LOW GEAR AND NEEDLE ROLLER BEAR ING 5 REMOVE HIGH AND LOW CLUTCH SLEEVE ASSEMBLY OF IDLER GEAR ASSEMBLY 1 INSTALL FRONT TAPER ROLLER BEARING Using SST and a press install the front taper roller bear ing SST 09316 60010 09316 00010 09316 00030 ...

Page 176: ...NG Using SST and a press install the rear taper roller bear ing SST 09316 60010 09316 00010 09316 00070 5 MEASURE OIL CLEARANCE AND THRUST CLEARANCE OF IDLE LOW GEAR a Using a feeler gauge measure the idler low gear thrust clearance Standard clearance 0 125 0 275 mm 0 0049 0 0108 in Maximum clearance 0 275 mm 0 0108 in b Using a dial indicator measure the idler low gear oil clear ance Standard cle...

Page 177: ...CLEARANCE AND THRUST CLEARANCE OF HIGH SPEED GEAR a Using a feeler gauge measure the high speed gear thrust clearance Standard clearance 0 10 0 25 mm 0 0039 0 0098 in Maximum clearance 0 25 mm 0 0098 in b Using a dial indicator measure the high speed gear oil clearance Standard clearance 0 015 0 071 mm 0 0006 0 0028 in Maximum clearance 0 071 mm 0 0028 in ...

Page 178: ...ing SST and a press remove the front drive gear piece SST 09950 20017 09950 00020 NOTICE Be careful do not drop the center differential assembly 3 REMOVE FRONT TAPER ROLLER BEARING Using SST and a press remove the front taper roller bear ing SST 09950 00020 4 REMOVE HIGH SPEED OUTPUT GEAR AND SYNCHRO NIZER RING 5 REMOVE NEEDLE ROLLER BEARING ...

Page 179: ... keys 8 REMOVE HIGH SPEED OUTPUT GEAR BUSHING CLUTCH HUB AND SHIFTING KEY RETAINER a Using SST and a press remove the high speed output gear bushing clutch hub and shifting key retainer SST 09555 55010 b Using a magnetic finger remove the two straight pins 9 REMOVE REAR TAPER ROLLER BEARING Using SST and a press remove the rear taper roller bear ing SST 09950 00020 09950 20017 09958 30010 10 REMOV...

Page 180: ...REAR CASE Remove the twelve bolts and differential rear case 12 REMOVE REAR SIDE GEAR AND THRUST WASHER 13 REMOVE PINION SHAFT PINION GEAR AND THRUST WASHER a Remove the straight pin b Remove the pinion shaft pinion gear and thrust washer c Remove the front side gear and thrust washer ...

Page 181: ... gear and thrust washer to the differ ential front case b Install the two pinion gears and thrust washers to the dif ferential front case c Using a dial indicator measure the front case backlash HINT Push the pinion shaft Minimum backlash 0 05 mm 0 0020 in If the backlash is not within specification replace the thrust washer with one of the correct size and reinstall the thrust washer d Measure th...

Page 182: ...ENTIAL REAR CASE Temporary install the differential rear case and set bolts 5 TORQUE REAR CASE SET BOLTS a Torque the rear case set bolts Torque 88 N m 900 kgf cm 65 ftlbf b Loosen the rear case set bolts c Retorque the rear case set bolts Torque 98 N m 1000 kgf cm 72 ft lbf 6 INSTALL NEEDLE ROLLER BEARING AND SNAP RING ...

Page 183: ...low clutch sleeve b Install the shifting key springs NOTICE Install the key springs positioned so that their end gaps are not in line 10 INSTALL HIGH AND LOW CLUTCH SLEEVE ASSEMBLY AND HIGH SPEED OUTPUT GEAR BUSHING a Apply MP grease to the straight pin b Install the two straight pins c Using SST and a press install the clutch sleeve assembly and high speed output gear bushing SST 09316 60010 0931...

Page 184: ...utput gear and needle roller bearing NOTICE Align the ring slots with the shifting keys 12 INSTALL FRONT TAPER ROLLER BEARING Using SST and a press install the front taper roller bear ing SST 09316 60010 09316 00010 13 INSTALL FRONT DRIVE GEAR PIECE Using SST and a press install the front drive gear piece SST 09316 60010 09316 00010 14 INSTALL SNAP RING Select a snap ring that will allow minimum a...

Page 185: ... OUTPUT GEAR a Using a feeler gauge measure the high speed gear thrust clearance Standard clearance 0 10 0 25 mm 0 0039 0 0098 in Maximum clearance 0 25 mm 0 0098 in b Using a dial indicator measure the high speed gear oil clearance Standard clearance 0 015 0 071 mm 0 0006 0 0028 in Maximum clearance 0 071 mm 0 0028 in ...

Page 186: ...NSION HOUSING ASSEMBLY Front Extension Housing Assembly COMPONENTS DISASSEMBLY OF FRONT EXTENSION HOUSING ASSEMBLY 1 REMOVE DRIVE CLUTCH HUB a Using snap ring pliers remove the snap ring b Using SST remove the drive clutch hub SST 09950 2001 7 ...

Page 187: ...drive out the front output shaft 3 REMOVE DUST DEFLECTORS a Using SST and a press remove the dust deflector SST 09950 00020 b Using a screwdriver and hammer tap the dust deflector and remove it 4 REMOVE OIL SEAL Using a screwdriver pry out the oil seal 5 REMOVE BALL BEARING a Using a screwdriver remove the snap ring ...

Page 188: ...NSION HOUSING ASSEMBLY 1 INSTALL DUST DEFLECTORS a Using SST and a press install the dust deflector SST 09223 41020 09223 1 5020 b Using SST and a press install the dust deflector SST 09316 60010 09316 00010 09316 20011 2 INSTALL BALL BEARING a Using SST and a press install the ball bearing SST 09316 60010 09316 00010 09316 00030 b Using a screwdriver install the snap ring ...

Page 189: ...er drive in a new oil seal SST 09316 60010 09316 00010 09316 00060 4 INSTALL FRONT OUTPUT SHAFT AND DRIVE CLUTCH HUB a Using SST and press install the front output shaft and drive clutch hub SST 09316 20011 09316 60010 09316 00010 09316 00040 09316 00070 b Using snap ring pliers install the new snap ring ...

Page 190: ...TR 32 TRANSFER COMPONENT PARTS REAR EXTENSION HOUSING ASSEMBLY Rear Extension Housing Assembly COMPONENTS ...

Page 191: ...SING ASSEMBLY 1 REMOVE OIL PUMP DRIVE SHAFT 2 REMOVE OIL PUMP COVER a Using a torx socket wrench remove the three screws Torx socket wrench T30 09042 00010 b Install two suitable bolts to the pump cover c Remove the pump cover from rear extension housing 3 REMOVE DRIVE ROTOR 4 REMOVE DRIVEN ROTOR ...

Page 192: ...emove the screw plug b Using a magnetic finger remove the spring ball and valve seat 6 REMOVE CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY a Using snap ring pliers remove the snap ring b Remove the coupling assembly 7 REMOVE SEPARATOR Remove the two bolts and the separator 8 REMOVE OIL PUMP PLATE Remove the bolt and the oil pump plate ...

Page 193: ...liers remove the snap ring b Remove the speedometer drive gear 10 REMOVE REAR OUTPUT SHAFT a Using snap ring pliers remove the snap ring b Using SST and a hammer remove the rear output shaft SST 09325 12010 11 REMOVE DUST DEFLECTORS a Using a screwdriver and hammer remove the rear exten sion housing dust deflectors ...

