Driveline: Section

TRANSMISSION & DRIVELINE
SECTION DLN DRIVELINE

B
DLN
E
CONTENTS
TRANSFER: ETX13C WARNING/INDICATOR/CHIME LIST ........................18 F
WARNING/INDICATOR/CHIME LIST : Warning/
PRECAUTION ............................................... 6 Indicator (On Information Display) ...........................18
G
PRECAUTIONS ................................................... 6 DIAGNOSIS SYSTEM (AWD CONTROL
Precaution for Supplemental Restraint System UNIT) ................................................................. 19
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- CONSULT Function .................................................19
SIONER" ................................................................... 6 H
Precautions for Removing Battery Terminal ............. 6 ECU DIAGNOSIS INFORMATION .............. 21
Service Notice or Precautions for Transfer ............... 6
AWD CONTROL UNIT ...................................... 21 I
PREPARATION ............................................ 8 Reference Value ......................................................21
Fail-safe ...................................................................22
PREPARATION ................................................... 8 Protection Function ..................................................23
Special Service Tools ................................................ 8 DTC Inspection Priority Chart ..................................23 J
Commercial Service Tools ........................................ 9 DTC Index ...............................................................23
Lubricant or/and Sealant ........................................... 9
WIRING DIAGRAM ...................................... 24 K
SYSTEM DESCRIPTION ............................. 11
AWD SYSTEM .................................................. 24
COMPONENT PARTS .......................................11 Wiring Diagram ........................................................24
Component Parts Location ...................................... 11 L
AWD Control Unit .................................................... 12 BASIC INSPECTION ................................... 29
Electric Controlled Coupling .................................... 12
AWD Solenoid ......................................................... 12 DIAGNOSIS AND REPAIR WORK FLOW ....... 29
M
Transfer Fluid Temperature Sensor ........................ 12 Work Flow ................................................................29
Diagnostic Work Sheet ............................................30
STRUCTURE AND OPERATION .......................13
Sectional View ......................................................... 13 DTC/CIRCUIT DIAGNOSIS ......................... 32 N
Operation Description ............................................. 13
C1201 AWD CONTROL UNIT .......................... 32
SYSTEM .............................................................15 DTC Description ......................................................32
O
Diagnosis Procedure ...............................................32
AWD SYSTEM ........................................................... 15
AWD SYSTEM : System Description ...................... 15 C1203 ABS ACTUATOR AND ELECTRIC
AWD SYSTEM : Circuit Diagram ............................ 16 UNIT (CONTROL UNIT) .................................... 33 P
AWD SYSTEM : Fail-safe ....................................... 17 DTC Description ......................................................33
AWD SYSTEM : Protection Function ...................... 17 Diagnosis Procedure ...............................................33
INFORMATION DISPLAY (COMBINATION C1204 AWD SOLENOID ................................... 34

METER) ..................................................................... 17 DTC Description ......................................................34
INFORMATION DISPLAY (COMBINATION Diagnosis Procedure ...............................................34
METER) : AWD Warning ......................................... 17 Component Inspection .............................................36
Revision: 2015 January DLN-1 2015 Q50

C1205 AWD ACTUATOR RELAY ..................... 37 REMOVAL AND INSTALLATION .............. 56
DTC Description ..................................................... 37
Diagnosis Procedure .............................................. 37 AWD CONTROL UNIT ...................................... 56
Exploded View ........................................................ 56
C1210 ECM ........................................................ 39 Removal and Installation ......................................... 56
DTC Description ..................................................... 39
Diagnosis Procedure .............................................. 39 FRONT OIL SEAL ............................................. 57
Exploded View ........................................................ 57
P1804 AWD CONTROL UNIT ........................... 40 Removal and Installation ......................................... 57
DTC Description ..................................................... 40 Inspection ................................................................ 57
Diagnosis Procedure .............................................. 40
REAR OIL SEAL ............................................... 58
P1809 AWD CONTROL UNIT ........................... 41 Exploded View ........................................................ 58
DTC Description ..................................................... 41 Removal and Installation ......................................... 58
Diagnosis Procedure .............................................. 41 Inspection ................................................................ 60
P1826 TRANSFER FLUID TEMPERATURE ... 42 AIR BREATHER ................................................ 61
DTC Description ..................................................... 42 Exploded View ........................................................ 61
Diagnosis Procedure .............................................. 42 Removal and Installation ......................................... 61
Component Inspection ............................................ 44
UNIT REMOVAL AND INSTALLATION .... 63
U1000 CAN COMM CIRCUIT ............................ 45
DTC Description ..................................................... 45 TRANSFER ASSEMBLY ................................... 63
Diagnosis Procedure .............................................. 45 Exploded View ........................................................ 63
Removal and Installation ......................................... 63
U1010 CONTROL UNIT (CAN) ......................... 46 Inspection ................................................................ 64
DTC Description ..................................................... 46
Diagnosis Procedure .............................................. 46 UNIT DISASSEMBLY AND ASSEMBLY ... 65
POWER SUPPLY AND GROUND CIRCUIT ..... 47 FRONT CASE AND REAR CASE ..................... 65
Diagnosis Procedure .............................................. 47 Exploded View ........................................................ 65
Disassembly ............................................................ 66
SYMPTOM DIAGNOSIS ............................. 50 Assembly ................................................................ 69
Inspection ................................................................ 73
HEAVY TIGHT-CORNER BRAKING SYMP-
TOM OCCURS ................................................... 50 MAIN SHAFT ..................................................... 75
Description .............................................................. 50 Exploded View ........................................................ 75
Diagnosis Procedure .............................................. 50 Disassembly ............................................................ 76
Assembly ................................................................ 77
VEHICLE DOES NOT ENTER AWD MODE ..... 51 Inspection ................................................................ 78
Description .............................................................. 51
Diagnosis Procedure .............................................. 51 FRONT DRIVE SHAFT AND DRIVE CHAIN ..... 80
Exploded View ........................................................ 80
AWD HIGH TEMP IS DISPLAYED ON INFOR- Disassembly ............................................................ 81
MATION DISPLAY ............................................. 52 Assembly ................................................................ 81
Description .............................................................. 52 Inspection ................................................................ 82
TIRE SIZE INCORRECT IS DISPLAYED ON SERVICE DATA AND SPECIFICATIONS
INFORMATION DISPLAY ................................. 53 (SDS) .......................................................... 83
Description .............................................................. 53
Diagnosis Procedure .............................................. 53 SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................. 83
NOISE, VIBRATION AND HARSHNESS
General Specifications ............................................ 83
(NVH) TROUBLESHOOTING ............................ 54
NVH Troubleshooting Chart ................................... 54
FRONT PROPELLER SHAFT: 2S56A
PERIODIC MAINTENANCE ........................ 55 PRECAUTION ............................................ 84
TRANSFER FLUID ............................................ 55 PRECAUTIONS ................................................. 84

Inspection ............................................................... 55 Precautions for Removing Battery Terminal ........... 84
Draining .................................................................. 55 Service Notice or Precautions for Propeller Shaft ... 84
Refilling ................................................................... 55

PREPARATION ........................................... 85 REAR PROPELLER SHAFT ............................. 97
Inspection ................................................................97 A
PREPARATION ..................................................85
Commercial Service Tools ...................................... 85 REMOVAL AND INSTALLATION ............... 98
SYSTEM DESCRIPTION ............................. 86 REAR PROPELLER SHAFT ............................. 98 B
Exploded View .........................................................98
STRUCTURE AND OPERATION .......................86 Removal and Installation .........................................98
Sectional View ......................................................... 86 Inspection .............................................................. 101 C
SYMPTOM DIAGNOSIS .............................. 87 SERVICE DATA AND SPECIFICATIONS
NOISE, VIBRATION AND HARSHNESS (SDS) .......................................................... 102 DLN
(NVH) TROUBLESHOOTING ............................87 SERVICE DATA AND SPECIFICATIONS
NVH Troubleshooting Chart .................................... 87 (SDS) ............................................................... 102
General Specifications ........................................... 102 E
PERIODIC MAINTENANCE ......................... 88
Propeller Shaft Runout .......................................... 102
FRONT PROPELLER SHAFT ............................88 Journal Axial Play .................................................. 102
Inspection ................................................................ 88 REAR PROPELLER SHAFT: 3F80A-R F
REMOVAL AND INSTALLATION ............... 89 PRECAUTION ............................................ 103

FRONT PROPELLER SHAFT ............................89 PRECAUTIONS ............................................... 103 G
Exploded View ........................................................ 89 Precautions for Removing Battery Terminal .......... 103
Removal and Installation ......................................... 89 Service Notice or Precautions for Propeller Shaft.. 103
Inspection ................................................................ 90 H
PREPARATION ......................................... 104
SERVICE DATA AND SPECIFICATIONS
PREPARATION ............................................... 104
(SDS) ............................................................ 92 I
Commercial Service Tools ..................................... 104
SYSTEM DESCRIPTION ........................... 105
(SDS) ..................................................................92
General Specifications ............................................ 92 J
STRUCTURE AND OPERATION ................... 105
Propeller Shaft Runout ............................................ 92 Sectional View ....................................................... 105
Journal Axial Play .................................................... 92
REAR PROPELLER SHAFT: 3S80A-R SYMPTOM DIAGNOSIS ............................ 106 K
PRECAUTION .............................................. 93 NOISE, VIBRATION AND HARSHNESS

(NVH) TROUBLESHOOTING ......................... 106 L
PRECAUTIONS ..................................................93 NVH Troubleshooting Chart .................................. 106
Precautions for Removing Battery Terminal ........... 93
Service Notice or Precautions for Propeller Shaft.... 93 PERIODIC MAINTENANCE ...................... 107
M
PREPARATION ........................................... 94 REAR PROPELLER SHAFT ........................... 107
Inspection .............................................................. 107
PREPARATION ..................................................94
Commercial Service Tools ...................................... 94 REMOVAL AND INSTALLATION ............. 108 N
SYSTEM DESCRIPTION ............................. 95 REAR PROPELLER SHAFT ........................... 108

Exploded View ....................................................... 108 O
STRUCTURE AND OPERATION .......................95 Removal and Installation ....................................... 108
Sectional View ......................................................... 95 Inspection .............................................................. 111
SYMPTOM DIAGNOSIS .............................. 96 SERVICE DATA AND SPECIFICATIONS P
NOISE, VIBRATION AND HARSHNESS (SDS) .......................................................... 113

(NVH) TROUBLESHOOTING ............................96 SERVICE DATA AND SPECIFICATIONS
NVH Troubleshooting Chart .................................... 96 (SDS) ............................................................... 113
General Specifications ........................................... 113
PERIODIC MAINTENANCE ......................... 97
Propeller Shaft Runout .......................................... 113
Journal Axial Play .................................................. 113

FRONT FINAL DRIVE: F160A Exploded View ...................................................... 128
Disassembly .......................................................... 129
PRECAUTION ............................................ 114 Assembly .............................................................. 130
Inspection .............................................................. 130
PRECAUTIONS ............................................... 114
Precautions for Removing Battery Terminal ..........114 DIFFERENTIAL ASSEMBLY ........................... 131
Service Notice or Precautions for Front Final Drive Exploded View ...................................................... 131
..114 Disassembly .......................................................... 132
Assembly .............................................................. 135
PREPARATION .......................................... 115 Adjustment ............................................................ 139
Inspection .............................................................. 144
PREPARATION ............................................... 115
Special Service Tools ............................................115 DRIVE PINION .................................................. 145
Commercial Service Tools .....................................117 Exploded View ...................................................... 145
Lubricant or/and Sealant .......................................118 Disassembly .......................................................... 146
Assembly .............................................................. 147
SYSTEM DESCRIPTION ........................... 119 Adjustment ............................................................ 149
STRUCTURE AND OPERATION .................... 119 Inspection .............................................................. 152
Sectional View .......................................................119 SERVICE DATA AND SPECIFICATIONS
SYMPTOM DIAGNOSIS ............................ 120 (SDS) ......................................................... 153
NOISE, VIBRATION AND HARSHNESS SERVICE DATA AND SPECIFICATIONS

(NVH) TROUBLESHOOTING .......................... 120 (SDS) ................................................................ 153
NVH Troubleshooting Chart ..................................120 General Specifications .......................................... 153
Preload Torque ..................................................... 153
PERIODIC MAINTENANCE ....................... 121 Drive Gear Runout ................................................ 153
Backlash ............................................................... 153
FRONT DIFFERENTIAL GEAR OIL ................ 121 Companion Flange Runout ................................... 153
Inspection ..............................................................121 Differential Side Gear Clearance .......................... 153
Draining .................................................................121 REAR FINAL DRIVE: R190
Refilling ..................................................................121
PRECAUTION ........................................... 154
REMOVAL AND INSTALLATION .............. 122
PRECAUTIONS ................................................ 154
FRONT OIL SEAL ........................................... 122 Precautions for Removing Battery Terminal ......... 154
Removal and Installation .......................................122 Service Notice or Precautions for Rear Final Drive. 154
SIDE OIL SEAL ............................................... 123 PREPARATION ......................................... 155
LEFT SIDE ...............................................................123
PREPARATION ................................................ 155
LEFT SIDE : Removal and Installation ..................123
Special Service Tools ........................................... 155
RIGHT SIDE .............................................................123 Commercial Service Tools .................................... 157
RIGHT SIDE : Exploded View ...............................123 Lubricant or/and Sealant ....................................... 157
RIGHT SIDE : Removal and Installation ................123
RIGHT SIDE : Inspection .......................................124 SYSTEM DESCRIPTION .......................... 158
AIR BREATHER .............................................. 125 STRUCTURE AND OPERATION ..................... 158

Exploded View .......................................................125 Sectional View ...................................................... 158
Removal and Installation .......................................125
SYMPTOM DIAGNOSIS ........................... 159
UNIT REMOVAL AND INSTALLATION .... 126 NOISE, VIBRATION AND HARSHNESS
FRONT FINAL DRIVE ASSEMBLY ................ 126 (NVH) TROUBLESHOOTING ........................... 159
Exploded View .......................................................126 NVH Troubleshooting Chart .................................. 159
Removal and Installation .......................................126
Inspection ..............................................................127
PERIODIC MAINTENANCE ...................... 160
REAR DIFFERENTIAL GEAR OIL ................... 160
UNIT DISASSEMBLY AND ASSEMBLY .. 128
Inspection .............................................................. 160
SIDE SHAFT .................................................... 128 Draining ................................................................. 160

Refilling ................................................................. 160 DIFFERENTIAL ASSEMBLY .......................... 169
Exploded View ....................................................... 169 A
REMOVAL AND INSTALLATION ............. 161 Disassembly .......................................................... 170
Assembly ............................................................... 171
FRONT OIL SEAL ............................................ 161
Adjustment ............................................................. 173 B
Exploded View ...................................................... 161
Inspection .............................................................. 176
Removal and Installation ....................................... 161
Inspection .............................................................. 164 DRIVE PINION ................................................ 178
Exploded View ....................................................... 178 C
SIDE OIL SEAL ................................................ 165
Disassembly .......................................................... 178
Exploded View ...................................................... 165
Assembly ............................................................... 180
Removal and Installation ....................................... 165
Adjustment ............................................................. 183 DLN
Inspection .............................................................. 165
Inspection .............................................................. 184
AIR BREATHER ............................................... 166
Exploded View ...................................................... 166
E
Removal and Installation ....................................... 166 (SDS) .......................................................... 185
UNIT REMOVAL AND INSTALLATION .... 167 SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................... 185 F
REAR FINAL DRIVE ASSEMBLY ................... 167 General Specifications ........................................... 185
Exploded View ...................................................... 167 Preload Torque ...................................................... 185
Removal and Installation ....................................... 167 Drive Gear Runout ................................................. 185 G
Inspection .............................................................. 168 Backlash ................................................................ 185
Differential Side Gear Clearance ........................... 185
UNIT DISASSEMBLY AND ASSEMBLY . 169
H

PRECAUTIONS
< PRECAUTION > [TRANSFER: ETX13C]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000011281936
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this
Service Manual.
WARNING:
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precautions for Removing Battery Terminal INFOID:0000000011508643
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
NOTE:
ECU may be active for several tens of seconds after the ignition
switch is turned OFF. If the battery terminal is removed before ECU
stops, then a DTC detection error or ECU data corruption may
occur.
• For vehicles with the 2-batteries, be sure to connect the main bat-
tery and the sub battery before turning ON the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of
SEF289H
main battery and sub battery disconnected, then DTC may be
detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
Service Notice or Precautions for Transfer INFOID:0000000011281937
• Never reuse transfer fluid, once it has been drained.