Page 194: ...ING a Using a screwdriver remove the snap ring b Using SST and a press remove the ball bearing SST 09316 60010 09316 00010 09316 00020 INSPECTION OF OIL PUMP 1 CHECK BODY CLEARANCE OF DRIVEN ROTOR Install the drive rotor to the driven rotor Using a feeler gauge measure body clearance between drive rotor and extension housing Standard body clearance 0 08 0 17 mm 0 0031 0 0067 in Maximum body cleara...

Page 195: ...learance is greater than the maximum replace the drive rotor or driven rotor 3 CHECK SIDE CLEARANCE OF OIL PUMP Using a steel straight edge and a feeler gauge measure the side clearance of oil pump Standard side clearance 0 03 0 10 mm 0 0012 0 0039 in Maximum side clearance 0 10 mm 0 0039 in If the side clearance greater than the maximum replace the drive rotor or driven rotor ASSEMBLY OF REAR EXT...

Page 196: ...0 b Using SST and a press install a new rear extension hous ing dust deflector SST 09316 20011 09316 60010 09316 00010 3 INSTALL OIL SEAL Using SST and a hammer drive in a new oil seal SST 09316 60010 09316 00010 09316 00030 4 INSTALL REAR OUTPUT SHAFT a Using SST and a press install the rear output shaft SST 09316 60010 09316 00010 09316 00030 09316 20011 b Using snap ring pliers install the snap...

Page 197: ...PUMP PLATE SEPARATOR a Install the oil pump plate b Install the separator c Install and torque the three bolts Torque 4 9 Nm 50 kgfcm 43 in lbf 7 INSTALL CENTER DIFFERENTIAL CONTROL COUPLING ASSEMBLY a Install the coupling assembly b Using snap ring pliers install the snap ring 8 INSTALL VALVE SEAT BALL SPRING AND SCREW PLUG a Apply gear oil to the ball b Install the valve seat ball and spring ...

Page 198: ...DRIVEN ROTOR a Apply gear oil to the driven rotor b Install the driven rotor 10 INSTALL DRIVE ROTOR a Apply gear oil to the drive rotor b Install the drive rotor HINT Align the alignment marks 11 INSTALL OIL PUMP COVER a Install the oil pump cover b Using a torx socket wrench install and torque the three screws Torx socket wrench T30 09042 00010 Torque 4 9 N m 50 kgfcm 43 in lbf NOTICE Align the o...

Page 199: ...316 20011 b Using SST and a hammer install the idle gear bearing race SST 0931 6 60010 0931 6 00010 09316 00040 2 INSTALL OIL RECEIVER TO FRONT CASE a Install the oil receiver b Install and torque the bolt Torque 11 7 Nm 120 kgf cm 8 6 ft lbf 3 INSTALL SHIFT OUTER LEVER AND INNER LEVER a Install the shift outer lever and inner lever b Using a pin punch hammer and socket wrench install the lever lo...

Page 200: ...ORK NO 1 AND FORK SHAFT Using a pin punch and a hammer drive in the slotted spring pin 5 INSTALL IDLE GEAR ASSEMBLY CENTER DIFFEREN TIAL ASSEMBLY AND HIGH AND LOW SHIFT FORK AS SEMBLY TO FRONT CASE 6 INSTALL INPUT SHAFT ASSEMBLY Using a plastic hammer tap in the input shaft 7 INSTALL TWO BEARING RACES TO REAR CASE ...

Page 201: ... of the front case b Apply seal packing to the front case as shown Seal packing Part No 08826 00090 THREE BOND 1281 or equivalent HINT Install the rear case as soon as the seal packing is applied c Using a plastic hammer tap the rear case and assemble it d Apply liquid sealer to the A bolt threads Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent e Install and torque the eight ...

Page 202: ...REE BOND 1344 LOCTITE 242 or equivalent e Install and torque the five bolts Torque 37 Nm 380 kgfcm 27 ftlbf 11 SELECT ADJUSTING SHIMS FOR IDLER GEAR REAR TAPER ROLLER BEARING a Using a vernier calipers measure dimension HINT Lightly hold down the bearing outer race in the thrust direction to eliminate any looseness before making the measurement b Using a steel straight edge and feeler gauge measur...

Page 203: ...he five bolts Torque 39 2 Nm 400 kgf cm 28 ft lbf 14 INSTALL REAR EXTENSION HOUSING a Install the oil pump drive shaft b Remove any packing material and be careful not drop oil on the contacting surfaces of the rear case c Apply seal packing to the rear case as shown Seal packing Part No 08826 00090 THREE BOND 1281 or equivalent HINT Install the rear extension housing as soon as the seal packing i...

Page 204: ...Remove any packing material and be careful not to drop oil on the contacting surfaces of the front case b Apply seal packing to the front case as shown Seal packing Part No 08826 00090 THREE BOND 1281 or equivalent HINT Install the front extension housing as soon as the seal packing is applied c Set the clutch sleeve in 4WD condition in differential lock condition install the front extension housi...

Page 205: ...uid sealer to the bolt threads Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent c Install and torque the ten bolts Torque 19 Nm 195 kgf cm 14 ft lbf 20 INSTALL TRANSFER INDICATOR SWITCHES Install and torque the Center Diff Lock indicator switch L4 position switch and neutral position switch Torque 37 Nm 380 kgf cm 27 ft lbf 21 INSTALL BALL SPRING AND SCREW PLUG a Install the b...

Page 206: ...t to drop oil on the contacting surfaces of the front case b Apply seal packing to the front case as shown Seal packing Part No 08826 00090 THREE BOND 1281 or equivalent HINT Install the motor actuator as soon as the seal packing is applied c Install the motor actuator HINT Set the motor actuator in differential lock condi tion d Install and torque the four bolts Torque 18 1 N m 185 kgfcm 13 3 ft ...

Page 207: ...SPECTION INSPECT SHIFT LEVER POSITION a Start the engine and center differential lock switch turned to OFF b Check that the center differential indicator light comes on when the transfer shift lever shifted to L position Check that the light goes off when the lever is shifted to N or H position ...

Page 208: ...and recheck the circuit b Apply battery voltage between terminals and check that there is continuity between terminals as shown in the chart If continuity is not as specified replace the relay 2 INSPECT MOTOR ACTUATOR a Using an ohmmeter measure the resistance between ter minals 2 and 3 Standard resistance 0 3 100 fi b Using an ohmmeter measure the resistance between ter minals 2 or 3 and body gro...

Page 209: ...TRANSFER SERVICE SPECIFICATIONS TR 51 SERVICE SPECIFICATIONS SERVICE DATA ...

Page 210: ...TR 52 TRANSFER SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS ...

Page 211: ...ER TO LAND CRUISER STATION WAGON REPAIR MANUAL FOR CHASSIS AND BODY Pub No RM184E NOTE The following pages contain only the points which differ from the above listed man ual STATION WAGON DESCRIPTION PR 2 PROPELLER SHAFT PR 3 ...

Page 212: ...PR 2 PROPELLER SHAFT STATION WAGON DESCRIPTION DESCRIPTION DESCRIPTION The propeller shaft is connected to the front differential and the transfer via two joints ...

Page 213: ...PROPELLER SHAFT STATION WAGON PROPELLER SHAFT PR 3 PROPELLER SHAFT COMPONENTS ...

Page 214: ... 4 PROPELLER SHAFT STATION WAGON PROPELLER SHAFT PROPELLER SHAFT ASSEMBLY HINT When replacing the spider be sure that the grease fitting assembly hole is facing in the direction shown in the illustration ...

Page 215: ...nts which differ from the above listed manuals HARDTOP CANVAS TOP FRONT DIFFERENTIAL SA 2 ASSEMBLY REMOVAL AND INSTALLATION SA 2 STATION WAGON WHEEL ALIGNMENT SA 3 PRIMARY INSPECTION SA 3 FRONT WHEEL ALIGNMENT SA 4 FRONT DIFFERENTIAL SA 6 ASSEMBLY REMOVAL AND INSTALLATION SA 6 SERVICE SPECIFICATIONS SA 7 ...