• Check the fluid level or replace the fluid only with the vehicle parked on level ground.
• During removal or installation, keep inside of transfer clear of dust or dirt.

PRECAUTIONS
< PRECAUTION > [TRANSFER: ETX13C]
• Replace all tires at the same time. Always use tires of the proper size and the same brand and pattern. Fit-
ting improper size and unusually worn tires applies excessive force to vehicle mechanism and can cause A
longitudinal vibration.
• Disassembly should be done in a clean work area, it is preferable to work in dustproof area.
• Before proceeding with disassembly, thoroughly clean the transfer. It is important to prevent the internal
B
parts from becoming contaminated by dirt or other foreign matter.
• All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or
reassembly.
• Check for the correct installation status prior to removal or disassembly. If matching marks are required, be C
certain they do not interfere with the function of the parts when applied.
• Check appearance of the disassembled parts for damage, deformation, and unusual wear. Replace them
with a new ones if necessary. DLN
• Gaskets, seals and O-rings should be replaced any time the transfer is disassembled.
• In principle, tighten bolts or nuts gradually in several steps working diagonally from inside to outside. If tight-
ening sequence is specified, use it.
• Observe the specified torque when assembling. E
• Clean and flush the parts sufficiently and blow-dry them.
• Be careful not to damage sliding surfaces and mating surfaces.
• Clean inner parts with lint-free cloth or towels. Do not use cotton work gloves and rags to prevent adhering F
fibers.

PREPARATION
< PREPARATION > [TRANSFER: ETX13C]
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000011281938
The actual shapes of TechMate tools may differ from those of special service tools illustrated here.
Tool number
(TechMate No.) Description
Tool name
ST27862000 Installing front oil seal
( — )
Drift
a: 62.5 mm (2.461 in) dia.
b: 42 mm (1.65 in) dia.
ZZA0194D
KV381054S0 Removing rear oil seal

(J-34286)
Puller
ZZA0601D
ST30720000 • Installing rear oil seal

(J-25405) • Installing main shaft oil seal
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ZZA0811D
KV40104830 Installing rear oil seal

( — )
Drift
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.500 in) dia.
ZZA1003D
ST33052000 Removing main shaft assembly

( — )
Drift
a: 28 mm (1.10 in) dia.
b: 22 mm (0.87 in) dia.
ZZA1000D
ST35321000 Installing main shaft assembly

( — )
Drift
a: 49 mm (1.93 in) dia.
b: 41 mm (1.61 in) dia.
ZZA1000D

PREPARATION
Tool number
(TechMate No.) Description A
Tool name
ST31214000 • Removing front drive shaft front bearing
(J-25269-B) • Removing front drive shaft rear bearing B
Drift
a: 34 mm (1.34 in) dia.
b: 25.5 mm (1.004 in) dia.
C
ZZA0534D
ST33200000 Installing front drive shaft front bearing DLN

(J-26082)
Drift
a: 60 mm (2.36 in) dia.
b: 44.5 mm (1.752 in) dia.
E
ZZA1002D F
KV38104010 Installing front drive shaft rear bearing
( — )
Drift G
a: 67 mm (2.64 in) dia.
b: 49 mm (1.93 in) dia.
H
ZZA1000D
Commercial Service Tools INFOID:0000000011281939 I
Tool name Description J

Flange wrench Removing and installing self-lock nut
L
NT771
Separator • Removing front drive shaft front bearing

• Removing front drive shaft rear bearing M
ZZB0823D
Power tool Loosening bolts and nuts O
PBIC0190E
Lubricant or/and Sealant INFOID:0000000011281940

PREPARATION
Item Use
Anaerobic Liquid Gasket
Application to mating surface of rear case
(Three Bond 1133C or equivalent)

COMPONENT PARTS
< SYSTEM DESCRIPTION > [TRANSFER: ETX13C]
SYSTEM DESCRIPTION A
COMPONENT PARTS
Component Parts Location INFOID:0000000011281941
B
DLN
JSDIA4519GB
M
Instrument lower panel LH removed Transfer inside
N
No. Component Function
Mainly transmits the following signals to AWD control unit via
CAN communication. O
• Accelerator pedal position signal
ECM
• Engine speed signal
For detailed installation location, refer to EC-17, "ENGINE
CONTROL SYSTEM : Component Parts Location". P
CAN communication.
• Each wheel speed signal
ABS actuator and electric unit (control unit)
• Stop lamp switch signal (brake signal)
For detailed installation location, refer to BRC-10, "Compo-
nent Parts Location".

COMPONENT PARTS
No. Component Function
CAN communication.
• Parking brake switch signal
Mainly receives the following signals from AWD control unit
Combination meter
via CAN communication.
• AWD warning signal
For detailed installation location, refer to MWI-7, "METER
SYSTEM : Component Parts Location".
AWD control unit
Refer to DLN-12, "AWD Control Unit".
• AWD actuator relay
Electric controlled coupling Refer to DLN-12, "Electric Controlled Coupling".
AWD solenoid Refer to DLN-12, "AWD Solenoid".
Transfer fluid temperature sensor Refer to DLN-12, "Transfer Fluid Temperature Sensor".
AWD Control Unit INFOID:0000000011281942
• AWD control unit controls driving force distribution by signals from each sensor from rear wheel driving
mode (0:100) to 4-wheel driving mode (50:50).
• Rear wheel driving conditions is available by fail-safe function if malfunction is detected in AWD system.
AWD ACTUATOR RELAY
AWD actuator relay is integrated with AWD control unit, and supplies AWD solenoid with voltage.
Electric Controlled Coupling INFOID:0000000011281943
Electric controlled coupling is installed in transfer and transmits driving force to front final drive. For operation,
refer to DLN-13, "Operation Description".
AWD Solenoid INFOID:0000000011281944
AWD solenoid is integrated with electric controlled coupling, and controls electric controlled coupling by com-
mand current from AWD control unit.
Transfer Fluid Temperature Sensor INFOID:0000000011281945
• Transfer fluid temperature sensor is integrated with electric controlled coupling.

• Transfer fluid temperature sensor detects the transfer fluid temper-
ature and transmits a signal to AWD control unit.
JSDIA0804GB
• The electrical resistance of the sensor decreases as temperature

increases.
JSDIA0805GB

STRUCTURE AND OPERATION
A
Sectional View INFOID:0000000011281946
DLN
I
JSDIA0803ZZ
Electromagnet Control clutch Cam J

Drive chain Front case Main shaft
Front drive shaft Main clutch Rear case
K
Operation Description INFOID:0000000011281947
POWER TRANSFER DIAGRAM L
O
JPDIE0253GB
OPERATION PRINCIPLE
P
ELECTRIC CONTROLLED COUPLING

JPDIE0214ZZ
Main clutch Control clutch Cam

Electromagnet
Torque flow Current commanded from AWD con- From transmission
trol unit
To front propeller shaft
1. AWD control unit supplies command current to electric controlled coupling (AWD solenoid).
2. Control clutch is engaged by electromagnet and torque is detected in control clutch.
3. The cam operates in response to control clutch torque and applies pressure to main clutch.
4. Main clutch transmits torque to front wheels according to pressing power.
• Transmission torque to front wheels is determined according
to command current.
SDIA1844E

SYSTEM
SYSTEM
A
AWD SYSTEM
AWD SYSTEM : System Description INFOID:0000000011281948
B
• Pressing force of multiple disc clutch is controlled by electric control. Driving torque distribution of front and
rear wheels changes automatically between approximately 0 : 100 (Rear wheel drive) and 50 : 50 (AWD) to
have an optimized torque distribution adapted to road condition change. C
• In accordance with fail-safe function, when system is malfunctioning, AWD control stops, and the system
becomes rear wheel drive. Refer to DLN-17, "AWD SYSTEM : Fail-safe".
• When a high load status continues for electric controlled coupling, AWD control temporarily becomes rear
wheel drive, according to protection function. Refer to DLN-17, "AWD SYSTEM : Protection Function". DLN
SYSTEM DIAGRAM
E
M
JSDIA4700GB
Signal with Communication Line

N
Major signal transmission between each unit via CAN communication lines are shown in the following table.
Component parts Signal item

O
Mainly transmits the following signals to AWD control unit via CAN communication.
ECM • Accelerator pedal position signal
• Engine speed signal
Mainly transmits the following signals to AWD control unit via CAN communication. P
ABS actuator and electric unit
• Each wheel speed signal
(control unit)
• Stop lamp switch signal (brake signal)
Mainly transmits the following signals to AWD control unit via CAN communication.
• Parking brake switch signal
Combination meter
Mainly receives the following signals from AWD control unit via CAN communication.
• AWD warning signal

SYSTEM
OPERATION CHARACTERISTIC
Vehicle Starts Control
• At the start, torque distribution for front and rear wheels is fixed by
electric control and stable start is achieved.
• Makes possible stable driving, with no wheel spin, on snowy roads
or other slippery surfaces.
JPDIE0255GB
Normal Control
• On roads which do not require AWD, it contributes to improved fuel economy by driving in conditions close to
rear-wheel drive and it results in better fuel efficiency and provides FR-like steering characteristics.
• When spin occurs on rear wheel, distribute optimum torque to front wheel and keep stable driving.
• The vehicle cornering status is judged according to information from each sensor, and the optimum torque is
distributed to front wheels for preventing tight cornering/braking symptom.
AWD SYSTEM : Circuit Diagram INFOID:0000000011281949
JSDIA4704GB

SYSTEM
AWD SYSTEM : Fail-safe INFOID:0000000011281950
A
• If any malfunction occurs in AWD electrical system, and control unit detects the malfunction, AWD warning
on information display (combination meter) is displayed to indicate system malfunction.
• When AWD warning (AWD Error) is displayed, vehicle changes to rear-wheel drive or shifts to 4-wheel drive B
(front-wheels still have some driving torque).
AWD SYSTEM : Protection Function INFOID:0000000011281951
C
AWD system activates its protection function (shuts down AWD system temporarily) if AWD system detects
high load continuously or the front wheel tire size differs from the rear tire size. (AWD system is automatically
restored if AWD system no longer detects any overload or the tire size difference is eliminated.)
DLN
AWD warning (on infor- Contents of protection

DTC Error area and root cause
mation display) function
E
Refer to DLN-17, "IN- Transfer assembly in protection mode. It is not malfunction.
—
FORMATION DISPLAY (Internal temperature rise of electronic controlled coupling) Shuts down AWD sys-
(COMBINATION tem temporarily
— METER) : AWD Warn- Malfunction in each tire or different tire diameter (Rear wheel drive) F
ing".
NOTE:
• If the AWD warning displays during driving but remains not displayed after the engine is restarted, the sys- G
tem is normal. If it again displays after driving for some time, vehicle must be inspected.
• When there is a difference of revolution speed between the front and rear wheel the shift occasionally
changes to direct 4-wheel driving conditions automatically. This is not a malfunction.
H
INFORMATION DISPLAY (COMBINATION METER)
INFORMATION DISPLAY (COMBINATION METER) : AWD Warning INFOID:0000000011281952
I
DESIGN/PURPOSE
AWD warning is displayed when the AWD system has a malfunction. AWD warning indicates that the vehicle
is in fail-safe mode or protection function mode. J
Symbol Message Condition

AWD Error K
AWD system malfunction.
See Owner’s Manual
Protection function is activated due to heavy load to
AWD High Temp. electric controlled coupling. (AWD system is not L
Stop vehicle malfunctioning and AWD system changes to rear
wheel drive.)
M
Tire Size Incorrect
Large difference in diameter of front/rear tires.
See Owner’s Manual
JSDIA4707ZZ
N
SYNCHRONIZATION WITH MASTER WARNING LAMP

Applicable O
For master warning lamp, refer to MWI-34, "WARNING LAMPS/INDICATOR LAMPS : Master Warning Lamp".

SYSTEM
SYSTEM DIAGRAM
JSDIA4623GB
SIGNAL PATH
• The AWD control unit judges and decides a mode from among normal mode, fail-safe mode, and protection
function mode, according to signals received from each switch, sensor, and control unit.
• The AWD control unit transmits AWD warning signal to the combination meter via CAN communication when
judging fail-safe mode or protection function mode.
• The combination meter displays AWD warning on the information display when receiving AWD warning sig-
nal transmitted from the AWD control unit.
WARNING CONDITION
AWD warning is displayed when the AWD system goes into fail-safe mode or protection function mode.
WARNING CANCEL CONDITION
When any of the conditions listed below is satisfied:
• Ignition switch is in a position other than ON.
• AWD warning becomes invisible when the AWD system returns to normal.
WARNING/INDICATOR/CHIME LIST
WARNING/INDICATOR/CHIME LIST : Warning/Indicator (On Information Display)
INFOID:0000000011281953
Name Function
Refer to DLN-17, "INFORMATION DISPLAY (COMBINATION METER) : AWD Warn-
AWD warning
ing".

DIAGNOSIS SYSTEM (AWD CONTROL UNIT)
A
CONSULT Function INFOID:0000000011281954
APPLICATION ITEMS B
CONSULT can display each diagnostic item using the diagnostic test modes as follows.
Diagnostic test mode Function C

ECU Identification AWD control unit part number can be read.
Self Diagnostic Result Self-diagnostic results and freeze frame data can be read and erased quickly.*
Data Monitor Input/Output data in the AWD control unit can be read. DLN
Diagnostic Test Mode in which CONSULT drives some actuators apart from the AWD control unit
Active Test
and also shifts some parameters in a specified range.
E
* : The following diagnosis information is erased by erasing.
• DTC
• Freeze frame data (FFD)
F
ECU IDENTIFICATION
AWD control unit part number can be read.
SELF DIAGNOSTIC RESULT G
Refer to DLN-23, "DTC Index".
When “PRSNT” is displayed on self-diagnosis result.
• The system is presently malfunctioning. H
When “PAST” is displayed on self-diagnosis result.

• System malfunction in the past is detected, but the system is presently normal.
I
FREEZE FRAME DATA (FFD)
The following vehicle status is recorded when DTC is detected and is displayed on CONSULT.
J
Item name Display item
The number of times that ignition switch is turned ON after the DTC is detected is displayed.
• When “0” is displayed: It indicates that the system is presently malfunctioning.
K
• When except “0” is displayed: It indicates that system malfunction in the past is detected, but the system is pres-
IGN COUNTER ently normal.
(0 – 39) NOTE:
Each time when ignition switch is turned OFF to ON, numerical number increases in 1→2→3...38→39. L
When the operation number of times exceeds 39, the number do not increase and “39” is displayed until self-
diagnosis is erased.
DATA MONITOR M
NOTE:
The following table includes information (items) inapplicable to this vehicle. For information (items) applicable
to this vehicle, refer to CONSULT display items.
N
Monitor item (Unit) Remarks
STOP LAMP SW [On/Off] Stop lamp switch signal status via CAN communication line is displayed.
O
ENG SPEED SIG [Run/Stop] Engine status is displayed.
ETS ACTUATOR [On/Off] Operating condition of AWD actuator relay (integrated in AWD control unit) is displayed.
4WD WARN LAMP [On/Off] Control status of AWD warning (on information display) is displayed. P
4WD MODE SW [##]*1 Mode switch is not equipped, but displayed.
4WD MODE MON [AUTO] Control status of AWD is displayed.
DIS-TIRE MONI [mm] Improper size tire installed condition is displayed.
P BRAKE SW [On/Off] Parking brake switch signal status via CAN communication line is displayed.
BATTERY VOLT [V] Power supply voltage for AWD control unit.

Monitor item (Unit) Remarks
THRTL POS SEN [%] Throttle opening status is displayed.
ETS SOLENOID [A] Monitored value of current at AWD solenoid.
FR RH SENSOR [km/h] or [mph] Wheel speed calculated by front RH wheel sensor signal is displayed.
FR LH SENSOR [km/h] or [mph] Wheel speed calculated by front LH wheel sensor signal is displayed.
RR RH SENSOR [km/h] or [mph] Wheel speed calculated by rear RH wheel sensor signal is displayed.
RR LH SENSOR [km/h] or [mph] Wheel speed calculated by rear LH wheel sensor signal is displayed.
*1: It is not setting, but it is displayed.
ACTIVE TEST
Use this mode to determine and identify the details of a malfunction based on self-diagnostic results or data
monitor. AWD control unit gives drive signal to actuator with receiving command from CONSULT to check
operation of actuator.
Test item Condition Description

Change command current value to AWD solenoid, and then change driving
mode. (Monitor value is normal if it is within approx. ±10% of command val-
• Vehicle stopped ue.)
ETS S/V
• Engine running • Qu: Increase current value in increments of 0.2 A
(Detects AWD solenoid)
• No DTC detected • Qd: Decrease current value in increments of 0.2 A
• UP: Increase current value in increments of 0.02 A
• DOWN: Decrease current value in increments of 0.02 A
CAUTION:
Never energize continuously for a long time.

AWD CONTROL UNIT
< ECU DIAGNOSIS INFORMATION > [TRANSFER: ETX13C]
ECU DIAGNOSIS INFORMATION A

AWD CONTROL UNIT
Reference Value INFOID:0000000011281955
B
VALUES ON THE DIAGNOSIS TOOL

NOTE: C
The following table includes information (items) inapplicable to this vehicle. For information (items) applicable
to this vehicle, refer to CONSULT display items.
Monitor item Condition Value/Status DLN

Brake pedal: Depressed On
STOP LAMP SW
Brake pedal: Released Off
E
Engine stopped
Stop
(Engine speed: Less than 400 rpm)
ENG SPEED SIG
Engine running F
Run
(Engine speed: 400 rpm or more)
Engine stopped (Ignition switch: ON) Off
ETS ACTUATOR
Engine running On G
AWD warning (on information display): Displayed On
4WD WARN LAMP
AWD warning (on information display): Not displayed Off
H
4WD MODE SW*1 Always ##
4WD MODE MON Engine running AUTO
Vehicle running with normal size tire installed 0 – 4 mm I
DIS-TIRE MONI Vehicle running with improper size tire installed (Front/rear tire size
4 – 8 mm, 8 – mm
difference, wear condition)
Parking brake operated On J
P BRAKE SW
Parking brake not operated Off
BATTERY VOLT Always Battery voltage
K
When depressing accelerator pedal
THRTL POS SEN 0 – 100%
(Value rises gradually in response to throttle position.)
Engine running
• At idle speed
Approx. 0.000 A L
ETS SOLENOID
Engine running
• 3,000 rpm or more constant Approx. 0.000 – 0.500 A*2
M
Vehicle stopped 0.00 km/h (0.00 mph)
FR RH SENSOR Vehicle running Approx. equal to the indication

CAUTION: on speedometer (Inside of
Check air pressure of tire under standard condition. ±10%) N
FR LH SENSOR Vehicle running Approx. equal to the indication

CAUTION: on speedometer (Inside of O
Check air pressure of tire under standard condition. ±10%)
P
RR RH SENSOR Vehicle running Approx. equal to the indication
RR LH SENSOR Vehicle running Approx. equal to the indication


AWD CONTROL UNIT
*1: It is not setting, but it is displayed.
*2: The values are changed by depressed accelerator pedal opening and engine speed.
TERMINAL LAYOUT
JSDIA0057ZZ
PHYSICAL VALUES
Terminal No.
Description
(Wire color)
Condition Value (Approx.)
Input/
+ - Signal name
Output
1 AWD solenoid power sup- Engine speed: At idle 0V

Ground Output
(BR) ply Engine speed: 3,000 rpm or more constant 3.1 V*1
2 Engine speed: At idle 0V

Ground AWD solenoid ground Input
(Y) Engine speed: 3,000 rpm or more constant 0V
3 Transfer fluid temperature
Ground Input Always 0V
(W/B) sensor ground
7 Ignition switch: ON Battery voltage

Ground Ignition switch Input
(G) Ignition switch: OFF 0V
8 Input/
— CAN-H — —
(L) Output
9 Power supply (AWD sole-
Ground Input Always Battery voltage
(BG) noid)
10
Ground Ground — Always 0V
(B)
11
Ground Ground — Always 0V
(B)
13 Transfer fluid temperature Transfer temperature: 20°C (68°F) 1.56 V

Ground Output
(LG) sensor power supply Transfer temperature: 80°C (176°F) 0.44 V
15 Power supply (AWD con-
Ground Input Always Battery voltage
(W) trol unit)
16
Input/
(R)*2 — CAN-L — —
Output
(P)*3
*1: The values are changed by depressed accelerator pedal opening and engine speed.
*2: With Gateway.
*3: Without Gateway.
CAUTION:
When using circuit tester to measure voltage for inspection, be sure not to extend forcibly any con-
nector terminals.
Fail-safe INFOID:0000000011281956
• If any malfunction occurs in AWD electrical system, and control unit detects the malfunction, AWD warning
on information display (combination meter) is displayed to indicate system malfunction.

AWD CONTROL UNIT
• When AWD warning (AWD Error) is displayed, vehicle changes to rear-wheel drive or shifts to 4-wheel drive
(front-wheels still have some driving torque). A
Protection Function INFOID:0000000011281957
AWD system activates its protection function (shuts down AWD system temporarily) if AWD system detects B
high load continuously or the front wheel tire size differs from the rear tire size. (AWD system is automatically
restored if AWD system no longer detects any overload or the tire size difference is eliminated.)
C
AWD warning (on infor- Contents of protection
DTC Error area and root cause
mation display) function
—
Refer to DLN-17, "IN- Transfer assembly in protection mode. It is not malfunction. DLN
FORMATION DISPLAY (Internal temperature rise of electronic controlled coupling) Shuts down AWD sys-
(COMBINATION tem temporarily
— METER) : AWD Warn- Malfunction in each tire or different tire diameter (Rear wheel drive)
ing". E
NOTE:
• If the AWD warning displays during driving but remains not displayed after the engine is restarted, the sys-
tem is normal. If it again displays after driving for some time, vehicle must be inspected. F
• When there is a difference of revolution speed between the front and rear wheel the shift occasionally
changes to direct 4-wheel driving conditions automatically. This is not a malfunction.
DTC Inspection Priority Chart INFOID:0000000011281958
G
If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart. H
Priority Detected items (DTC)

• U1000 CAN COMM CIRCUIT I
1
• U1010 CONTROL UNIT (CAN)
• C1201 CONTROLLER FAILURE
• C1205 4WD ACTUATOR RLY
2 J
• P1804 CONTROL UNIT 3
• P1809 CONTROL UNIT 4
• C1203 ABS SYSTEM
3 K
• C1210 ENGINE SIGNAL 1
• C1204 4WD SOLENOID
4
• P1826 OIL TEMP SEN
L
DTC Index INFOID:0000000011281959
DTC Display Items Reference

M
C1201 CONTROLLER FAILURE DLN-32, "DTC Description"

C1203 ABS SYSTEM DLN-33, "DTC Description" N
C1204 4WD SOLENOID DLN-34, "DTC Description"
C1205 4WD ACTUATOR RLY DLN-37, "DTC Description"
C1210 ENGINE SIGNAL 1 DLN-39, "DTC Description" O
P1804 CONTROL UNIT 3 DLN-40, "DTC Description"
P1809 CONTROL UNIT 4 DLN-41, "DTC Description"
P
P1826 OIL TEMP SEN DLN-42, "DTC Description"
U1000 CAN COMM CIRCUIT DLN-45, "DTC Description"
U1010 CONTROL UNIT (CAN) DLN-46, "DTC Description"
NOTE:
If some DTCs are displayed at the same time, refer to DLN-23, "DTC Inspection Priority Chart".

AWD SYSTEM
< WIRING DIAGRAM > [TRANSFER: ETX13C]
WIRING DIAGRAM
AWD SYSTEM
Wiring Diagram INFOID:0000000011281960
JRDWC0910GB

AWD SYSTEM
DLN
JRDWC4143GB

AWD SYSTEM
JRDWC4144GB

AWD SYSTEM
DLN
JRDWC4145GB

AWD SYSTEM
JRDWC4146GB

DIAGNOSIS AND REPAIR WORK FLOW
< BASIC INSPECTION > [TRANSFER: ETX13C]
BASIC INSPECTION A
Work Flow INFOID:0000000011281961
B
DETAILED FLOW
1.INTERVIEW FROM THE CUSTOMER C
Clarify customer complaints before inspection. First of all, perform an interview utilizing DLN-30, "Diagnostic
Work Sheet" and reproduce symptoms as well as fully understand it. Ask customer about his/her complaints
carefully. Check symptoms by driving vehicle with customer, if necessary. DLN
CAUTION:
Customers are not professional. Never guess easily like “maybe the customer means that...,” or
“maybe the customer mentions this symptom”. E
>> GO TO 2.
2.CHECK SYMPTOM F
Reproduce the symptom that is indicated by the customer, based on the information from the customer
obtained by interview. Also check that the symptom is not caused by protection function. Refer to DLN-23,
"Protection Function". G
CAUTION:
When the symptom is caused by normal operation, fully inspect each portion and obtain the under-
standing of customer that the symptom is not caused by a malfunction. H
>> GO TO 3.
3.PERFORM SELF-DIAGNOSIS I
With CONSULT
Perform self-diagnosis for “ALL MODE AWD/4WD”. J
Is any DTC detected?
YES >> Record or print self-diagnosis results. GO TO 4.
NO >> GO TO 6. K
4.RECHECK SYMPTOM
With CONSULT
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”. L
2. Perform DTC confirmation procedures for the error detected system.
NOTE:
If some DTCs are detected at the same time, determine the order for performing the diagnosis based on DLN- M
23, "DTC Inspection Priority Chart".
YES >> GO TO 5. N
NO >> Check harness and connectors based on the information obtained by interview. Refer to GI-42,
"Intermittent Incident".
5.REPAIR OR REPLACE ERROR-DETECTED PARTS O
• Repair or replace error-detected parts.
• Reconnect part or connector after repairing or replacing.
• When DTC is detected, erase self-diagnostic results for “ALL MODE AWD/4WD”. P
>> GO TO 7.
6.IDENTIFY ERROR-DETECTED SYSTEM BY SYMPTOM DIAGNOSIS
Estimate error-detected system based on symptom diagnosis and perform inspection.
Can the error-detected system be identified?

YES >> GO TO 7.
NO >> Check harness and connectors based on the information obtained by interview. Refer to GI-42,
"Intermittent Incident".
7.FINAL CHECK
With CONSULT
1. Check the reference value for AWD control unit.
2. Recheck the symptom and check that symptom is not reproduced on the same conditions.
Is the symptom reproduced?
YES >> GO TO 3.
NO >> INSPECTION END
Diagnostic Work Sheet INFOID:0000000011281962
DESCRIPTION
• In general, customers have their own criteria for a problem. Therefore, it is important to understand the
symptom and status well enough by asking the customer about his/her concerns carefully. To systemize all
the information for the diagnosis, prepare the interview sheet referring to the interview points.
• In some cases, multiple conditions that appear simultaneously may cause a DTC to be detected.
INTERVIEW SHEET SAMPLE
Interview sheet
Registration Initial year
Customer number registration
MR/MS
name
Vehicle type VIN
Storage date Engine Mileage km (Mile)
Vehicle does not enter AWD mode.
AWD warning (AWD Error) is displayed.
Heavy tight-corner braking symptom occurs
Symptom
Noise Vibration
Others
( )
First occurrence Recently Others ( )
Frequency of occurrence Always Under a certain conditions of Sometimes (time(s)/day)
Irrelevant
Climate con- Weather Fine Cloud Rain Snow Others ( )

ditions Temperature Hot Warm Cool Cold Temperature (Approx. °C)
Relative humidity High Moderate Low
Urban area Suburb area High way
Road conditions
Mounting road (uphill or down hill) Rough road
Irrelevant
When engine starts During idling
Operation conditions, etc.
During driving During acceleration At constant speed driving
During deceleration During cornering (right curve or left curve)

Interview sheet
A
Registration Initial year
Customer number registration
MR/MS
name
Vehicle type VIN
B
Storage date Engine Mileage km (Mile)
Other conditions
C
Memo
DLN

C1201 AWD CONTROL UNIT
< DTC/CIRCUIT DIAGNOSIS > [TRANSFER: ETX13C]
DTC/CIRCUIT DIAGNOSIS
C1201 AWD CONTROL UNIT
DTC Description INFOID:0000000011281963
DTC DETECTION LOGIC
CONSULT screen terms

DTC No. DTC detecting condition
(Trouble diagnosis content)
CONTROLLER FAILURE
C1201 Malfunction has occurred inside AWD control unit.
(Control unit failure)
POSSIBLE CAUSE
Internal malfunction of AWD control unit
FAIL-SAFE
Vehicle changes to rear-wheel drive or shifts to 4-wheel drive (front-wheels still have some driving torque).
DTC CONFIRMATION PROCEDURE
1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and
wait at least 10 seconds before conducting the next test.
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE
With CONSULT
1. Turn the ignition switch OFF to ON.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”.
Is DTC “C1201” detected?
YES >> Proceed to diagnosis procedure. Refer to DLN-32, "Diagnosis Procedure".
NO-1 >> To check malfunction symptom before repair: Refer to GI-42, "Intermittent Incident".
NO-2 >> Confirmation after repair: INSPECTION END
Diagnosis Procedure INFOID:0000000011281964
1.PERFORM SELF-DIAGNOSIS
With CONSULT
1. Erase self-diagnostic results for “ALL MODE AWD/4WD”.
2. Turn the ignition switch OFF, and then wait 10 seconds or more.
YES >> Replace AWD control unit. Refer to DLN-56, "Removal and Installation".
NO >> Check AWD control unit pin terminals for damage or loose connection with harness connector. If
any items are damaged, repair or replace error-detected parts.

C1203 ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
C1203 ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)
A
DTC DETECTION LOGIC B

(Trouble diagnosis content) C
ABS SYSTEM Malfunction related to wheel sensor has been detected by
C1203
(ABS system) ABS actuator and electric unit (control unit).
POSSIBLE CAUSE DLN

ABS malfunction (wheel speed signal error)
FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE H
With CONSULT
1. Start the engine and drive at 30 km/h (19 MPH) or more for approximately 1 minute.
2. Perform self-diagnosis for “ALL MODE AWD/4WD”. I
NO-1 >> To check malfunction symptom before repair: Refer to GI-42, "Intermittent Incident". J
K
1.PERFORM ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) SELF-DIAGNOSIS
With CONSULT L
Perform self-diagnosis for “ABS”.
YES >> Check the DTC. Refer to BRC-58, "DTC Index". M
NO >> GO TO 2.
2.CHECK TERMINALS AND HARNESS CONNECTORS
N
Check AWD control unit pin terminals for damage or loose connection with harness connector.
Is inspection result normal?
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC O
“C1203” is detected, Replace AWD control unit. Refer to DLN-56, "Removal and Installation".
NO >> Repair or replace error-detected parts.