Page 216: ...SA 2 SUSPENSION AND AXLE HARDTOP CANVAS TOP FRONT DIFFERENTIAL FRONT DIFFERENTIAL ASSEMBLY REMOVAL AND INSTALLATION COMPONENTS ...

Page 217: ... Tire runout 3 0 mm 0 118 in or less c Check the wheel bearings for looseness d Check the suspension for looseness e Check the steering linkage for looseness f Check that the absorbers work properly by using the stan dard bounce test 2 MEASURE FOLLOW SPRING CLEARANCE AND BUMPER STOPPER CLEARANCE A Follow spring clearance Front B Bumper stopper clearance Rear If the clearance of the vehicle is not ...

Page 218: ...ALIGNMENT 1 INSTALL WHEEL ALIGNMENT EQUIPMENT Follow the specific instructions of the equipment manufacturer 2 INSPECT CAMBER AND STEERING AXIS INCLINATION Camber 1 00 45 1 00 0 75 Cross camber 30 or less 0 50 or less Steering axis inclination 13 00 45 13 00 0 75 If the steering axis inclination is not as specified after camber have been correctly adjusted recheck the steer ing knuckle and front w...

Page 219: ...topper bolts and check the steering angles Wheel angle HINT When the steering wheel is fully turned make sure that the wheel is not touching the body or brake flexi ble hose If maximum steering angles differ from the standard value adjust the wheel angle with the knuckle stopped bolts Torque 44 N m 450 kgfcm 33 ft lbf If the wheel angle still cannot be adjusted within limits in spect and replace d...

Page 220: ...SA 6 SUSPENSION AND AXLE STATION WAGON FRONT DIFFERENTIAL FRONT DIFFERENTIAL ASSEMBLY REMOVAL AND INSTALLATION COMPONENTS ...

Page 221: ...SUSPENSION AND AXLE SERVICE SPECIFICATIONS SA 7 SERVICE SPECIFICATIONS SERVICE DATA STATION WAGON ...

Page 222: ...SA 8 SUSPENSION AND AXLE SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS HARDTOP CANVAS TOP STATION WAGON ...

Page 223: ... ADJUSTMENT BR 4 MASTER CYLINDER BR 6 LOAD SENSING PROPORTIONING AND BY PASS VALVE LSP BV BR 13 ANTI LOCK BRAKE SYSTEM ABS BR 2O DESCRIPTION BR 2O DIAGNOSIS SYSTEM BR 24 SPEED SENSOR AND DECELERATION SENSOR DIAGNOSIS SYSTEM BR 34 DECELERATION SENSOR OPERATION DIAGNOSIS SYSTEM BR 38 ABS ACTUATOR BR 40 CONTROL RELAY BR 45 FRONT SPEED SENSOR BR 46 REAR SPEED SENSOR BR 51 ANTI LOCK BRAKE SYSTEM CIRCUI...

Page 224: ...0 00210 ABS Actuator Checker Sub harness E w ABS 09990 00200 ABS Actuator Checker Sub harness C w ABS 09990 00163 ABS Actuator Checker Sheet A w ABS 09990 00150 ABS Actuator Checker and Sub harness w ABS 09843 18020 Diagnosis Check Wire w ABS 09751 36011 Brake Tube Union Nut 10 x 12 mm Wrench 09737 00010 Brake Booster Push Rod Gauge 09709 29017 LSPV Gauge Set 09023 00100 Union Nut Wrench 10 mm ...

Page 225: ...BR 3 BRAKE SYSTEM STATION WAGON PREPARATION LUBRICANT Item Brake fluid Capacity Classification SAE J17O3 or FMVSS No 116 DOT 3 ...

Page 226: ... 02 0 09 in i Tighten the stop light switch lock nut j Connect the connector to the stop light switch k Check that the stop lights come on when the brake pedal is depressed and go off when the brake pedal is released I After adjusting the pedal height check the pedal freeplay HINT If clearance A between the stop light switch and the brake pedal stopper has been adjusted correctly the pedal freepla...

Page 227: ... CORRECT AS SHOWN Release the parking brake With the engine running depress the pedal and measure the pedal reserve distance as shown Pedal reserve distance from asphalt sheet at 490 N 50 kgf 110 2 Ibf More than 68 mm 2 68 in If the reserve distance is incorrect troubleshoot the brake system ...

Page 228: ... WAGON MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER REMOVAL Brake Booster Gasket Master Cylinder Clamp Brake Booster Gasket Clamp Master Cylinder w o ABS Bracket w ABS RHD LHD Bracket 3 Way Specified torque Non reusable part ...

Page 229: ...ake fluid remain on a painted sur face Wash it off immediately 3 DISCONNECT BRAKE LINES Using SST disconnect brake lines from the master cylinder SST 09023 00100 4 REMOVE MASTER CYLINDER a Remove the mounting nuts b w ABS Remove the 3 way clamp and the bracket w o ABS Remove the clamp and the bracket c Pull out the master cylinder and gasket ...

Page 230: ...iner Reservoir No 1 Piston and Spring Boot Grommet No 2 Piston and Spring Snap Ring Gasket Clamp Piston Stopper Bolt Cap Strainer Reservoir No 1 Piston and Spring Grommet Snap Ring No 2 Piston and Spring Gasket Piston Stopper Bolt Clamp Specified torque Non reusable part w ABS ...

Page 231: ...t the reservoir 4 REMOVE TWO GROMMETS 5 PLACE CYLINDER IN VISE 6 REMOVE NO 2 PISTON STOPPER BOLT Using a screwdriver push the pistons in all the way and remove the No 2 piston stopper bolt and gasket HINT Tape the screwdriver tip before use 7 REMOVE TWO PISTONS a Push in the piston with a screwdriver and remove the snap ring with snap ring pliers b Remove the No 1 piston and spring by hand pulling...

Page 232: ...PECT CYLINDER BORE FOR RUST OR SCORING 2 INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary clean or replace the cylinder MASTER CYLINDER ASSEMBLY 1 APPLY LITHIUM SOAP BASE GLYCOL GREASE TO RUB BER PARTS INDICATED BY ARROWS 2 INSTALL TWO PISTONS NOTICE Be careful not to damage the rubber lips on the pistons a Install the two springs and pistons straight in not at an angle NOTICE If insert at an angl...

Page 233: ...e 1 7 Nm 17 5 kgfcm 15 2 in lbf 6 INSTALL RESERVOIR CAP a Align the matchmark on the reservoir cap with the mat chmark on the OPEN side of reservoir b Push down on the reservoir cap and turn it clockwise until it locks c Check that the matchmark on the reservoir cap is now aligned with the matchmark on the CLOSE side of the reservoir 7 INSTALL MASTER CYLINDER BOOT With the UP mark on the master cy...

Page 234: ... on the brake booster with the four nuts b Tighten the mounting nuts Torque 13 Nm 130 kgfcm 9 ftlbf 3 CONNECT BRAKE LINES Using SST connect the brake lines to the master cylinder Torque the union nuts SST 09023 00100 Torque 15 Nm 155 kgfcm 11 ftlbf 4 CONNECT LEVEL WARNING SWITCH CONNECTOR 5 FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM See pub No RM184E page BR 7 6 CHECK FOR LEAKS 7...

Page 235: ...PONENTS Set Plate Load Sensing Proportioning and By pass Valve Valve Bracket Load Sensing Spring Assembly Plate Washer Plate Washer Load Sensing Valve Boot Shackle No 1 Shackle No 2 Cotter Pin Collar Cushion Retainer Cushion Shackle Braket Collar Bushing Load Sensing Spring Bushing Load Sensing Spring Boot Specified torque Non reusable part ...