C1204 AWD SOLENOID
C1204 AWD SOLENOID
DTC DETECTION LOGIC

AWD SOLENOID
C1204 Malfunction related to AWD solenoid has been detected.
(AWD solenoid)
POSSIBLE CAUSE
• Internal malfunction of electronic controlled coupling
• Malfunction of AWD solenoid power supply circuit (open or short)
• Malfunction of AWD solenoid command current
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1.CHECK AWD SOLENOID POWER SUPPLY (1)

1. Turn the ignition switch OFF.
2. Disconnect AWD control unit harness connector.
3. Check the voltage between AWD control unit harness connector and ground.
AWD control unit

— Voltage
Connector Terminal
M42 9 Ground Battery voltage
4. Turn the ignition switch ON.
CAUTION:
Never start the engine.
AWD control unit

— Voltage
Connector Terminal
Is the inspection result normal?
YES >> GO TO 3.

C1204 AWD SOLENOID
NO >> GO TO 2.
2.CHECK AWD SOLENOID POWER SUPPLY (2) A

2. Check the 10A fuse (#70)
B
3. Check the harness for open or short between AWD control unit harness connector No.9 terminal and 10A
(#70).
C
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-13, "Wiring Diagram - BAT-
TERY POWER SUPPLY -".
DLN
3.CHECK AWD CONTROL UNIT GROUND
Check the continuity between AWD control unit harness connector and ground.
E
AWD control unit
— Continuity
Connector Terminal
10 F
M42 Ground Existed
11
Is the inspection result normal? G
YES >> GO TO 4.
4.CHECK AWD SOLENOID CIRCUIT (1) H
Check the resistance between AWD control unit terminals.
AWD control unit

I
Resistance (Approx.)
Connector Terminal
M42 1 2 2.45 Ω J
YES >> GO TO 7.
NO >> GO TO 5. K
5.CHECK AWD SOLENOID CIRCUIT (2)
1. Disconnect AWD solenoid harness connector.
L
2. Check the continuity between AWD control unit harness connector and AWD solenoid harness connector.
AWD control unit AWD solenoid

Continuity M
Connector Terminal Connector Terminal
1 1
M42 F48 Existed
2 2 N
3. Check the continuity between AWD control unit harness connector and the ground.
O
AWD control unit
— Continuity
Connector Terminal
1 P
M42 Ground Not existed
2
YES >> GO TO 6.
6.CHECK AWD SOLENOID
Check AWD solenoid. Refer to DLN-36, "Component Inspection".

C1204 AWD SOLENOID
YES >> GO TO 7.
NO >> AWD solenoid is malfunctioning. Replace electric controlled coupling. Refer to DLN-76, "Disas-
sembly" and DLN-77, "Assembly".
• Check AWD control unit pin terminals for damage or loose connection with harness connector.
• Check AWD solenoid pin terminals for damage or loose connection with harness connector.
Component Inspection INFOID:0000000011281969

3. Check the resistance between AWD solenoid connector terminals.
AWD solenoid
Resistance (Approx.)
Terminal
1 2 2.45 Ω
YES >> INSPECTION END

C1205 AWD ACTUATOR RELAY
A

Malfunction has been detected from AWD actuator relay in-
AWD ACTUATOR RLY
C1205 tegrated with AWD control unit, or malfunction related to
(AWD actuator relay)
AWD solenoid has been detected.
DLN
POSSIBLE CAUSE
• Internal malfunction of AWD control unit
• Malfunction of AWD solenoid power supply circuit (open or short) E
FAIL-SAFE
F
1.PRECONDITIONING
If “DTC CONFIRMATION PROCEDURE” has been previously conducted, always turn ignition switch OFF and G
H
>> GO TO 2.
With CONSULT I
Is DTC “C1205” detected? J
NO-2 >> Confirmation after repair: INSPECTION END K
1.CHECK AWD SOLENOID CIRCUIT (1) L

3. Check the continuity between AWD control unit harness connector and the ground. M
AWD control unit

— Continuity N
Connector Terminal
1
2 O
YES >> GO TO 2.
NO >> GO TO 3. P
1. Check AWD control unit pin terminals for damage or loose connection with harness connector.
2. Check AWD solenoid pin terminals for damage or loose connection with harness connector.
YES >> After connecting each harness connector, perform DTC confirmation procedure again. When DTC
“C1205” is detected, replace AWD control unit. Refer to DLN-56, "Removal and Installation".

NO >> Repair or replace damaged parts.
2. Check the continuity between AWD solenoid harness connector and the ground.
AWD solenoid
— Continuity
Terminal
1
Ground Not existed
2
YES >> GO TO 4.
4.CHECK AWD SOLENOID CIRCUIT
Check the continuity between AWD control unit harness connector and the ground.
AWD control unit

— Continuity
Connector Terminal
1
2
YES >> GO TO 5.
1. Check AWD control unit pin terminals for damage or loose connection with harness connector.
2. Check AWD solenoid pin terminals for damage or loose connection with harness connector.
YES >> After connecting each harness connector, perform DTC confirmation procedure again. When DTC
“C1205” is detected, GO TO 1.

C1210 ECM
C1210 ECM
A

ENGINE SIGNAL 1
C1210 Malfunction related to engine signal has been detected.
(Engine signal 1)
POSSIBLE CAUSE DLN

Malfunction of engine control system
FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
With CONSULT
1. Start the engine. Drive the vehicle for a while.
K
1.PERFORM ECM SELF-DIAGNOSIS
With CONSULT L
Perform self-diagnosis for “ENGINE”.
YES >> Check the DTC. Refer to EC-108, "DTC Index". M
NO >> GO TO 2.
N
Check AWD control unit pin terminals for damage or loose connection with harness connector.
YES >> After turning the ignition switch OFF, perform DTC confirmation procedure again. When DTC O
“C1210” is detected, Replace AWD control unit. Refer to DLN-56, "Removal and Installation".

P1804 AWD CONTROL UNIT
DTC DETECTION LOGIC

CONTROL UNIT 3
P1804 Malfunction has occurred inside AWD control unit.
(Control unit 3)
POSSIBLE CAUSE
Malfunction is detected in the memory (EEPROM) system of AWD control unit.
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
Is DTC “P1804” detected?
1.REPLACE AWD CONTROL UNIT

CAUTION:
Replace AWD control unit when DTC “P1804” is detected simultaneously with other items.
>> Replace AWD control unit. Refer DLN-56, "Removal and Installation".

A

CONTROL UNIT 4
P1809 Malfunction has occurred inside AWD control unit.
(Control unit 4)
POSSIBLE CAUSE DLN

AD converter system of AWD control unit is malfunctioning.
FAIL-SAFE E
1.PRECONDITIONING F
G
>> GO TO 2.
With CONSULT
K
1.REPLACE AWD CONTROL UNIT
CAUTION: L
Replace AWD control unit when DTC “P1809” is detected simultaneously with other items.
>> Replace AWD control unit. Refer DLN-56, "Removal and Installation". M

P1826 TRANSFER FLUID TEMPERATURE
DTC DETECTION LOGIC

OIL TEMP SEN Transfer fluid temperature sensor voltage condition is con-
P1826
(Oil temperature sensor) tinued 0 V or more than 2.45 V for several seconds.
POSSIBLE CAUSE
• Malfunction of transfer fluid temperature sensor or transfer fluid temperature sensor circuit.
• Malfunction of AWD control unit.
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1.CHECK TRANSFER FLUID TEMPERATURE SENSOR SIGNAL (1)

4. Check the voltage between AWD solenoid harness connector terminals.
AWD solenoid Voltage

Connector Terminal (Approx.)
F48 6 7 2.5 V
YES >> GO TO 2.
NO >> GO TO 3.
2.CHECK TRANSFER FLUID TEMPERATURE SENSOR
Check transfer fluid temperature sensor. Refer to DLN-44, "Component Inspection".
YES >> GO TO 6.
NO >> Transfer fluid temperature sensor is malfunctioning. Replace electric controlled coupling. Refer to
DLN-76, "Disassembly" and DLN-77, "Assembly".

3.CHECK TRANSFER FLUID TEMPERATURE SENSOR SIGNAL (2) A

Check the voltage between AWD solenoid harness connector and ground.
AWD solenoid Voltage B

—
Connector Terminal (Approx.)
F48 6 Ground 2.5 V

C
YES >> GO TO 4.
NO >> GO TO 5.
DLN
4.CHECK AWD CONTROL UNIT GROUND
2. Disconnect AWD control unit harness connector. E
3. Check the continuity between AWD control unit harness connector and ground.
AWD control unit F

— Continuity
Connector Terminal
10
M42 Ground Existed G
11
YES >> GO TO 5. H
5.CHECK TRANSFER FLUID TEMPERATURE SENSOR CIRCUIT
1. Turn the ignition switch OFF. I
3. Check the continuity between AWD control unit harness connector and AWD solenoid harness connector.
J
AWD control unit AWD solenoid
Continuity
K
13 6
M42 F48 Existed
3 7
4. Check the continuity between AWD control unit harness connector and the ground. L
AWD control unit

— Continuity
Connector Terminal M
13
3
N
YES >> GO TO 2.
NO >> Repair or replace error-detected parts. O
• Check AWD control unit pin terminals for damage or loose connection with harness connector.
• Check transfer fluid temperature sensor pin terminals for damage or loose connection with harness connec- P
tor.

Component Inspection INFOID:0000000011281980

1. Turn ignition switch OFF.
3. Check resistance between AWD solenoid connector terminals.
AWD solenoid Resistance

Condition
Terminal (Approx.)
20°C (68°F) 2.5 kΩ

6 7
80°C (176°F) 0.3 kΩ
NO >> Transfer fluid temperature sensor is malfunctioning. Replace electric controlled coupling. Refer to
DLN-76, "Disassembly" and DLN-77, "Assembly".

U1000 CAN COMM CIRCUIT
U1000 CAN COMM CIRCUIT
A
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul- B
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring. C
Each control unit communicate data but selectively reads required data only.
DTC DETECTION LOGIC
DLN
CAN COMM CIRCUIT AWD control unit is not transmitting/receiving CAN commu-
E
U1000
(CAN communication circuit) nication signal for 2 seconds or more.
POSSIBLE CAUSE F
CAN communication error
FAIL-SAFE
Vehicle changes to rear-wheel drive or shifts to 4-wheel drive (front-wheels still have some driving torque). G
1.PRECONDITIONING H
I
>> GO TO 2.
2.DTC REPRODUCTION PROCEDURE J
With CONSULT
2. Perform self-diagnosis for “ALL MODE AWD/4WD”. K
Is DTC “U1000” detected?
NO-1 >> To check malfunction symptom before repair: Refer to GI-42, "Intermittent Incident". L
M
Proceed to LAN-24, "Trouble Diagnosis Flow Chart".

U1010 CONTROL UNIT (CAN)
U1010 CONTROL UNIT (CAN)
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring.
Each control unit communicate data but selectively reads required data only.
DTC DETECTION LOGIC

CONTROL UNIT (CAN) Detecting error during the initial diagnosis of CAN controller
U1010
[Control unit (CAN)] of AWD control unit.
POSSIBLE CAUSE
Internal malfunction of AWD control unit
FAIL-SAFE
1.PRECONDITIONING
>> GO TO 2.
With CONSULT
1.CHECK AWD CONTROL UNIT

Check AWD control unit harness connector for disconnection and deformation.

POWER SUPPLY AND GROUND CIRCUIT
A
1.CHECK AWD CONTROL UNIT POWER SUPPLY (1) B

3. Check the voltage between AWD control unit harness connector and ground. C
AWD control unit

— Voltage (Approx.) DLN
Connector Terminal
M42 7 Ground 0V
4. Turn the ignition switch ON. E
CAUTION:
F
AWD control unit
— Voltage
Connector Terminal
G
YES >> GO TO 3. H
NO >> GO TO 2.
2.CHECK AWD CONTROL UNIT POWER SUPPLY (2)
I
2. Check the 10A fuse (#22).
3. Disconnect fuse block (J/B) harness connector.
4. Check the continuity between AWD control unit harness connector and fuse block (J/B) harness connec- J
tor.
AWD control unit Fuse block (J/B) K

Continuity
M42 7 M133 6C Existed
L
AWD control unit M

— Continuity
Connector Terminal
M42 7 Ground Not existed
N
YES >> Perform the trouble diagnosis for ignition power supply circuit. Refer to PG-57, "Wiring Diagram -
IGNITION POWER SUPPLY -".
NO >> Repair or replace error-detected parts. O

1. Turn the ignition switch OFF. P
AWD control unit

— Voltage (Approx.)
Connector Terminal

CAUTION:
AWD control unit

— Voltage
Connector Terminal
YES >> GO TO 5.
NO >> GO TO 4.
3. Disconnect fuse block (J/B) harness connector.
4. Check the continuity between AWD control unit harness connector and fuse block (J/B) harness connec-
tor.
AWD control unit Fuse block (J/B)

Continuity
M42 15 M133 29C Existed
AWD control unit

— Continuity
Connector Terminal
M42 15 Ground Not existed
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-13, "Wiring Diagram - BAT-
AWD control unit

— Voltage
Connector Terminal
CAUTION:
AWD control unit

— Voltage
Connector Terminal
YES >> GO TO 7.
NO >> GO TO 6.

3. Check the harness for open or short between AWD control unit harness connector No.9 terminal and fuse A
box.
YES >> Perform the trouble diagnosis for power supply circuit. Refer to PG-13, "Wiring Diagram - BAT- B
7.CHECK AWD CONTROL UNIT GROUND C
2. Check the continuity between AWD control unit harness connector and ground.
DLN
AWD control unit
— Continuity
Connector Terminal
E
10
M42 Ground Existed
11
Is the inspection result normal? F
G

HEAVY TIGHT-CORNER BRAKING SYMPTOM OCCURS
< SYMPTOM DIAGNOSIS > [TRANSFER: ETX13C]
SYMPTOM DIAGNOSIS
HEAVY TIGHT-CORNER BRAKING SYMPTOM OCCURS
Description INFOID:0000000011281986
Heavy tight-corner braking symptom occurs when the vehicle is driven and the steering wheel is turned fully to
either side after the engine is started.
NOTE:
Light tight-corner braking symptom may occur depending on driving conditions. This is not malfunction.
1.PERFORM ECM SELF-DIAGNOSIS

With CONSULT
Perform self-diagnosis for “ENGINE”.
YES >> Check the DTC. Refer to EC-108, "DTC Index".
NO >> GO TO 2.
2.PERFORM SELF-DIAGNOSIS
With CONSULT
Perform self-diagnosis for “ALL MODE AWD/4WD”.
YES >> Proceed to DLN-45, "Diagnosis Procedure".
NO >> GO TO 3.
Perform the trouble diagnosis of the transfer fluid temperature sensor. Refer to DLN-42, "Diagnosis Proce-
dure".
YES >> GO TO 4.
NO >> Repair or replace the error-detected parts.
Perform the trouble diagnosis of the AWD solenoid. Refer to DLN-34, "Diagnosis Procedure".
YES >> GO TO 5.
5.CHECK ELECTRIC CONTROLLED COUPLING
2. Set the transmission to neutral. Release the parking brake.
3. Lift up the vehicle.
4. Rotate the rear propeller shaft.
5. Hold the front propeller shaft lightly.
Does the front propeller shaft rotate?
YES >> Replace electric controlled coupling for mechanical malfunction (clutch sticking etc.). Refer to
DLN-75, "Exploded View".
NO >> Check each harness connector pin terminal for disconnection.

VEHICLE DOES NOT ENTER AWD MODE
VEHICLE DOES NOT ENTER AWD MODE
A
Vehicle does not enter 4-wheel drive mode even though AWD warning is not displayed. B
1.CHECK INFORMATION DISPLAY (COMBINATION METER) C

Perform the trouble diagnosis of combination meter. Refer to MWI-62, "On Board Diagnosis Function".
DLN
YES >> GO TO 2.
2.CRUISE TEST E
Drive the vehicle for a period of time.
Does any symptom occur?
YES >> Replace electric controlled coupling for mechanical malfunction (mechanical engagement of F
clutch is not possible). Refer to DLN-75, "Exploded View".
NO >> Check each harness connector pin terminal for disconnection.
G

AWD HIGH TEMP IS DISPLAYED ON INFORMATION DISPLAY
AWD HIGH TEMP IS DISPLAYED ON INFORMATION DISPLAY
While driving, AWD warning (AWD High Temp. Stop vehicle) is displayed on information display (combination
meter).
NOTE:
• This symptom protects drivetrain parts when a heavy load is applied to the electric controlled coupling and
multiple disc clutch temperature increases. Also, optional distribution of torque sometimes becomes rigid
before AWD warning (AWD High Temp. Stop vehicle) is displayed. Both cases are not malfunction. Refer to
DLN-23, "Protection Function".
• When this symptom occurs, stop vehicle and allow it to idle for some times. Displays will stop and system
will be restored.

TIRE SIZE INCORRECT IS DISPLAYED ON INFORMATION DISPLAY
TIRE SIZE INCORRECT IS DISPLAYED ON INFORMATION DISPLAY
A
While driving, AWD warning (Tire Size Incorrect: See Owner’s Manual) is displayed on information display B
(combination meter).
C
1.CHECK TIRE
Check the following.
• Tire pressure DLN
• Wear condition
• Front and rear tire size (There is no difference between front and rear tires.)
Is the inspection result normal? E
YES >> GO TO 2.
NO >> Repair or replace error-detected parts. And then, drive the vehicle at speed of 20 km/h (12 MPH)
or more for 5 seconds or more. Improper size information is initialized accordingly. F
2. CHECK INPUT SIGNAL OF TIRE DIAMETER
With CONSULT
1. Start the engine. G
2. Drive at 20 km/h (12 MPH) or more for approximately 4 minutes.
3. Check “DIS-TIRE MONI” of CONSULT “DATA MONITOR” for “ALL MODE AWD/4WD”.
Does the item on “DATA MONITOR” indicate “0 - 4 mm”? H
NO >> GO TO 3.
3.TERMINAL INSPECTION I
Check AWD control unit harness connector for disconnection.

Is the inspection result normal? J
K

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting Chart INFOID:0000000011281993
Use the chart below to find the cause of the symptom. The numbers indicate the order of the inspection. If nec-
essary, repair or replace these parts.
DLN-65, "Exploded View"
DLN-65, "Exploded View"

DLN-55, "Inspection"
Reference
TRANSFER FLUID (Level too high)

TRANSFER FLUID (Level low)
TRANSFER CASE (Damaged)

BEARING (Worn or damaged)
OIL SEAL (Worn or damaged)
LIQUID GASKET (Damaged)
TRANSFER FLUID (Wrong)
GEAR (Worn or damaged)

SUSPECTED PARTS
(Possible cause)
Noise 1 2 3 3 3
Symptom
Transfer fluid leakage 4 1 2 2 3

TRANSFER FLUID
< PERIODIC MAINTENANCE > [TRANSFER: ETX13C]
PERIODIC MAINTENANCE A
TRANSFER FLUID
Inspection INFOID:0000000011281994
B
FLUID LEAKAGE
Check transfer surrounding area (oil seal, drain plug, and filler plug etc.) for fluid leakage. C
Repair or replace parts causing fluid leakage, if necessary.
FLUID LEVEL
If there is no fluid leakage, the fluid level is judged as normal. DLN
Draining INFOID:0000000011281995
1. Run the vehicle to warm up the transfer unit sufficiently. E
2. Stop the engine, and remove the drain plug to drain the trans-
fer fluid.
F
3. Set a new gasket onto drain plug, and install it on the transfer
and tighten to the specified torque. Refer to DLN-65, "Exploded
View".
CAUTION: G
Never reuse gasket.
JPDIE0130ZZ
Refilling INFOID:0000000011281996 I
1. Remove filler plug and gasket. Then fill fluid up to mounting

hole for the filler plug. J
Recommended fluid : Refer to MA-10, "Fluids and Lu-

and capacity bricants". K
CAUTION:
Carefully fill the fluid. (Fill up for approximately 3 minutes.)
2. Leave the vehicle for 3 minutes, and check the fluid level again. L
3. Set a new gasket onto filler plug, and install it on transfer and
tighten to the specified torque. Refer to DLN-65, "Exploded JPDIE0129ZZ
View". M
CAUTION:
Never reuse gasket.
N

AWD CONTROL UNIT
< REMOVAL AND INSTALLATION > [TRANSFER: ETX13C]
REMOVAL AND INSTALLATION

AWD CONTROL UNIT
Exploded View INFOID:0000000011281997
JSDIA4523GB
AWD control unit

: Vehicle front
: N·m (kg-m, in-lb)
Removal and Installation INFOID:0000000011281998
REMOVAL
2. Instrument lower panel LH. Refer to IP-13, "Removal and Installation".
3. Remove steering column assembly mounting parts to lower steering column assembly. Refer to ST-32,
"Removal and Installation" (Models with vehicle speed sensitive P/S), ST-92, "Removal and Installation"
(Models with direct adaptive steering).
5. Remove AWD control unit mounting bolts.
6. Remove AWD control unit.
INSTALLATION
Install in the reverse order of removal.

FRONT OIL SEAL
FRONT OIL SEAL
A
DLN
JSDIA4532ZZ
G
Transfer assembly Front oil seal
Oil seal lip
: Vehicle front H
: Always replace after every disassembly.
: Apply transfer fluid.
I
: Apply multi-purpose grease.

J
REMOVAL
1. Remove the drain plug to drain the transfer fluid. Refer to DLN-55, "Draining".
K
2. Remove the front propeller shaft. Refer to DLN-89, "Removal and Installation".
3. Remove front oil seal.
CAUTION: L
Never damage the front case and front drive shaft of transfer.
INSTALLATION
1. Apply transfer fluid to outside of front oil seal, install it with a drift M
(A) [SST: ST27862000 ( — )] until the end face of front case.
CAUTION:
• Never reuse front oil seal. N
• Apply multi-purpose grease to oil seal lip.
• When installing, never incline front oil seal.
2. Install front propeller shaft. Refer to DLN-89, "Removal and
Installation". O
3. Fill with new transfer fluid. Refer to DLN-55, "Refilling".
4. Perform inspection after installation. Refer to DLN-57, "Inspec-
P
tion". JPDIE0058ZZ
INSPECTION AFTER INSTALLTION

Check fluid level and for fluid leakage. Refer to DLN-55, "Inspection".

REAR OIL SEAL
REAR OIL SEAL
JSDIA4533GB
Transfer assembly Rear oil seal Companion flange

Self-lock nut
Oil seal lip
: Vehicle front
: N·m (kg-m, ft-lb)
REMOVAL
1. Remove the rear propeller shaft. Refer to DLN-108, "Removal and Installation".
2. Remove self-lock nut of companion flange with a flange wrench (commercial service tool).
3. Put matching mark on the end of the main shaft. The mark
should be in line with the mark on the companion flange.
CAUTION:
For matching mark, use paint. Never damage main shaft.
JPDIE0060ZZ

REAR OIL SEAL
4. Remove the companion flange with a puller (A).
CAUTION: A
Never damage the companion flange.
JPDIE0061ZZ
DLN
5. Remove the rear oil seal with the puller (A) [SST: KV381054S0
(J-34286)].
CAUTION:
E
Never damage the rear case.
G
JPDIE0132ZZ
INSTALLATION
H
1. Apply transfer fluid to rear oil seal, install it with the drifts (A and
B) within the dimension (L) shown as follows.
A : Drift [SST: ST30720000 (J-25405)] I

B : Drift [SST: KV40104830 ( — )]
L : 6.7 – 7.3 mm (0.264 – 0.287 in) J
CAUTION:
• Never reuse rear oil seal.
• Apply multi-purpose grease to oil seal lip. K
JPDIE0133ZZ
• When installing, never incline rear oil seal.
2. Align the matching mark of main shaft with the mark of L

companion flange, then install the companion flange.
JPDIE0060ZZ O

REAR OIL SEAL
3. Using a flange wrench (A) (commercial service tool), install the
self-lock nut of companion flange and tighten to the specified
torque. Refer to DLN-58, "Exploded View".
CAUTION:
Never reuse self-lock nut.
4. Install the rear propeller shaft. Refer to DLN-108, "Removal and
Installation".
tion".
JPDIE0131ZZ
INSPECTION AFTER INSTALLTION

Check fluid level and for fluid leakage. Refer to DLN-55, "Inspection".

AIR BREATHER
AIR BREATHER
A
DLN
JSDIA4520ZZ
G
Transfer assembly Air breather hose
: Vehicle front
H
REMOVAL
I
1. Remove rear propeller shaft. Refer to DLN-108, "Removal and Installation".
2. Remove control rod of A/T. Refer to TM-212, "Removal and Installation".
3. Support transfer assembly with a jack. J
CAUTION:
Secure transfer assembly to a jack.
4. Remove rear engine mounting member and engine mounting insulator. Refer to EM-83, "AWD : Exploded K
View".
5. Lower jack to the position where the transfer air breather hose
can be removed.
L
6. Remove air breather hose.
PDIA0560J
INSTALLATION O
Note the following, and install in the reverse order of removal.
• When installing transfer air breather hose, make sure there are no pinched or restricted areas on the transfer
air breather hose caused by bending or winding. P

AIR BREATHER
- Set transfer air breather hose with the paint mark facing upward.
JSDIA4522ZZ
- Be sure to insert air breather hose to air breather tube until

hose end reaches the tube bend R portion.
JPDIE0106ZZ

TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: ETX13C]
UNIT REMOVAL AND INSTALLATION A

TRANSFER ASSEMBLY
B
DLN
JSDIA4515GB
G
Transfer assembly
H
: Vehicle front
I
REMOVAL
J
1. Remove rear propeller shaft. Refer to DLN-108, "Removal and Installation".
2. Remove front propeller shaft. Refer to DLN-89, "Removal and Installation".
3. Disconnect AWD solenoid harness connector and separate harness from transfer assembly. K
4. Remove control rod of A/T. Refer to TM-212, "Removal and Installation".
5. Support transfer assembly and transmission assembly with a jack.
CAUTION: L
Secure transfer assembly and transmission assembly to a jack.
6. Remove rear engine mounting member and engine mounting insulator. Refer to EM-83, "AWD : Exploded
View". M
7. Lower jack to the position where the top transfer mounting bolts
can be removed.
8. Remove transfer breather hose. Refer to DLN-61, "Removal and N
Installation".
9. Remove transfer mounting bolts and separate transfer from
transmission.
O
P
PDIA0560J
INSTALLATION

TRANSFER ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [TRANSFER: ETX13C]
• When installing the transfer to the transmission, install the mount-
ing bolts following the standard below, tighten bolts to the specified
torque. For each tightening torque, refer to DLN-63, "Exploded
View".
Bolt symbol
Quantity 1 1 4 2 3 1
75 45 40 30 75 40
Bolt length “ L ” mm (in)
(2.95) (1.77) (1.57) (1.18) (2.95) (1.57)
Transfer to JSDIA4518ZZ
Insertion direction Transmission to transfer
transmission
• Perform inspection after installation. Refer to DLN-64, "Inspection".
INSPECTION AFTER INSTALLATION

• Check the fluid level, fluid leakage. Refer to DLN-55, "Inspection".
• Check the A/T positions. Refer to TM-103, "Inspection and Adjustment".

FRONT CASE AND REAR CASE
< UNIT DISASSEMBLY AND ASSEMBLY > [TRANSFER: ETX13C]
UNIT DISASSEMBLY AND ASSEMBLY A

B
DLN
JSDIA4506GB
M
Front oil seal Main shaft oil seal Front case

Front drive shaft front bearing Front drive shaft Front drive shaft rear bearing N
Plug Main shaft bearing Snap ring
Snap ring Spacer Steel ball
Oil pump Main shaft Needle bearing O
Sprocket Drive chain Spacer
Snap ring Circlip Electric controlled coupling
P
Oil cover Retainer O-ring
Transfer fluid temperature sensor Spacer Baffle plate
Dowel pin Snap ring Rear case
Harness bracket Breather tube Gasket
Filler plug Drain plug Rear bearing

Snap ring Spacer Rear oil seal
Companion flange Self-lock nut
Oil seal lip Matching surface


: Apply Genuine Anaerobic Liquid Gasket Three Bond 1133C or equivalent.
Disassembly INFOID:0000000011282011
1. Remove drain plug, filler plug and gaskets.

2. Remove main shaft oil seal from front case.
CAUTION:
Never damage the front case and main shaft.
3. Remove front oil seal from front case.
CAUTION:
Never damage the front case and front drive shaft.
4. Remove self-lock nut.
5. Put a matching mark on the end of main shaft. The mark
should be in line with the mark on the companion flange.
CAUTION:
For the matching mark, use paint. Never damage main
shaft.
JPDIE0060ZZ
6. Remove companion flange with a puller (A).

CAUTION:
Never damage the companion flange.
JSDIA0806ZZ
7. Remove rear oil seal from rear case with the puller (A) [SST:
KV381054S0 (J-34286)].
CAUTION:
Never damage the rear case.
8. Remove spacer from main shaft.
JPDIE0132ZZ

9. Remove front case and rear case fixing bolts, then remove har-
ness bracket. A
Bolts symbol Quantity

B
13
(TORX bolt) 2
*: With harness bracket. C
DLN
G
JSDIA4505ZZ
10. Remove front case from rear case by levering it up with a H

suitable tool.
CAUTION:
Never damage the mating surface.
I
JPDIE0140ZZ
K
11. Remove snap ring from front case.
CAUTION:
Never damage front case. L
12. Remove main shaft bearing from front case.
CAUTION:
Never use tools. Always remove by hand. M
JPDIE0109ZZ
13. Remove snap ring from main shaft. O

CAUTION:
Never damage main shaft.
P
JPDIE0122ZZ

14. Remove spacer and steel ball from main shaft.

CAUTION:
Be careful not to drop the steel ball.
15. Remove oil pump from main shaft.
16. Remove drive chain and front drive shaft assembly.
CAUTION:
Never use tools. Always remove by hand.
JPDIE0123ZZ
17. Remove transfer fluid temperature sensor bolt from rear case.
And then, remove transfer fluid temperature sensor .
JPDIE0198ZZ
18. Remove oil cover .

19. Remove retainer from AWD solenoid harness connector.
20. Remove AWD solenoid harness connector from rear case.
JPDIE0197ZZ
21. Remove main shaft assembly from rear case with the drift (A)
[SST: ST33052000 ( — )].
JPDIE0114ZZ
22. Remove snap ring from rear case.

23. Remove rear bearing from rear case.
CAUTION:
JPDIE0111ZZ

24. Remove baffle plate from rear case.

A
25. Remove breather tube from rear case.
26. Perform inspection after disassembly. Refer to DLN-73, "Inspec-
tion".
B
JPDIE0112ZZ
DLN
Assembly INFOID:0000000011282012
1. Install breather tube to rear case within the angle shown as E

follows.
Angle : 80 – 100°
F
CAUTION:
Never reuse breather tube.
2. Install baffle plate to rear case. G
3. Install rear bearing to rear case.
CAUTION:
Never use tools. Always install by hand. JSDIA4510ZZ H
4. Install snap ring to rear case.