Page 236: ...f cm2 869 86 psi HINT The brake pedal should not be depressed twice and or returned while setting to the specified pressure Read the value of rear pressure two seconds after ad justing the specified fluid pressure 4 IF NECESSARY ADJUST FLUID PRESSURE a Disconnect the No 2 shackle from the shackle bracket b Adjust the length of the No 2 shackle turning it Low pressure Lengthen A High pressure Short...

Page 237: ... CHECK VALVE BODY a Assemble the valve body in the uppermost position HINT When the brakes are applied the piston will move down about 1 mm 0 039 in Even at this time the piston should not make contact with or move the load sensing spring b In this position check the rear brake pressure LSP BV REMOVAL 1 DISCONNECT SHACKLE NO 2 FROM BRACKET a Remove the cotter pin b Remove the nut and disconnect th...

Page 238: ...cket and two bolts from the valve body 2 DISCONNECT SPRING FROM VALVE Using pliers remove the clip and remove the spring from the valve 3 REMOVE SHACKLE NO 1 AND NO 2 a Remove the bolt and nut then remove the following parts Load sensing spring Two plate washers b Loosen the two nuts and remove the shackle No 1 from the shackle No 2 4 DISASSEMBLY LOAD SENSING SPRING Disassembly the following parts...

Page 239: ...oot c Bushings d Rubber plates e Collars HINT Apply lithium soap base glycol grease to all rubb ing areas Do not mistake the valve side for the shackle side of the load sensing spring 2 INSTALL SHACKLE NO 1 AND NO 2 TO LOAD SENSING SPRING a Install the lock nut and shackle No 1 to the shackle No 2 b Install and torque the bolt and nut as shown in illustra tion Torque 18 Nm 185 kgf cm 13 ftlbf 3 IN...

Page 240: ... 13 ftlbf LSP BV INSTALLATION 1 INSTALL LSP BV ASSEMBLY Install the LSP BV assembly to the frame with the four bolts Torque 19 Nm 195 kgfcm 14 ftlbf 2 CONNECT SHACKLE NO 2 TO BRACKET a Set the dimension A by turning shackle No 2 Initial set 90 mm 3 54 in b Tighten the lock nut Torque 25 Nm 250 kgfcm 18 ftlbf c Install the two bushings and collar to the load sensing spr ing shackle d Install the lo...

Page 241: ...ee page BR 16 5 SET VALVE BODY a When pulling down the load sensing spring confirm that the valve piston moves down smoothly b Position the valve body so that the valve piston lightly contacts the load sensing spring c Tighten the valve body mounting nuts Torque 13 Nm 130 kgfcm 9 ft lbf 6 BLEED BRAKE SYSTEM See pub No RM184E page BR 7 7 CHECK FLUID LEAKAGE 8 CHECK AND ADJUST LSP BV FLUID PRESSURE ...

Page 242: ...ke while keeping the effect upon stability and steerability to a minimum even on curves The function of the ABS is to help maintain directional stability and vehicle steerability on most road condi tions However the system cannot prevent the vehicle from skidding if the cornering speed limit is ex ceeded The ABS has a longitudinal deceleration sensor to match braking characteristics to the full ti...

Page 243: ... the center differential is locked Controls the brake fluid pressure to each disc brake cylinder through signals from the ECU From the wheel speed signals from each sensor it calculates ac celeration deceleration and slip values and sends signals to the ac tuator to control brake fluid pressure Detect the deceleration speed of the vehicle and sends a signal ac cordingly to the ABS ECU SYSTEM PARTS...

Page 244: ...BR 22 BRAKE SYSTEM STATION WAGON ANTI LOCK BRAKE SYSTEM ABS WIRING DIAGRAM ...

Page 245: ...E SYSTEM STATION WAGON ANTI LOCK BRAKE SYSTEM ABS BR 23 CONNECTORS ABS Actuator CONNECTOR A CONNECTOR B Control Relay Front Speed Sensor Deceleration Sensor Rear Speed Sensor LH Rear Speed Sensor RH ABS ECU ...

Page 246: ... the number of blinks diagnostic code of the war ning light In the event of two codes that having the smallest numbered code will be identified first HINT The warning light does not show the diagnostic codes while the vehicle is running When the transfer is in L center differential lock posi tion the ABS does not operate and the ABS warning light stays on DIAGNOSIS SYSTEM INSPECTION 1 INSPECT BATT...

Page 247: ...it code If there are two or more codes there will be a 2 5 second pause between each and indication will begin after 4 0 second pause from the smaller value and continue in order to larger e If the system is operating normally no malfunction the warning light will blink once every 0 5 seconds f Repair the system g After the malfunctioning components has been repaired clear the diagnostic codes sto...

Page 248: ...BR 26 BRAKE SYSTEM STATION WAGON ANTI LOCK BRAKE SYSTEM ABS DIAGNOSTIC CODE ...

Page 249: ...onnect terminals Tc and of the check con nector SST 09843 18020 HINT Keep the vehicle stopped vehicle speed 0 km h 0 mph d Clear the diagnostic codes stored in ECU by depressing the brake pedal 8 or more times within 3 seconds e Check that the warning light shows the normal code f Remove the SST from terminals Tc and Ei of the check connector SST 09843 18020 g Check that the warning light goes off...

Page 250: ...idding noise occurs while ABS operating ABS operates inefficiently When the transfer is in L center differential lock position the ABS operates Also check the parts of the brake system brake cylinders pads hydraulic lines etc not specifically part of the ABS No 1 2 3 1 6 4 4 4 4 4 5 6 1 ABS warning light comes on Is center differential locked transfer in L position YES Pull out the short pin and c...

Page 251: ... ECU connector Is there 10 16 V between terminal IG on ECU wire harness side connector and body ground Ignition switch on NO Faulty power circuit YES Does warning light go off when both the ECU connector and service connector are disconnected Ignition switch on NO Come on Short circuit in wire harness between ECU terminal W and control relay Terminal W YES Goes off Faulty ECU ...

Page 252: ... W of the female side connector Ignition switch on NO Does warning light come on Bulb burned out or open circuit in wire harness between warning light and control relay terminal W YES Disconnect connectors from ECU and control relay and ground terminal W or ECU wire harness side con enctor Ignition switch on Does warning light come on YES NO Open circuit in wire harness between ECU terminal W and ...

Page 253: ...ed sensors installed in place And are each installation bolts tightened securely NO Speed sensor installation faulty Try speed sensor and deceleration sensor diagnosis system Is sensor signal level OK See page BR 34 YES NO Inspectspeed sensor and replace ifnecessary Try speed sensor and deceleration sensor diagnosis system Is sensor signal change OK See page BR 34 NO Inspect sensor rotor and repla...

Page 254: ...ty Inspect the actuator operation See page BR 52 Is actuator operation OK NO Faulty actuator YES Repalce ECU 5 Anti lock brake system operations infficiently Pull out the short pin and connect terminals and of check connector See page BR 25 Does warning light show the diagnostic normal code Ignition switch on NO YES See diagnostic code See page BR 26 Is there battery voltage between ECU terminal S...

Page 255: ...e transfer is in L position does the center dif ferential lock indicator light come on NO Open circuit in center differential lock in dicator switch or wire harness Faulty center differential lock YES When the ECU connector is disconnected is there con tinuity between the body and terminal EX1 on the vehi cle wire harness side NO Open circuit in wire harness YES Replace ECU ...