CAUTION:
Never reuse snap ring. I
JPDIE0111ZZ
5. Install main shaft assembly to rear case with the drift (A) [SST: L
ST35321000 ( — )].
CAUTION:
Apply transfer fluid to the sliding surface of main shaft and M
needle bearing.
6. Install AWD solenoid harness connector into rear case.
CAUTION: N
• O-ring is non-reusable. When replace it, replace electric
controlled coupling.
• Apply transfer fluid to O-ring.
O
7. Install retainer to AWD solenoid harness connector. JPDIE0115ZZ

8. Hold electric controlled coupling harness with oil cover hold
plate part , install oil cover to rear case .
JPDIE0199ZZ
9. Install transfer fluid temperature sensor to rear case.
JPDIE0198ZZ
10. Set drive chain to front drive shaft.

CAUTION:
Identification mark of drive chain should be in the side of
front bearing of front drive shaft.
11. Install drive chain to main shaft, and then install front drive shaft
assembly.
CAUTION:
Never use tools. Always install by hand.
12. Install oil pump to main shaft.
JPDIE0075ZZ

13. Install spacer and steel ball to main shaft.
A
JPDIE0123ZZ
DLN
14. Install snap ring to main shaft.
CAUTION:
• Never reuse snap ring. E
• Never damage main shaft.
15. Install main shaft bearing to front case.
CAUTION:
Never use tools. Always install by hand. F
G
JPDIE0122ZZ
16. Install snap ring to front case. H

CAUTION:
• Never reuse snap ring.
• Never damage front case.
I
JPDIE0109ZZ
K
17. Apply liquid gasket to mating surface of rear case.
CAUTION:
Remove old sealant adhering to mounting surfaces. Also L
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
18. Set front case to rear case. M
CAUTION:
Never damage the mating surface transmission side.
N
JPDIE0142ZZ

19. Tighten front case and rear case fixing bolts.
• For “*” mark bolt, tighten it after attach harness bracket.
Bolts symbol Quantity

13
(TORX bolt) 2
*: With harness bracket.
20. Install spacer to main shaft.
JSDIA4505ZZ
21. Apply transfer fluid to outside of rear oil seal, and install rear oil
seal to rear case with the drifts (A and B) within the dimension
(L) shown as follows.
A : Drift [SST: ST30720000 (J-25405)]

B : Drift [SST: KV40104830 ( — )]
L : 6.7 – 7.3 mm (0.264 – 0.287 in)

CAUTION:
• Never reuse rear oil seal. JPDIE0116ZZ
• When installing, never incline rear oil seal.
22. Install companion flange while aligning the matching mark of

main shaft with the mark of companion flange.
JPDIE0060ZZ

23. Tighten self-lock nut to the specified torque with flange wrench
(A) (commercial service tool). A
CAUTION:
Never reuse self-lock nut.
B
JPDIE0131ZZ
DLN
24. Apply transfer fluid to outside of main shaft oil seal, and install
main shaft oil seal until it is flush with the end face of front case
with the drift (A) [SST: ST30720000 (J-25405)].
E
CAUTION:
• Never reuse main shaft oil seal.
• When installing, never incline main shaft oil seal. F
G
JPDIE0118ZZ
25. Apply transfer fluid to outside of front oil seal, and install front oil
H
seal until it is flush with the end face of front case with the drift
(A) [SST: ST27862000 ( — )].
CAUTION:
• Never reuse front oil seal. I
• When installing, never incline front oil seal.
26. Set gasket to drain plug. Install it to rear case. J
CAUTION:
Never reuse gasket.
27. Set gasket to filler plug. Install it to rear case. JPDIE0119ZZ
K
CAUTION:
• Never reuse gasket.
• After oil is filled, tighten filler plug to specified torque.
L
INSPECTION AFTER DISASSEMBLY M

Check items below. If necessary, replace them with new ones.
Cases
• Contact surfaces of bearing for wear, damage, etc. N
• Damage and cracks of case.
JPDIE0120ZZ
Bearing

Damage and rough rotation of bearing.
PDIA0300E
Gears and Chain

• Excessive wear, damage, peeling, etc. of gear and chain.
• Cracks, damage, wear, etc. of drive chain.
SDIA2365E

MAIN SHAFT
MAIN SHAFT
A
DLN
L
JSDIA4506GB
Front oil seal Main shaft oil seal Front case M

Front drive shaft front bearing Front drive shaft Front drive shaft rear bearing
N
Oil pump Main shaft Needle bearing

Sprocket Drive chain Spacer O
Transfer fluid temperature sensor Spacer Baffle plate P

MAIN SHAFT


1. Separate front case and rear case, then remove main shaft assembly. Refer to DLN-66, "Disassembly".
2. Remove snap ring from main shaft.
JPDIE0137ZZ

CAUTION:
JPDIE0124ZZ
4. Using a press, remove electric controlled coupling from main

shaft.
JSDIA0818ZZ

MAIN SHAFT
5. Remove circlip from notch of electric controlled coupling.
A
: Front side
CAUTION:
• Never remove the circlip from the electric controlled cou- B
pling rear side.
• Never damage electric control coupling spline, bush, etc.
6. Remove snap ring from main shaft. C
JSDIA0858ZZ
DLN
CAUTION:
Be careful not to drop the steel ball. E
8. Remove sprocket from main shaft.
9. Remove needle bearing from main shaft.
10. Perform inspection after disassembly. Refer to DLN-78, "Inspec- F
tion".
G
JSDIA0796ZZ
H
1. Install needle bearing to main shaft.
CAUTION:
Apply transfer fluid to the periphery of needle bearing. I
2. Install sprocket to main shaft.
CAUTION: J
CAUTION: K
Never reuse snap ring.
JSDIA0796ZZ
M
5. Install circlip to notch of the electric controlled coupling.
: Front side N
CAUTION:
• Never install the circlip to the notches other than notch .
• Never install the circlip from the electric controlled cou- O
pling rear side.
• Never reduce the outer diameter of circlip to less than
43.2 mm (1.701 in). P
• Never damage electric control coupling spline, bush, etc.
JSDIA0858ZZ
• Never reuse circlip.
• Never reuse O-ring of AWD solenoid harness connector. When replace it, replace electric con-
trolled coupling.
6. Install electric controlled coupling to main shaft.
CAUTION:
Securely insert it until locked.

MAIN SHAFT
CAUTION:
JPDIE0124ZZ

CAUTION:
Never reuse snap ring.
9. Install main shaft assembly to rear case, then install front case
and rear case. Refer to DLN-69, "Assembly".
JPDIE0137ZZ
INSPECTION AFTER DISASSEMBLY

Bearing
PDIA0300E
Shaft
Damage, peeling, dent, uneven wear, bending, etc. of shaft.
JPDIE0143ZZ
Gears and Chain

MAIN SHAFT
• Cracks, damage, wear, etc. of drive chain. A
SDIA2365E
DLN

FRONT DRIVE SHAFT AND DRIVE CHAIN
JSDIA4506GB
Front oil seal Main shaft oil seal Front case

Front drive shaft front bearing Front drive shaft Front drive shaft rear bearing
Oil pump Main shaft Needle bearing
Sprocket Drive chain Spacer
Transfer fluid temperature sensor Spacer Baffle plate

A
: Always replace after every disassembly. B

: Apply multi-purpose grease. C
Disassembly INFOID:0000000011282019 DLN
1. Separate front case and rear case. Refer to DLN-66, "Disassembly".

2. Remove drive chain and front drive shaft assembly. E
CAUTION:
3. Remove front drive shaft front bearing with the drift (A) and sep- F
arator (B).
A : Drift [SST: ST31214000 (J-25269-B)] G

B : Separator (commercial service tool)
I
JPDIE0084ZZ
4. Remove front drive shaft rear bearing with the drift (A) and sepa-
rator (B). J
A : Drift [SST: ST31214000 (J-25269-B)]

B : Separator (commercial service tool) K
5. Remove plug from front drive shaft.
6. Perform inspection after disassembly. Refer to DLN-82, "Inspec-
tion". L
JPDIE0085ZZ
M
1. Install plug to front drive shaft.

CAUTION: N
Never reuse plug.
2. Install front drive shaft front bearing with the drift (A) [SST:
ST33200000 (J-26082)]. O
JPDIE0138ZZ

3. Install front drive shaft rear bearing with the drift (A) [SST:
KV38104010 ( — )].
JPDIE0139ZZ
4. Set drive chain to front drive shaft.

CAUTION:
Identification mark of drive chain should be in the side of
front bearing of front drive shaft.
5. Install drive chain to main shaft, and then install front drive shaft.
CAUTION:
Never use tools. Always install by hand.
6. Install front case to rear case. Refer to DLN-69, "Assembly".
JPDIE0075ZZ

Bearing
PDIA0300E
Gears and Chain

• Cracks, damage, wear, etc. of drive chain.
SDIA2365E

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [TRANSFER: ETX13C]
SERVICE DATA AND SPECIFICATIONS (SDS) A

General Specifications INFOID:0000000011282022
B
Axle AWD
C
Applied model Engine VQ37VHR
Transmission A/T
Transfer model ETX13C DLN
Fluid capacity Refer to MA-10, "Fluids and Lubricants".

PRECAUTIONS
< PRECAUTION > [FRONT PROPELLER SHAFT: 2S56A]
PRECAUTION
PRECAUTIONS
NOTE:
occur.
NOTE:
SEF289H
detected.
NOTE:
Service Notice or Precautions for Propeller Shaft INFOID:0000000011282023
• Replace the propeller shaft assembly if there is a breakage or deflection on tube.

• Never hit the tube or apply an impact on it during repair service. Never damage the tube as well.
• The joint cannot be disassembled. Never disassemble it.

PREPARATION
< PREPARATION > [FRONT PROPELLER SHAFT: 2S56A]
PREPARATION A
PREPARATION
Commercial Service Tools INFOID:0000000011282024
B
Tool name Description

C
Power tool Loosening bolts and nuts
DLN
E
PBIC0190E

< SYSTEM DESCRIPTION > [FRONT PROPELLER SHAFT: 2S56A]
SYSTEM DESCRIPTION
PART OF JOINT
Universal Type (Shell Type)
JSDIA4709ZZ

Symptom
Reference
×: Applicable
Revision: 2015 January

< SYMPTOM DIAGNOSIS >
Noise
Shake
Vibration
Possible cause and SUSPECTED PARTS
NVH Troubleshooting Chart
SYMPTOM DIAGNOSIS
Uneven rotating torque DLN-88, "Inspection"
×
×
Center bearing improper installation —
×
×
×
Excessive center bearing axial end play —
×
×
DLN-87
Center bearing mounting (insulator) cracks, damage or deterioration —
×
×
Excessive joint angle —
×
×
×
Rotation imbalance DLN-88, "Inspection"
×
×
Excessive runout DLN-88, "Inspection"
×
×
DIFFERENTIAL NVH of FRONT and REAR FINAL DRIVE in this section.
×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU, and RSU section.
×
×
×
TIRE NVH in WT section.
×
×
×
ROAD WHEEL NVH in WT section.
×
×
Use the chart below to find the cause of the symptom. If necessary, repair or replace these parts.
DRIVE SHAFT NVH in FAX and RAX section.
×
×
×
BRAKE NVH in BR section.
×
×
STEERING NVH in ST section.
×
×
×
[FRONT PROPELLER SHAFT: 2S56A]
INFOID:0000000011282026
2015 Q50
I
L
F
P
K
E
B
A
N
H
C
O
G
M
DLN
FRONT PROPELLER SHAFT
< PERIODIC MAINTENANCE > [FRONT PROPELLER SHAFT: 2S56A]
PERIODIC MAINTENANCE
APPEARANCE AND NOISE

Check the propeller shaft tube surface for dents or cracks. If malfunction is detected, replace propeller shaft
assembly.
VIBRATION
If vibration is present at high speed, adjust the propeller shaft phase first.
1. Check the propeller shaft for bend and damage. If damaged, replace propeller shaft assembly.
2. Perform a cruise test drive to check the propeller shaft for runout. If vibration occurs, separate propeller
shaft at final drive companion flange; then change the phase between companion flange and propeller
shaft by the one bolt hole at a time and install propeller shaft.
3. If vibration is still detected, measure propeller shaft runout after removing it. Refer to DLN-90, "Inspec-
tion".

< REMOVAL AND INSTALLATION > [FRONT PROPELLER SHAFT: 2S56A]
REMOVAL AND INSTALLATION A

B
DLN
JSDIA4447GB
G
Propeller shaft assembly O-ring

H
: Vehicle front
: Always replace after every disassembly. I
Removal and Installation INFOID:0000000011282029 J
REMOVAL
1. Shift transmission to the neutral position, and then release parking brake. K
2. Remove front under cover. Refer to EXT-33, "FRONT UNDER COVER : Exploded View".
3. Remove front cross bar. Refer to FSU-40, "Exploded View".
L
4. Remove exhaust front tube and three-way catalyst (bank 1). Refer to EX-6, "Removal and Installation".
5. Remove steering gear assembly. Refer to ST-103, "Removal and Installation". (Models with direct adap-
tive steering)
M
6. Put matching marks on propeller shaft flange yoke and final
drive companion flange.
CAUTION:
For matching mark, use paint. Never damage propeller shaft N
flange yoke and final drive companion flange.
P
JSDIA4487ZZ

7. Remove propeller shaft assembly fixing bolts and nuts, and sep-
arate propeller shaft assembly from final drive companion
flange.
JSDIA4488ZZ
8. Remove propeller shaft assembly from the vehicle.

CAUTION:
• Never damage transfer front oil seal.
• Never damage O-ring.
• Wrap transmission interference area with shop cloth or
equivalent to protect propeller shaft from breakage.
: Vehicle front
9. Perform inspection after removal. Refer to DLN-90, "Inspection".
JSDIA0849ZZ
INSTALLATION
• For non-reusable parts, refer to DLN-89, "Exploded View".
• For each tightening torque, refer to DLN-89, "Exploded View".
• Apply multi-purpose grease onto O-ring.
• When installing propeller shaft assembly to transfer, never damage transfer front oil seal.
• Wrap power steering piping interference area with shop cloth or equivalent to protect power steering piping
from breakage. (Models with vehicle speed sensitive P/S)
• Align matching marks to install propeller shaft flange yoke and
final drive companion flange.
JSDIA4487ZZ
INSPECTION AFTER REMOVAL

Appearance
Check propeller shaft tube surface for dents or cracks. If malfunction is detected, replace propeller shaft
assembly.
Propeller Shaft Runout

Check propeller shaft runout at measuring points with a dial indica-
tor. If runout exceeds specifications, replace propeller shaft assem- A
bly.
Propeller shaft runout : Refer to DLN-92, "Propeller B

Shaft Runout".
JSDIA0083ZZ
DLN
• Propeller shaft runout measuring point (Point “ ”).
Dimension E
A : 381.5 mm (15.02 in)
G
PDIA0768J
Journal Axial Play

As shown in the figure, while fixing yoke on one side, check axial H
play of joint. If it is outside the standard, replace propeller shaft
assembly.
I
Journal axial play : Refer to DLN-92, "Journal Axial
Play".
CAUTION: J
Never disassemble joints.
K
PDA0005D

After assembly, perform a driving test to check propeller shaft vibration. If vibration occurred, separate propel- L
ler shaft from final drive. Reinstall companion flange by changing the phase between companion flange and
propeller shaft by the one bolt hole at a time. Then perform driving test and check propeller shaft vibration
again at each point.
M

< SERVICE DATA AND SPECIFICATIONS (SDS) [FRONT PROPELLER SHAFT: 2S56A]

Axle AWD
Transmission A/T
Propeller shaft model 2S56A
Number of joints 2
1st joint Universal (Shell type)
Joint type
2nd joint Universal (Shell type)
Transfer side Sleeve type
Coupling method
Front final drive side Flange type
Shaft length (Spider to spider) 763.0 mm (30.04 in)
Shaft outer diameter 42.7 mm (1.681 in)
Propeller Shaft Runout INFOID:0000000011282032
Unit: mm (in)
Item Standard
Propeller shaft runout 0.8 (0.031) or less
Journal Axial Play INFOID:0000000011282033
Unit: mm (in)
Item Standard
Journal axial play 0 (0)