Page 256: ... Check that the ABS warning light turns on for 3 seconds If not inspect and repair or replace the fuse bulb and wire harness c Check that the ABS warning light turns off d Turn the ignition switch off 3 PERFORM FOLLOWING STEPS a Using SST connect terminals and of the check con nector in engine room SST 09843 18020 b Start the engine c Check that the warning light blinks about 4 times every 1 secon...

Page 257: ...n step 4 does not occur an abnormal signal is output The high speed check is possible at 80 km h 50 mph or highter 6 READ DIAGNOSTIC CODE a Stop the vehicle and warning light will being to blink b Using SST connect the terminals and of check con nector c Read the number of blinks of the ABS warning light See page BR 37 HINT If normal the warning light blinks about 4 times every 1 second If two or ...

Page 258: ...RAKE SYSTEM ABS 7 REPAIR MALFUNCTIONING PARTS Repair or replace the malfunctioning parts HINT When repairing or replacing parts turn the igni tion switch to OFF 8 REMOVE SST Remove the SST from terminals and of the check connector SST 09843 18020 ...

Page 259: ...BR 37 BRAKE SYSTEM STATION WAGON ANTI LOCK BRAKE SYSTEM ABS DIAGNOSTIC CODE ...

Page 260: ...r or replace the fuse bulb and wire harness c Check that the ABS warning light turns off d Turn the ignition switch to OFF 3 PERFORM FOLLOWING STEPS a Using SST connect the terminal to of the check con nector SST 09843 18020 b Check that the warning light blinks about 4 time every 1 second when 3 seconds after the engine is started 4 INSPECT SENSOR DETECTION POINT a Jack up the rear side of the ve...

Page 261: ... depress the brake pedal b Check that there is no change in the warning light pat tern c Drive the vehicle straight ahead at about 20 km h 12 4 mph or more depress the brake pedal a little strong d Check that the warning light turns on while braking e Drive the vehicle straight ahead at about 20 km h 12 4 mph or more depress the brake pedal strongly f Check that the warning light pattern changes w...

Page 262: ... STATION WAGON ANTI LOCK BRAKE SYSTEM ABS ABS ACTUATOR ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts as shown Control Relay Rubber Cushion Holder ABS Actuator Clamp Actuator Bracket Specified torque ...

Page 263: ... BR 41 MAIN POINTS OF REMOVAL AND INSTALLATION 1 DISCONNECT AND CONNECT BRAKE LINES Using SST disconnect and connect the brake lines from to the ABS actuator SST 09023 00100 Torque 15 Nm 155 kgfcm 11 ftlbf 2 BLEED BRAKE SYSTEM See pub No RM184E page BR 7 ...

Page 264: ...TOR CHECKER SST TO ACTUATOR a Connect the actuator checker SST to the actuator con trol relay and body side wire harness through the sub wire harness C and E SST as shown SST 09990 00150 09990 00200 09990 00210 b Connect the red cable of the checker to the battery positive terminal and black cable to the negative terminal Connect the black cable of the sub wire harness to the battery negative term...

Page 265: ...d down for more than 10 seconds f Release the switch and check that the pedal goes down g Push and hold in the SUB MOTOR switch for a few seconds and check that the pedal returns h Release the brake pedal i Push and hold in the SUB MOTOR switch for a few seconds j Depress the brake pedal and hold it for about 1 5 seconds As you hold the pedal down push the MOTOR SWITCH for a few seconds Check that...

Page 266: ...CKER SST FROM AC TUATOR Disconnect the actuator checker SST and sub wire harness SST from the actuator control relay and body side wire harness SST 09990 00150 09990 00200 09990 00210 8 CONNECT CONNECTORS a Connect the two connectors to the control relay b Connect the connector to the actuator c Install the control relay to the actuator bracket 9 CLEAR DIAGNOSTIC CODES See page BR 27 ...

Page 267: ...at there is continuity between terminals 1 and 9 b Check that there is no continuity between terminals 2 and 5 c Connect the positive lead from the ohmmeter to terminal 5 and connect negative lead to terminal 4 d Check that there is continuity between terminals e Connect the two leads in reverse and check that there is no continuity between terminals If continuity is not as specified replace the r...

Page 268: ...NTS Front Speed Sensor Sensor Rotor Specified torque FRONT SPEED SENSOR INSPECTION 1 INSPECT SPEED SENSOR a Disconnect the speed sensor connector b Measure the resistance between terminals FR FR and FL F L Resistance 0 87 1 27 kQ If resistance value is not as specified replace the sensor ...

Page 269: ... hub with disc See pub No RM184E page SA 16 b Inspect the sensor rotor serrations for scratches cracks warping or missing teeth c Install the axle hub with disc See pub No RM184E page SA 19 FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION REFERENCE INSPECT FRONT SPEED SENSOR AND SENSOR ROTOR SER RATIONS BY USING AN OSCILLOSCOPE a Connect an oscilloscope to the speed sensor connector b Run...

Page 270: ...SENSOR CONNECTOR 2 REMOVE SPEED SENSOR a Remove the four clamp bolts holding the sensor harness RH from the axle housing b Remove the eight clamp bolts holding the sensor harness LH from the axle housing and leading arm c Remove the speed sensor LH and RH from the steering knuckle FRONT SPEED SENSOR INSTALLATION 1 INSTALL SPEED SENSOR WIRE HARNESS a Install the sensor harness LH with the clamps an...

Page 271: ...he sensor adjust the air gap a Install the speed sensor LH and RH to the steering knuckle Torque 18 N m 185 kgf cm 13 ft lbf b Connect the connector FRONT SPEED SENSOR AIR GAP ADJUSTMENT FRONT SPEED SENSOR AIR GAP ADJUSTMENT a Install the speed sensor and 0 2 mm spacer to the steer ing knuckle b Try speed sensor and deceleration sensor diagnosis system c If diagnosis code 71 or 72 is not displayed...

Page 272: ... code 71 or 72 is not displayed remove the 0 2 mm spacer and install the speed sensor to the steer ing knuckle g If diagnosis code 71 or 72 is displayed replace the 0 35 mm spacer with a 0 25 mm spacer h Repeating a and b to the step 1 i If diagnosis code 71 or 72 is not displayed remove the 0 2 mm spacer and install the speed sensor to the steer ing knuckle j If diagnosis code 71 or 72 is display...

Page 273: ...ENTS Rear Speed Sensor Disc Brake Assembly Specified torque Brake Disc REAR SPEED SENSOR INSPECTION 1 INSPECT SPEED SENSOR a Disconnect the speed sensor connector b Measure the resistance between terminals Resistance 0 7 1 1 kQ If resistance value is not as specified replace the sensor ...

Page 274: ...age BR 57 b Inspect the sensor rotor serrations for scratches cracks warping or missing teeth c Install the brake disc See pub No RM184E page BR 64 NOTICE To prevent damage to the serrations do not strike the axle hub REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION REFERENCE INSPECT REAR SPEED SENSOR AND SENSOR ROTOR SERRA TIONS BY USING AN OSCILLOSCOPE a Connect an oscilloscope to the sp...

Page 275: ...NSOR CONNECTOR a Disconnect the speed sensor connector b Remove the five clamp bolts holding the sensor wire harness from the suspension arm and frame 2 REMOVE SPEED SENSOR Remove the speed sensor from the axle end REAR SPEED SENSOR INSTALLATION 1 INSTALL SPEED SENSOR Install the speed sensor to the axle end Torque 18 Nm 185 kgf cm 13 ft lbf 2 CONNECT SPEED SENSOR CONNECTOR a Connect the speed sen...

Page 276: ...BR 54 BRAKE SYSTEM STATION WAGON ANTI LOCK BRAKE SYSTEM ABS b Install the sensor harness with the clamps and bolts in place 3 INSPECT SPEED SENSOR AND DECELERATION SENSOR DIAGNOSIS SYSTEM ...

Page 277: ...M ABS BR 55 ANTI LOCK BRAKE SYSTEM CIRCUIT SYSTEM CIRCUIT INSPECTION 1 INSPECT SYSTEM CIRCUIT WITH CONNECTOR CON NECTED a Remove the ABS ECU b Using a voltmeter with high impedance 10 kfl V minimum measure the voltage at each terminal and body ground ...

Page 278: ...YSTEM ABS If the circuit is not as specified check and repair or replace the trouble part shown in the table above 2 INSPECT SYSTEM CIRCUIT WITH CONNECTOR DISCON NECTED a Disconnect the connectors from the ECU inspect at the wire harness side connector ...

Page 279: ...BRAKE SYSTEM STATION WAGON SERVICE SPECIFICATIONS BR 57 SERVICE SPECIFICATIONS SERVICE DATA TORQUE SPECIFICATIONS ...

Page 280: ...g pages contain only the points which differ from the above listed manuals HARDTOP CANVAS TOP STATION WAGON WIPER AND WASHER SYSTEM BE 2 COMBINATION METER BE 3 POWER SEAT CONTROL SYSTEM BE 21 CRUISE CONTROL SYSTEM BE 29 EXTRA SUB TANK SYSTEM BE 5O SATELLITE NAVIGATION SYSTEM BE 59 ...

Page 281: ...ry to ter minal 2 and the negative lead to terminal 1 check that the moor operates at high speed If operation is not as specified replace the motor OPERATION STOPPING AT STOP POSITION a Operate the motor at low speed and stop the motor opera tion anywhere except at the stop position by disconnec ting positive lead from terminal 3 b Connect terminal 3 and 5 c Connect the positive lead from the batt...

Page 282: ...BODY ELECTRICAL SYSTEM COMBINATION METER BE 3 COMBINATION METER PARTS LOCATION ...

Page 283: ...BE 4 BODY ELECTRICAL SYSTEM COMBINATION METER METER CIRCUIT ...

Page 284: ...BODY ELECTRICAL SYSTEM COMBINATION METER BE 5 METER CIRCUIT ...

Page 285: ...BE 6 BODY ELECTRICAL SYSTEM COMBINATION METER METER CIRCUIT ...

Page 286: ...BODY ELECTRICAL SYSTEM COMBINATION METER BE 7 ...

Page 287: ...NG The table below will be useful for you in troubleshooting these electrical problems The most likely causes of the malfunction are shown in the order of their probability Inspect each part in the order shown and replace the part when it is found to be faulty ...

Page 288: ...BODY ELECTRICAL SYSTEM COMBINATION METER BE 9 ...

Page 289: ...ibration and abnor mal noise HINT Pointer vibration can be caused by a loose speedometer cable SPEED SENSOR INSPECTION a Connect the positive lead from battery to terminal 1 and negative lead to terminal 2 b Connect the positive lead from tester to terminal 3 and negative lead to terminal 2 c Revolve shaft d Check that there is voltage changer from approx 0 V to 11 V or more between terminal 3 and...

Page 290: ...lace the tachometer FUEL GAUGE SYSTEM FUEL RECEIVER GAUGE INSPECTION OPERATION a Disconnect the connector from the sender gauge b Turn the ignition switch ON check that the receiver gauge needle indicates EMPTY c Connect terminals 4 and 5 on the wire harness side con nector through a 3 4 watts test bulb d Turn the ignition switch ON check that the bulb lights up and the receiver gauge needle moves...

Page 291: ...resistance between terminals 4 and 5 If resistance value is not as specified replace the sender gauge FUEL LEVEL WARNING SYSTEM INSPECT WARNING LIGHT a Disconnect the connector from the sender gauge b Connect terminals 1 and 5 on the wire harness side con nector c Turn the ignition switch ON check that the warning light lights up If the warning light does not light up test the bulb INSPECT WARNING...

Page 292: ...TION a Disconnect the connector from the sender gauge b Turn the ignition switch ON check that the receiver gauge needle indicates COOL c Ground terminal on the wire harness side connector through a 3 4 watts test bulb d Turn the ignition switch ON check that the bulb lights up and the receiver gauge needle moves to the hot side If operation is as specified replace the sender gauge Then recheck th...

Page 293: ...are the tester and voltmeter indications If error is excessive replace the voltmeter RESISTANCE Measure the receiver gauge resistance between ter minals Resistance 90 110 Q If resistance value is not as specified replace the receiver gauge HINT This resistance include fuel receiver gauge resistance ...

Page 294: ... If operation is not as specified measure the receiver gauge resistance RESISTANCE Measure the receiver gauge resistance between ter minals Resistance 22 28 Q If resistance value is not as specified replace the receiver gauge OIL PRESSURE SENDER GAUGE INSPECTION INSPECT SENDER GAUGE a Disconnect the connector from the sender gauge b Apply battery voltage to the sender gauge terminal through a test...

Page 295: ...p and strainer b Disconnect the connector c Check that there is no continuity between terminals with the switch OFF float up d Use syphon etc to take fluid out of the reservoir tank e Check that there is continuity between terminals with the switch ON float down f Pour the fluid back in the reservoir tank If operation is not as specified replace the switch OPEN DOOR WARNING SYSTEM OPEN DOOR WARNIN...

Page 296: ...t light test the bulb SEAT BELT BUCKLE SWITCH INSPECTION INSPECT SWITCH a Check that there is no continuity between terminals with the switch ON belt unfastened b Check that there is continuity between terminals with the switch OFF belt fastened If operation is not as specified replace the seat belt inner DOOR COURTESY SWITCH DOOR COURTESY SWITCH INSPECTION See page BE 16 SEAT BELT WARNING RELAY I...

Page 297: ...ide connector b Turn the ignition switch ON check that the warning light lights up If the warning light does not light up test the bulb TIRE HALF LOCK INDICATOR SWITCH INSPECTION INSPECT SWITCH a Check that there is continuity between terminal and the switch body with the ON switch pin released opened door b Check that there is no continuity between terminal and the switch body with the OFF switch...

Page 298: ...n oil bath c Check that there is continuity between terminals with the switch ON float up d Check that there is no continuity between terminals with the switch OFF float down If operation is not as specified replace the sensor METER ILLUMINATION CONTROL SYSTEM INSPECT LIGHT CONTROL RHEOSTAT a Connect terminals 1 and 3 through a 3 4 watts test bulb b Connect the positive lead from the battery to te...

Page 299: ...ON METER HINT Illumination lights with adjustable brightness Cigarette Lighter Ash Receptacle Antenna Switch Defogger Switch Headlight Cleaner Switch Audio A C Control Assembly Center Diff Lock Switch Hazard Warning Light Switch Shift Lever ...

Page 300: ...CONTROL SYSTEM PARTS LOCATION Fuse Block POWER Fuse Lumber Support Motor Reclining Motor Rear Vertical Motor Front Vertical Motor Power Seat Switch Slide Motor Reclining Motor Lumber Support Switch Power Seat Switch Rear Vertical Motor Slide Motor Front Vertical Motor ...

Page 301: ...below will be useful for you in troubleshooting these electrical problems The most likely causes of the malfunction are shown in the order of their probability Inspect each part in the order shown and replace the part when it is found to be faulty D Driver s Seat P Passenger s Seat ...

Page 302: ...AL SYSTEM POWER SEAT CONTROL SYSTEM BE 23 POWER SEAT SWITCH POWER SEAT SWITCH INSPECTION DRIVER S SIDE CONTINUITY Inspect the switch continuity between terminals If continuity is not as specified replace the switch ...