PRECAUTIONS
< PRECAUTION > [REAR PROPELLER SHAFT: 3S80A-R]
PRECAUTION A
PRECAUTIONS
B
NOTE: C
stops, then a DTC detection error or ECU data corruption may DLN
occur.
NOTE: E
SEF289H
detected. F
NOTE:
G
• Replace the propeller shaft assembly if there is a breakage or deflection on tube. H

• The angle which rubber coupling forms with companion flange must be 4 degrees or less. Never damage
grease seal in rubber coupling. I

PREPARATION
< PREPARATION > [REAR PROPELLER SHAFT: 3S80A-R]
PREPARATION
PREPARATION

PBIC0190E

< SYSTEM DESCRIPTION > [REAR PROPELLER SHAFT: 3S80A-R]
B
PART OF JOINT
Universal Type (Shell Type) C
DLN
JSDIA4709ZZ
F
Rubber Coupling Type

G
JSDIA4710ZZ
J

Symptom
Reference
×: Applicable

Noise
Shake
Vibration
SYMPTOM DIAGNOSIS
×
×
Center bearing improper installation DLN-98, "Exploded View"
×
×
×
×
×
DLN-96
Center bearing mounting (insulator) cracks, damage or deterioration DLN-101, "Inspection"
×
×
×
×
×
×
×
×
×
DIFFERENTIAL NVH of REAR FINAL DRIVE in this section.
×
×
×
×
×
×
×
×
×
DRIVE SHAFT NVH in RAX section.
×
×
×
×
×
×
×
×
[REAR PROPELLER SHAFT: 3S80A-R]
INFOID:0000000011282037
2015 Q50
REAR PROPELLER SHAFT
< PERIODIC MAINTENANCE > [REAR PROPELLER SHAFT: 3S80A-R]
B

• Check the propeller shaft tube surface for dents or cracks. If malfunction is detected, replace propeller shaft C
assembly.
• If center bearing is noisy or damaged, replace propeller shaft assembly.
VIBRATION DLN
2. If the alignment mark of the propeller shaft and the align- E
ment mark of the companion flanges on the final drive are not
on an axis, re-install these parts to a closer position as possible.
3. Perform a cruise test drive to check the propeller shaft for runout F
after installation. If vibration still occurs, separate propeller shaft
at final drive companion flange; then change the phase between
companion flange and propeller shaft by the one bolt hole at a
G
time and install propeller shaft.
4. If vibration is still detected, measure propeller shaft runout after
removing it. Refer to DLN-101, "Inspection".
JSDIA0077ZZ H

< REMOVAL AND INSTALLATION > [REAR PROPELLER SHAFT: 3S80A-R]

JSDIA4549GB
Propeller shaft assembly
: Vehicle front
REMOVAL
1. Shift transmission to the neutral position, and then release parking brake.
2. Remove tunnel stay.
3. Remove center muffler and exhaust front tube. Refer to EX-6, "Removal and Installation".
4. Remove heat insulator .
JSFIA1342ZZ

5. Put matching marks on propeller shaft rubber coupling and
final drive companion flange. A
CAUTION:
For matching mark, use paint. Never damage propeller shaft
rubber coupling and final drive companion flange.
B
JSDIA0814ZZ
DLN
6. Loosen mounting nuts of center bearing mounting bracket.
NOTE:
Tighten mounting nuts temporarily.
E
G
JSDIA4421ZZ
7. Remove propeller shaft assembly fixing bolts, nuts, and wash-

H
ers.
CAUTION:
Be careful not to remove wrong fixing bolts and nuts. Never
separate the rubber coupling from propeller shaft. I
JSDIA0010ZZ
K
8. Slightly separate rubber coupling from final drive companion
flange .
CAUTION: L
Never damage final drive companion flange and rubber
coupling.
M
N
JSDIA4422ZZ
9. Remove center bearing mounting bracket fixing nuts. O

CAUTION:

The angle which rubber coupling forms with compan-
ion flange must be 4 degrees or less. Never damage
grease seal .
10. Slide propeller shaft in the vehicle forward direction slightly. Sep-
arate propeller shaft from final drive companion flange.
CAUTION:
• The angle which rubber coupling forms with companion
flange must be 4 degrees or less.
• Never damage grease seal.
• Never damage rubber coupling.
11. Remove propeller shaft assembly from the vehicle. JSDIA4423ZZ
CAUTION:
Never damage rear oil seal of transmission.
INSTALLATION
• Never damage rubber coupling, protect it with a shop towel or equivalent.
• When installing propeller shaft assembly to transmission, never damage rear oil seal of transmission.
flange must be 4 degrees or less. Never damage grease seal
.
• Center bearing mounting bracket fixing nuts must be tightened in
the order from left to right.
JSDIA4423ZZ
• Align matching marks to install propeller shaft rubber coupling to

JSDIA0814ZZ
• If propeller shaft or final drive has been replaced, connect them as follows:
- Install propeller shaft while aligning its matching mark of pro-
peller shaft with matching mark of final drive on the joint as
close as possible.
• Perform inspection after installation. Refer to DLN-101, "Inspec-
tion".
JSDIA0077ZZ

A
INSPECTION AFTER REMOVAL
Appearance
B
• Check propeller shaft tube surface for dents or cracks. If malfunction is detected, replace propeller shaft
assembly.
• Check rubber coupling for wear, cracks, or damage. If malfunction is detected, replace propeller shaft
assembly. C
Propeller Shaft Runout
tor. If runout exceeds specifications, replace propeller shaft assem- DLN
bly.
Propeller shaft runout : Refer to DLN-102, "Propeller E

Shaft Runout".
JSDIA0078ZZ
G
• Propeller shaft runout measuring point (Point “ ”).
: Front side H
Dimension
A : 172 mm (6.77 in) I
B : 172 mm (6.77 in)
C : 172 mm (6.77 in)
J
JPDID0278ZZ
Journal Axial Play K

As shown in the figure, while fixing yoke on one side, check axial
assembly.
L
Play".
M
CAUTION:
N
PDA0005D
Center Bearing
Check center bearing for noise and damage. If malfunction is detected, replace propeller shaft assembly. O
CAUTION:
Never disassemble center bearing.
INSPECTION AFTER INSTALLATION P
After assembly, perform a driving test to check propeller shaft vibration. If vibration occurred, separate propel-

< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR PROPELLER SHAFT: 3S80A-R]

Axle 2WD
Transmission A/T
Propeller shaft model 3S80A-R
Number of joints 3
Joint type 2nd joint Universal (Shell type)
3rd joint Rubber coupling type
Transmission side Sleeve type
Coupling method
Rear final drive side Flange type
1st shaft (Spider to spider) 774.0 mm (30.47 in)
Shaft length
2nd shaft (Spider to rubber coupling center) 689.0 mm (27.13 in)
1st shaft 75.0 mm (2.953 in)
Shaft outer diameter
2nd shaft 65.0 mm (2.559 in)
Unit: mm (in)
Item Standard
Unit: mm (in)
Item Standard

PRECAUTIONS
< PRECAUTION > [REAR PROPELLER SHAFT: 3F80A-R]
PRECAUTION A
PRECAUTIONS
B
NOTE: C
stops, then a DTC detection error or ECU data corruption may DLN
occur.
NOTE: E
SEF289H
detected. F
NOTE:
G
• Replace the propeller shaft assembly if there is a breakage or deflection on tube. H

• The angle which rubber coupling forms with companion flange must be 4 degrees or less. Never damage
grease seal in rubber coupling. I

PREPARATION
< PREPARATION > [REAR PROPELLER SHAFT: 3F80A-R]
PREPARATION
PREPARATION

PBIC0190E

< SYSTEM DESCRIPTION > [REAR PROPELLER SHAFT: 3F80A-R]
B
PART OF JOINT
Universal Type (Shell Type) C
DLN
JSDIA4709ZZ
F
Rubber Coupling Type

G
JSDIA4710ZZ
J

Symptom
Reference
×: Applicable

Noise
Shake
Vibration
SYMPTOM DIAGNOSIS
×
×
Center bearing improper installation DLN-108, "Exploded View"
×
×
×
×
×
Center bearing mounting (insulator) cracks, damage or deterioration DLN-107, "Inspection"
×
×
DLN-106
×
×
×
×
×
×
×
DIFFERENTIAL NVH of FRONT and REAR FINAL DRIVE in this section.
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
[REAR PROPELLER SHAFT: 3F80A-R]
INFOID:0000000011282048
2015 Q50
< PERIODIC MAINTENANCE > [REAR PROPELLER SHAFT: 3F80A-R]
B

• Check the propeller shaft tube surface for dents or cracks. If malfunction is detected, replace propeller shaft C
assembly.
• If center bearing is noisy or damaged, replace propeller shaft assembly.
VIBRATION DLN
2. If the alignment mark of the propeller shaft and the align- E
ment mark of the companion flanges on the final drive are not
on an axis, re-install these parts to a closer position as possible.
3. Perform a cruise test drive to check the propeller shaft for runout F
after installation. If vibration still occurs, separate propeller shaft
at final drive companion flange; then change the phase between
companion flange and propeller shaft by the one bolt hole at a
G
time and install propeller shaft.
4. If vibration is still detected, measure propeller shaft runout after
removing it. Refer to DLN-111, "Inspection".
JSDIA0077ZZ H

< REMOVAL AND INSTALLATION > [REAR PROPELLER SHAFT: 3F80A-R]

JPDID0422GB
Propeller shaft assembly
: Vehicle front
REMOVAL
1. Shift transmission to the neutral position, and then release parking brake.
2. Remove tunnel stay.
3. Remove center muffler and exhaust front tube. Refer to EX-6, "Removal and Installation".
4. Remove heat insulator .
JSFIA1342ZZ

5. Put matching marks on propeller shaft flange yoke and trans-
fer companion flange. A
CAUTION:
flange yoke and transfer companion flange.
B
JSDIA4445ZZ
DLN
6. Put matching marks on propeller shaft rubber coupling and
CAUTION: E
rubber coupling and final drive companion flange.
G
JSDIA0814ZZ
7. Loosen mounting nuts of center bearing mounting bracket.

H
NOTE:
Tighten mounting nuts temporarily.
JSDIA4421ZZ
K
8. Remove propeller shaft assembly fixing bolts, nuts, and wash-
ers.
CAUTION: L
Be careful not to remove wrong fixing bolts and nuts. Never
separate the rubber coupling from propeller shaft.
M
N
JSDIA0010ZZ
9. Slightly separate rubber coupling from final drive companion O

flange .
CAUTION:
Never damage final drive companion flange and rubber P
coupling.
JSDIA4422ZZ

10. Remove propeller shaft assembly fixing bolts and nuts, and sep-
arate propeller shaft assembly from transfer companion flange.
JSDIA4446ZZ
11. Remove center bearing mounting bracket fixing nuts.

CAUTION:
The angle which rubber coupling forms with compan-
ion flange must be 4 degrees or less. Never damage
grease seal .
12. Slide propeller shaft in the vehicle forward direction slightly. Sep-
arate propeller shaft from final drive companion flange.
CAUTION:
flange must be 4 degrees or less.
• Never damage grease seal.
• Never damage rubber coupling.
13. Remove propeller shaft assembly from the vehicle. JSDIA4423ZZ

INSTALLATION
• Never damage rubber coupling, protect it with a shop towel or equivalent.
flange must be 4 degrees or less. Never damage grease seal
.
• Center bearing mounting bracket fixing nuts must be tightened in
the order from left to right.
JSDIA4423ZZ
• Align matching marks to install propeller shaft rubber coupling to

JSDIA0814ZZ

• Align matching marks to install propeller shaft flange yoke and
transfer companion flange. A
JPDID0207ZZ
DLN
• If propeller shaft or final drive has been replaced, connect them as follows:
- Install propeller shaft while aligning its matching mark of pro-
peller shaft with matching mark of final drive on the joint as E
close as possible.
tion". F
JSDIA0077ZZ
H
INSPECTION AFTER REMOVAL I

Appearance
• Check propeller shaft tube surface for dents or cracks. If malfunction is detected, replace propeller shaft
assembly. J
• Check rubber coupling for wear, cracks, or damage. If malfunction is detected, replace propeller shaft
assembly.
Propeller Shaft Runout K
tor. If runout exceeds specifications, replace propeller shaft assem-
bly.
L
Propeller shaft runout : Refer to DLN-113, "Propeller
Shaft Runout".
M
N
JSDIA0079ZZ
• Propeller shaft runout measuring point (Point “ ”). O

: Front side
P
Dimension
A : 192 mm (7.56 in)
B : 172 mm (6.77 in)
C : 172 mm (6.77 in)
JPDID0279ZZ

Journal Axial Play
As shown in the figure, while fixing yoke on one side, check axial
assembly.

Play".
CAUTION:
PDA0005D
Center Bearing
Check center bearing for noise and damage. If malfunction is detected, replace propeller shaft assembly.
CAUTION:
Never disassemble center bearing.
After assembly, perform a driving test to check propeller shaft vibration. If vibration occurred, separate propel-

< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR PROPELLER SHAFT: 3F80A-R]

B
Axle AWD
C
Transmission A/T
Propeller shaft model 3F80A-R DLN
Number of joints 3
E
Joint type 2nd joint Universal (Shell type)
3rd joint Rubber coupling type
Traansfer side Flange type F
Coupling method
Rear final drive side Flange type
1st shaft (Spider to spider) 514.0 mm (20.24 in)
Shaft length
2nd shaft (Spider to rubber coupling center) 709.0 mm (27.91 in) G
1st shaft 75.0 mm (2.953 in)
Shaft outer diameter
2nd shaft 65.0 mm (2.559 in)
H
Unit: mm (in) I
Item Standard
J
Unit: mm (in) K
Item Standard
L

PRECAUTIONS
< PRECAUTION > [FRONT FINAL DRIVE: F160A]
PRECAUTION
PRECAUTIONS
NOTE:
occur.
NOTE:
SEF289H
detected.
NOTE:
Service Notice or Precautions for Front Final Drive INFOID:0000000011282056
• Check for the correct installation status prior to removal or disassembly. If matching marks are required, be
certain they never interfere with the function of the parts when applied.
• Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
• Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of
the unit, preventing them from entering into the unit during disassembly or assembly.
with a new ones if necessary.
• Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
ening sequence is specified, observe it.
• When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
• Always use shop paper for cleaning the inside of components.
• Avoid using cotton gloves or shop rags to prevent entering of lint.
• During assembly, observe the specified tightening torque, and apply new gear oil, petroleum jelly, or multi-
purpose grease as specified for each vehicle, if necessary.
NOTE:
• Front oil seal cannot be replaced on vehicle, because there is not enough room.
• Left side oil seal cannot be replaced on vehicle, because it is attached to oil pan of engine. Replace it after
removing front final drive assembly from vehicle.

PREPARATION
< PREPARATION > [FRONT FINAL DRIVE: F160A]
PREPARATION A
PREPARATION
B
Tool number C
Tool name
KV381054S0 • Removing side oil seal (right side) DLN
(J-34286) • Removing side bearing outer race
Puller
ZZA0601D F
KV38100200 Installing side shaft oil seal
( — )
Drift G
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
H
ZZA1143D
ST30032000 • Installing side shaft

(J-26010-01) • Installing pinion rear bearing inner race I
Drift
a: 80 mm (3.15 in) dia.
b: 38 mm (1.50 in) dia.
c: 31 mm (1.22 in) dia.
J
S-NT107
K
KV10111100 Removing carrier cover
(J-37228)
Seal cutter
L
M
S-NT046
ST3306S001 Removing and installing side bearing inner

(J-22888-D) race
Differential side bearing puller set N
1: ST33051001
(J-22888-20)
Puller
O
2: ST33061000
(J-8107-2)
Base
a: 28.5 mm (1.122 in) dia. NT072
P
b: 38 mm (1.50 in) dia.