Page 303: ...BODY ELECTRICAL SYSTEM POWER SEAT CONTROL SYSTEM BE 24 PASSENGER S SIDE CONTINUITY Inspect the switch continuity between terminals If continuity is not as specified replace the switch ...

Page 304: ... operation noise within 4 to 60 seconds c Reverse the polarity check that the seat begins to move backwards within approximately 60 seconds If operation is not as specified replace the motor FRONT VERTICAL MOTOR INSPECTION MOTOR OPERATION a Connect the positive lead from the battery to ter minal 1 and the negative lead to terminal 2 check that the motor turns counterclockwise b Reverse the polarit...

Page 305: ...he positive lead and the negative lead from the battery to the rear vertical motor connector il lustrated terminals and move the front edge of seat cushion to the highest position b Continue to apply voltage check that there is a circuit breaker operation noise within 4 to 60 seconds c Reverse the polarity check that the seat cushion begins to descend within approximately 60 seconds If operation i...

Page 306: ...pply voltage check that there is a circuit breaker operation noise within 4 to 40 seconds c Reverse the polarity check that the seat starts to fall backwards within approximately 60 seconds If operation is not as specified replace the motor CIRCUIT BREAKER OPERATION PASSENGER S SEAT a Connect the positive lead from the battery to ter minal 2 and the negative lead to terminal 1 on the seat wire har...

Page 307: ...ation is not as specified replace the motor CIRCUIT BREAKER OPERATION a Connect the positive lead from the battery to ter minal 2 and the negative lead to terminal 1 on the lum bar support motor connector and move the lumbar sup port to front end position b Continue to apply voltage check that there is a circuit breaker operation noise within 4 to 60 seconds c Reverse the polarity check that the l...

Page 308: ...BODY ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM BE 29 CRUISE CONTROL SYSTEM PARTS LOCATION ...

Page 309: ...BODY ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM BE 30 CONNECTOR DIAGRAMS ...

Page 310: ...al 26 of the CC ECU When the occurs the position sensor sends the position of the actuator arm as a signal voltage from terminal 2 of the actuator to ter minal 25 of the CC ECU When the actual vehicle speed drops below the set speed the CC ECU sends a signal voltage from ter minal 12 terminal 6 of actuator motor terminal 7 of actuator terminal 11 of CC ECU This causes the motor to rotate the actua...

Page 311: ...N keep the SET or RESUME switch ON for 3 seconds d Check that the CRUISE indicator light lights up in the combination meter e Turn the SET COAST switch off f Meet the conditions listed in the table below g Read the diagnosis code on the cruise control indicator light HINT Indication codes appear in order from No 1 If there is no indication code perform troubleshooting and inspection See page BE 34...

Page 312: ...l blink 5 times b While stopped connect terminals 3 and Tc 11 of the check connector HINT If the ignition switch is turned off the diagnostic code will be erased from the computer memory c Read the diagnostic code on the indicator light CRUISE HINT When two or more codes are indicated the lowest numbered code will be displayed first When the vehicle speed is reduced on uphill roads the speed can b...

Page 313: ... SYSTEM BE 34 TROUBLESHOOTING You will find the source of the trouble more easily by properly using the table shown below In this table the numbers indicate the order of priority of the causes of trouble Check each part in the order shown ...

Page 314: ...BODY ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM BE 35 POWER SOURCE CIRCUIT HINT While carrying out the following inspection make certain that the connectors and terminals are pro perly connected ...

Page 315: ...E 36 BODY ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM CRUISE CONTROL INDICATOR CIRCUIT HINT While carrying out the following inspection make certain that the connectors and terminals are pro perly connected ...

Page 316: ...BODY ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM BE 37 CONTROL SWITCH CIRCUIT HINT While carrying out the following inspection make certain that the connectors and terminals are pro perly connected ...

Page 317: ...BODY ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM BE 38 ACTUATOR CIRCUIT HINT While carrying out the following inspection make certain that connectors and terminals are proper ly connected ...

Page 318: ...BODY ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM BE 39 ...

Page 319: ...BE 40 BODY ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM SPEED SENSOR CIRCUIT HINT While carrying out the following inspection make certain that the connectors and terminals are pro perly connected ...

Page 320: ...BODY ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM BE 41 STOP LIGHT SWITCH CIRCUIT HINT While carrying out the following inspection make certain that the connectors and terminals are pro perly connected ...

Page 321: ...BODY ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM BE 42 ...

Page 322: ...BODY ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM BE 43 PARKING BRAKE SWITCH CIRCUIT HINT While carrying out the following inspection make certain that the connectors and terminals are pro perly connected ...

Page 323: ...T HINT While carrying out the following inspection make certain that the connectors and terminals are pro perly connected H ECT SOLENOID No 2 CIRCUIT with A T I HINT While carrying out the following inspection make certain that the connectors and terminals are pro perly connected ...

Page 324: ...Y ELECTRICAL SYSTEM CRUISE CONTROL SYSTEM BE 45 IDL SIGNAL CIRCUIT w 1FZ FE Engine J HINT While carrying out the following inspection make certain that the connectors and terminals are pro perly connected ...

Page 325: ...LECTRICAL SYSTEM CRUISE CONTROL SYSTEM Cruise Control ECU Circuit INSPECT ECU CIRCUIT Disconnect connector and inspect connector on wire harness side as shown in the chart If circuit is as specified try another ECU ...

Page 326: ... set nut with switch pin released parking brake lever pulled up b Check that there is no continuity between terminal and the switch set nut with switch pin pushed in parking brake lever released If operation is not as specified replace the switch SPEED SENSOR INSPECTION INSPECT SENSOR a Connect the positive lead from battery to terminal 1 and negative lead to terminal 2 b Connect the positive lead...

Page 327: ... With the magnetic clutch ON connect the positive lead from the battery to terminal 6 and the negative lead to terminal 7 check that the arm moves to the open side b When the arm reached to the open position check that the motor operation stops c With the magnetic clutch ON connect the positive lead from the battery to terminal 7 and the negative lead to terminal 6 check that the arm moves to the ...

Page 328: ...ly is completed b With the magnetic clutch ON connect the positive lead from the battery to terminal 6 and the negative lead to terminal 7 Arm moves to the open side c With the magnetic clutch ON connect the positive lead from the battery to terminal 7 and the negative lead to terminal 6 Arm moves to the close side d Install the control link assembly to the actuator e Rotate the control link assem...

Page 329: ...BODY ELECTRICAL SYSTEM EXTRA SUB TANK SYSTEM BE 50 EXTRA SUB TANK SYSTEM PARTS LOCATION ...

Page 330: ...BODY ELECTRICAL SYSTEM EXTRA SUB TANK SYSTEM BE 51 ...

Page 331: ...m to check for malfunctions Repair any malfunctions found Then check for malfunction in the parts shown in the table below The most likely causes of malfunction are shown in the order of their probability Inspect each part in the order shown and replace the part when it is found to be faulty ...

Page 332: ...the fuel pump as far away from the battery as possi ble Always perform switching at the battery side If operation is not as specified replace the fuel pump SUB FUEL SWITCH INSPECT SUB FUEL SWITCH INSPECT INDICATOR LIGHT a Connect the positive lead from the battery to termi nal 8 and the negative lead to terminal 2 b Set the switch ON check that the indicator light lights up If the indicator light ...

Page 333: ...EM EXTRA SUB TANK SYSTEM BE 54 FUEL LEVEL SWITCH INSPECT FUEL LEVEL SWITCH Continuity FZJ7O type Main Tank FZJ7O type Extra Tank FZJ80 type Main Tank FZJ80 type Sub Tank If continuity is not as specified replace the switch ...

Page 334: ...8O type Main tank FZJ7O type Main tank FUEL SOLENOID VALVE INSPECT FUEL SOLENOID VALVE 1 Check that air flows out port A when battery voltage is applied across the terminals 2 Check that air does not flow out port A when battery voltage is not applied across the terminal Replace the valve if either test is not successful ...

Page 335: ... SUB TANK SYSTEM FUEL PUMP CONTROL ECU FUEL PUMP CONTROL ECU INSPECTION ECU CIRCUIT Disconnect the connector from the ECU and inspect the connector on the wire harness side as shown in the chart If circuit is as specified try other ECU ...

Page 336: ...ght Diagnostic code clearance 1 After completing repairs the diagnostic code retained in memory can be cleared by removing the battery terminal for 10 seconds or more with the ignition switch off 2 Check that the normal code is displayed after connecting the battery terminal Indication Code Diagnosis Normal Fuel level switch malfunction Main tank Open in switch circuit Main tank sender gauge malfu...

Page 337: ...itch ON 2 Connect terminals Tc and En of the check connector 3 Read the test code from the indicator light Indication code Condition indicated by signal input output Fuel level switch signal open or Main tank fuel level high Fuel sender gauge signal open or fuel level high Open or short in fuel pump circuit Open or short in fuel solenoid valve circuit Fuel level switch open or fuel level high Extr...

Page 338: ...BE 59 BODY ELECTRICAL SYSTEM SATELLITE NAVIGATION SYSTEM SATELLITE NAVIGATION SYSTEM PARTS LOCATION ...

Page 339: ...BE 60 BODY ELECTRICAL SYSTEM SATELLITE NAVIGATION SYSTEM WIRING DIAGRAMS ...

Page 340: ...ition switch ACC or ON b Push N A V I or SET c Push N A V I and SET simultaneously for 5 seconds d Display the condition of each system on the screen If a malfunction code is displayed check it again using other parts Normal Display Diagnosis Display malfunction GPS ECU malfunction GPS antenna malfunction Antenna cable faulty Malfunction in wire harness between GPS ECU and display ...

Page 341: ...as Top Station Wagon Chassis and Body Supplement Repair Manual Pub No RM183E RM184E RM290E NOTE The following pages contain only the points which differ from the above listed manuals HARDTOP CANVAS TOP DESCRIPTION AC 2 DRIVE BELT AC 10 REFRIGERATION LINES AC 11 COMPRESSOR AC 12 COOLING UNIT AC 14 AIR CONDITIONER AMPLIFIER AC 15 STATION WAGON DESCRIPTION AC 18 DRIVE BELT AC 22 COMPRESSOR AC 23 AIR ...

Page 342: ...AIR CONDITIONING SYSTEM DESCRIPTION Hardtop Canvas Top DESCRIPTION ELECTRICAL WIRING DIAGRAM AC 2 ...

Page 343: ...AIR CONDITIONING SYSTEM DESCRIPTION AC 3 ...

Page 344: ...AC 4 AIR CONDITIONING SYSTEM DESCRIPTION ...

Page 345: ...AIR CONDITIONING SYSTEM DESCRIPTION AC 5 MEMO ...

Page 346: ...AC 6 AIR CONDITIONING SYSTEM DESCRIPTION ...

Page 347: ...AC 7 AIR CONDITIONING SYSTEM DESCRIPTION ...

Page 348: ...AC 8 AIR CONDITIONING SYSTEM DESCRIPTION ...

Page 349: ...AC 9 AIR CONDITIONING SYSTEM DESCRIPTION ...

Page 350: ...R CONDITIONING SYSTEM DRIVE BELT DRIVE BELT ON VEHICLE INSPECTION INSPECT DRIVE BELT TENSION Drive belt tension at 10 kg 22 0 Ib 98N FZ Series Engine New belt 5 7 mm 0 20 0 28 in Used belt 7 9 5 mm 0 28 0 37 in ...

Page 351: ...AC 11 AIR CONDITIONING SYSTEM REFRIGERATION LINES REFRIGERATION LINES TIGHTENING ...

Page 352: ... MINUTES 2 STOP ENGINE 3 DISCONNECT NEGATIVE CABLE FROM BATTERY 4 DISCONNECT CONNECTOR FROM MAGNET CLUTCH 5 RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 6 DISCONNECT TWO HOSES FROM COMPRESSOR SER VICE VALVES Cap the open fittings immediately to keep the moisture and dust out of the system 7 REMOVE ENGINE UNDER COVER ...

Page 353: ...AC 13 AIR CONDITIONING SYSTEM COMPRESSOR 8 LOOSEN IDLE PULLEY LOCK NUT AND COMPRESSOR DRIVE BELT 9 REMOVE COMPRESSOR Remove the four bolts and pull the compressor upward MAGNET CLUTCH DISASSEMBLY ...

Page 354: ...MBLY Packing FZ Series Engine Upper Unit Case Packing Expansion Valve Grommet Drain Hose Packing Blower Resistor Lower Unit Case Evaporator Thermistor Blower Speed Control Relay Push Type A C Control Assembly A C Amplifier Clip Magnet Clutch Relay Wire Harness Rear Cooler Relay ...

Page 355: ... A C 1FZ F Engine INSPECT AMPLIFIER CIRCUIT Disconnect the amplifier and inspect the connector on the wire harness side as shown in the chart below Test conditions 1 Ignition switch ON 2 Temperature control lever MAX COOL 3 Blower switch HI If circuit is as specified replace the amplifier ...

Page 356: ...gine INSPECT AMPLIFIER CIRCUIT Disconnect the amplifier and inspect the connector on the wire harness side as shown in the chart below Test conditions 1 Ignition switch ON 2 Temperature control lever MAX COOL 3 Blower switch HI If circuit is as specified replace the amplifier ...

Page 357: ...AC 17 AIR CONDITIONING SYSTEM AIR CONDITIONER AMPLIFIERS MEMO ...

Page 358: ...AC 18 AIR CONDITIONING SYSTEM DESCRIPTION Station Wagon DESCRIPTION ELECTRICAL WIRING DIAGRAM ...

Page 359: ...AIR CONDITIONING SYSTEM DESCRIPTION AC 19 ...

Page 360: ...AC 20 AIR CONDITIONING SYSTEM DESCRIPTION ...

Page 361: ...AC 21 AIR CONDITIONING SYSTEM DESCRIPTION ...

Page 362: ...CTION INSPECT DRIVE BELT TENSION Drive belt tension at 10 kg 22 0 Ib 98 N FZ Series Engine New belt 5 7 mm 0 20 0 28 in Used belt 7 7 5 mm 0 28 0 37 in Reference Using SST check the drive belt tension SST 09216 00020 and 09216 00030 New belt 40 60 kg Used belt 20 40 kg ...

Page 363: ... MINUTES 2 STOP ENGINE 3 DISCONNECT NEGATIVE CABLE FROM BATTERY 4 DISCONNECT CONNECTOR FROM MAGNET CLUTCH 5 RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 6 DISCONNECT TWO HOSES FROM COMPRESSOR SER VICE VALVES Cap the open fittings immediately to keep the moisture and dust out of the system 7 REMOVE ENGINE UNDER COVER ...

Page 364: ...AC 24 AIR CONDITIONING SYSTEM COMPRESSOR 8 LOOSEN IDLE PULLEY LOCK NUT AND COMPRESSOR DRIVE BELT 9 REMOVE COMPRESSOR Remove the four bolts and pull the compressor upward MAGNET CLUTCH DISASSEMBLY ...

Page 365: ...it is as specified replace the amplifier AIR CONDITIONER AMPLIFIER INSPECT AMPLIFIER CIRCUIT Disconnect the amplifier and inspect the connector on the wire harness side as shown in the chart below Test conditions 1 Ignition ON 2 Temperature control lever MAX COOL 3 Blower switch HI ...

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