PREPARATION
Tool number
Tool name
ST33230000 Installing side bearing inner race
(J-25805-01)
Drift
a: 51 mm (2.01 in) dia.
b: 41 mm (1.61 in) dia.
c: 28.5 mm (1.122 in) dia.
ZZA1046D
ST30611000 Installing side bearing outer race (Use with

(J-25742-1) KV31103000)
Drift bar
S-NT090
KV31103000 Installing side bearing outer race

(J-38982)
Drift
a: 49 mm (1.93 in) dia.
b: 70 mm (2.76 in) dia.
ZZA1113D
ST33400001 • Installing side oil seal (right side)

(J-26082) • Installing front oil seal
Drift
a: 60 mm (2.36 in) dia.
b: 47 mm (1.85 in) dia.
ZZA0702D
KV38102100 Installing side oil seal (left side)

(J-25803-01)
Drift
a: 44 mm (1.73 in) dia.
b: 36 mm (1.42 in) dia.
c: 24.5 mm (0.965 in) dia.
ZZA1046D
ST3127S000 Measuring pinion bearing preload and total

(J-25765-A) preload
Preload gauge
ZZA0806D

PREPARATION
Tool number
(TechMate No.) Description A
Tool name
ST37820000 Installing pinion front and rear bearing outer
( — ) race B
Drift
a: 39 mm (1.54 in) dia.
b: 72 mm (2.83 in) dia.
C
ZZA0836D
KV38102510 Installing front oil seal DLN

( — )
Drift
a: 71 mm (2.80 in) dia.
b: 65 mm (2.56 in) dia.
E
ZZA0838D F
G
Oil seal remover Removing side shaft oil seal
H
JSDIA4998ZZ
J
Flange wrench Removing and installing drive pinion lock nut
L
NT035
Separator • Removing extension tube retainer

• Removing pinion rear bearing inner race M
ZZA0700D
Spacer Installing pinion front bearing inner race O

a: 60 mm (2.36 in) dia.
b: 36 mm (1.42 in) dia.
c: 30 mm (1.18 in)
P
ZZA1133D

PREPARATION
Spring gauge Measuring turning torque
NT127
PBIC0190E
Item Use
Red lead or equivalent Checking tooth contact

< SYSTEM DESCRIPTION > [FRONT FINAL DRIVE: F160A]
B
DLN
PDIA0647E
H
Side retainer Side bearing Differential case
Drive gear Pinion mate shaft Pinion mate gear
I
Side gear Side shaft Gear carrier
Drive pinion Companion flange Pinion front bearing
Pinion rear bearing Extension tube retainer Engine oil pan J

Symptom
Reference
×: Applicable

Noise
SYMPTOM DIAGNOSIS
Gear tooth rough DLN-144, "Inspection"
×
Gear contact improper DLN-139, "Adjustment"
DLN-120
Tooth surfaces worn DLN-144, "Inspection"
×
Backlash incorrect DLN-139, "Adjustment"
×
Companion flange excessive runout DLN-139, "Adjustment"
×
Gear oil improper DLN-121, "Inspection"
×
PROPELLER SHAFT NVH of FRONT and REAR PROPELLER SHAFT in this section.
×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections.
×
×
×
×
×
× STEERING NVH in ST section.
[FRONT FINAL DRIVE: F160A]
INFOID:0000000011282061
2015 Q50
FRONT DIFFERENTIAL GEAR OIL
< PERIODIC MAINTENANCE > [FRONT FINAL DRIVE: F160A]
FRONT DIFFERENTIAL GEAR OIL
B
OIL LEAKAGE
Make sure that oil is not leaking from final drive assembly or around it. C
OIL LEVEL
• Remove filler plug and check oil level from filler plug mounting
hole as shown in the figure. DLN
CAUTION:
Never start engine while checking oil level.
• Set a gasket on filler plug and install it on final drive assembly. E
Refer to DLN-131, "Exploded View".
CAUTION:
Never reuse gasket.
F
JPDID0188ZZ
G
1. Stop engine.
H
2. Remove drain plug and drain gear oil.
3. Set a gasket on drain plug and install it to final drive assembly
and tighten to the specified torque. Refer to DLN-131, "Exploded I
View".
CAUTION:
Never reuse gasket.
J
K
JPDID0189ZZ
Refilling INFOID:0000000011282064
L
1. Remove filler plug . Fill with new gear oil until oil level reaches
the specified level near filler plug mounting hole.
M
Recommended oil : Refer to MA-10, "Fluids and Lubri-
and capacity cants".
2. After refilling oil, check oil level. Set a gasket to filler plug, then N
install it to final drive assembly. Refer to DLN-131, "Exploded
View".
CAUTION: O
Never reuse gasket. JPDID0188ZZ

FRONT OIL SEAL
< REMOVAL AND INSTALLATION > [FRONT FINAL DRIVE: F160A]

FRONT OIL SEAL
NOTE:
Front oil seal cannot be replaced on vehicle, because there is not enough room.

SIDE OIL SEAL
SIDE OIL SEAL
A
LEFT SIDE
LEFT SIDE : Removal and Installation INFOID:0000000011282066
B
NOTE:
Left side oil seal cannot be replaced on vehicle, because it is attached to oil pan of engine. Replace it after
removing front final drive assembly from vehicle. C
RIGHT SIDE
RIGHT SIDE : Exploded View INFOID:0000000011282067
DLN
JPDID0298ZZ I
Front final drive assembly Side oil seal

Oil seal lip J
: Vehicle front
K
: Apply gear oil.
L
RIGHT SIDE : Removal and Installation INFOID:0000000011282068
REMOVAL M
1. Remove the front drive shaft. Refer to FAX-26, "RIGHT SIDE : Removal and Installation".
2. Remove the side oil seal using a puller (A) [SST: KV381054S0
(J-34286)]. N
CAUTION:
Never damage side retainer.
O
PDIA0838J
INSTALLATION

SIDE OIL SEAL
1. Using the drift (A) [SST: ST33400001 (J-26082)], press-fit side
oil seal so that its surface comes face-to-face with the end sur-
face of the side retainer.
CAUTION:
• Never reuse oil seal.
• When installing, never incline oil seal.
• Apply multi-purpose grease onto oil seal lip, and gear oil
onto the circumference of oil seal.
2. Install the front drive shaft. Refer to FAX-26, "RIGHT SIDE :
Removal and Installation".
3. Perform inspection after installation. Refer to DLN-124, "RIGHT PDIA0787J
SIDE : Inspection".
RIGHT SIDE : Inspection INFOID:0000000011282069

Check oil level and final drive for oil leakage. Refer to DLN-121, "Inspection".

AIR BREATHER
AIR BREATHER
A
DLN
JSDIA4494GB
G
Air breather tube Air breather hose Front final drive assembly
: Vehicle front
: N·m (kg-m, ft-lb) H
I
REMOVAL
1. Remove front under cover. Refer to EXT-33, "FRONT UNDER COVER : Exploded View".
2. Support engine with a suitable jack. J
CAUTION:
Secure engine assembly to a jack.
3. Remove engine mounting bracket (RH), engine mounting bracket (RH) (lower) and engine mounting insu- K
lator (RH). Refer to EM-83, "AWD : Exploded View" and EM-83, "AWD : Removal and Installation".
4. Remove air breather tube and air breather hose.
L
INSTALLATION
• Install air breather hose and tube as shown in the figure. M
CAUTION:
Make sure there are no pinched or restricted areas on air
breather hose caused by bending or winding when installing N
it.
- Make sure the paint mark facing up ( ).
- Securely install the hose until it seats the rounded portion of the
tube. (Front final drive side). O
- Securely install the hose until it to paint mark of the tube. (Air
breather tube side).
- Face the bend of air breather hose to the engine side ( ). JSDIA0018ZZ P

FRONT FINAL DRIVE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [FRONT FINAL DRIVE: F160A]
UNIT REMOVAL AND INSTALLATION

JSDIA4495GB
Front final drive assembly Side shaft assembly
: Vehicle front
REMOVAL
1. Remove engine assembly, transmission assembly, transfer assembly and front final drive assembly
together with front suspension member. Refer to EM-83, "AWD : Removal and Installation".
2. Lift and support engine assembly with hoist and remove engine mounting bracket (RH), engine mounting
bracket (RH) (lower) and engine mounting insulator (RH). Refer to EM-83, "AWD : Removal and Installa-
tion".
3. Remove air breather tube and air breather hose. Refer to DLN-125, "Removal and Installation".
4. Remove side shaft assembly.
5. Remove front final drive assembly.
INSTALLATION
Note the following, install in the reverse order of removal.
• When installing the side shaft assembly, apply multi-purpose grease to contact surface of side shaft and side
shaft oil seal.
• Tighten mounting bolts in the order described below when install-
ing front final drive assembly: side of gear carrier (1), upper side of
gear carrier (2), part of carrier cover (3). For each tightening
torque, refer to DLN-126, "Exploded View".
CAUTION:
Align the mating faces of gear carrier and oil pan for installa-
tion.
tion".
JSDIA4496ZZ

< UNIT REMOVAL AND INSTALLATION > [FRONT FINAL DRIVE: F160A]
A
When oil leaks while removing final drive assembly, check oil level after the installation. Refer to DLN-121,
"Inspection". B
DLN

SIDE SHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [FRONT FINAL DRIVE: F160A]
UNIT DISASSEMBLY AND ASSEMBLY

SIDE SHAFT
JSDIA0221GB
Drive pinion lock nut Companion flange Front oil seal

Pinion front bearing Drive pinion bearing adjusting wash- Drive pinion adjusting washer
er
Gear carrier Pinion rear bearing Pinion height adjusting washer
Drive pinion Drive gear Side oil seal (right side)
Side retainer O-ring Side bearing adjusting shim
Side bearing Differential case Breather connector
Dowel pin Filler plug Drain plug
Gasket Carrier cover Gear oil defense

SIDE SHAFT
Side gear thrust washer Side gear Circular clip
Pinion mate thrust washer Pinion mate gear Pinion mate shaft
A
Lock pin Side bearing adjusting washer Side oil seal (left side)
Side shaft bearing Extension tube retainer Side shaft oil seal B
Dust seal Side shaft
Oil seal lip Screw hole
C
: Always replace after every disassembly. DLN
: Select with proper thickness.
: Apply gear oil.
E
*: Apply anti-corrosion oil.
: Apply multi purpose grease.
F
: Apply Genuine Silicone RTV or equivalent. Refer to GI-22, "Recommended Chemical Products and Sealants".
: Apply Genuine Medium Strength Thread Locking Sealant or equivalent. Refer to GI-22, "Recommended Chemical Prod-
ucts and Sealants".
G
1. Hold extension tube retainer with separator (commercial service H

tool), then press out side shaft using a press.
2. Remove dust seal from side shaft.
I
PDIA0793J
K
3. Remove side shaft oil seal from extension tube retainer with
oil seal remover (commercial service tool). L
CAUTION:
Never damage extension tube retainer.
4. Remove side shaft bearing from extension tube retainer. M
5. Remove O-ring from extension tube retainer.
6. Perform inspection after disassembly. Refer to DLN-130,
"Inspection". N
PDIA0794J

SIDE SHAFT
1. Using the drift (A) [SST: KV38100200 ( — )], install side shaft
oil seal.
CAUTION:
• Apply multi-purpose grease onto oil seal lips, and gear oil
2. Install dust seal.
PDIA0814J
3. Support side shaft bearing with the drift (A) [SST: ST30032000
(J-26010-01)], then press side shaft into the side shaft bear-
ing together with extension retainer using a press.
4. Apply multi-purpose grease to O-ring, and install it to extension
tube retainer.
CAUTION:
Never reuse O-ring.
PDIA0815J

Bearing
• Clean up the disassembled parts.
• If any chipped (by friction), pitted, worn, rusted or scratched marks, or unusual noise from the bearing is
observed, replace as a bearing assembly (as a new set).
Oil Seal
• Whenever disassembled, replace.
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace.

DIFFERENTIAL ASSEMBLY
A
DLN
JSDIA0221GB
N
er O
Side retainer O-ring Side bearing adjusting shim P

Side shaft bearing Extension tube retainer Side shaft oil seal

: Apply gear oil.

ucts and Sealants".
1. Drain gear oil, if necessary.

2. Remove carrier cover mounting bolts.
3. Remove carrier cover to insert the seal cutter (A) [SST:
KV10111100 (J-37228)] between gear carrier and carrier cover.
CAUTION:
• Never damage the mating surface.
• Never insert flat-bladed screwdriver, this may damage the
mating surface.
PDIA0795J
4. Remove side retainer.

5. Remove side bearing adjusting shim.
6. Remove O-ring from side retainer.
PDIA0670E
7. Remove differential case assembly from gear carrier.
PDIA0671E

8. Remove side oil seal (right side) from side retainer.
A
PDIA0672E
DLN
9. Remove side bearing outer race with puller (A) [SST:
KV381054S0 (J-34286)].
10. Remove O-ring from gear carrier. E
11. Remove side oil seal (left side) from gear carrier.
G
PDIA0796J
12. Remove side bearing outer race with puller (A) [SST: H
KV381054S0 (J-34286)].
PDIA0797J K
13. Remove side bearing inner race with puller (A) and drift (B).
To prevent damage to bearing, engage puller jaws in groove
( ). L
A: Puller [SST: ST33051001 (J-22888-20)]

B: Base [SST: ST33061000 (J-8107-2)] M
CAUTION:
• To prevent damage to the side bearing and drive gear,
place copper plates between these parts and vise. N
• It is not necessary to remove side bearing inner race
except if it is replaced.
O
PDIA0758J

14. For proper reinstallation, paint matching marks on one differen-
tial case assembly.
CAUTION:
For matching marks, use paint. Never damage differential
case and drive gear.
15. Remove drive gear mounting bolts.
16. Tap drive gear off differential case assembly with a soft hammer.
CAUTION:
Tap evenly all around to keep drive gear from bending.
PDIA0496E
17. Remove lock pin of pinion mate shaft with a punch from drive
gear side.
PDIA0759J
18. Remove pinion mate shaft.
SDIA0031J
19. Turn pinion mate gear, then remove pinion mate gears, pinion
mate thrust washers, side gears and side gear thrust washers
from differential case.
"Inspection".
SDIA0032J

A
1. Install side gear thrust washers with the same thickness as the
ones installed prior to disassembly or reinstall the old ones on
the side gears. B
DLN
SDIA0193J
2. Install side gears and thrust washers into differential case. E

CAUTION:
• Never reuse circular clip.
• Make sure that the circular clip is installed to side gear
(side retainer side). F
3. Align 2 pinion mate gears in diagonally opposite positions, then
rotate and install them into differential case after installing thrust
washer to pinion mate gear. G
SDIA2025E H
4. Align the lock pin holes on differential case with shaft, and install
pinion mate shaft.
I
SDIA0195J
L
5. Measure side gear end play. If necessary, select the appropriate side gear thrust washers.
a. Place differential case straight up so that side gear to be mea-
sured comes upward.
M
JPDID0205GB

b. Using feeler gauge, measure the clearance between side gear
back and differential case at 3 different points, while rotating
side gear. Average the 3 readings, and then measure the clear-
ance of the other side as well.
Side gear back clearance : Refer to DLN-153, "Differ-

ential Side Gear Clear-
ance".
CAUTION:
To prevent side gear from tilting, insert feeler gauges with
the same thickness from both sides.
c. If the back clearance is outside the specification, use a thicker/
thinner side gear thrust washer to adjust. For selecting thrust
washer, refer to the latest parts information.
When the back clearance Use a thicker thrust wash-

is large: er.
When the back clearance Use a thinner thrust wash-
is small: er.
CAUTION:
Select a side gear thrust washer for right and left individu- PDIA0576E
ally.
6. Drive a lock pin into pinion mate shaft, using a punch.

Make sure lock pin is flush with differential case.
CAUTION:
Never reuse lock pin.
SPD030
7. Align the matching mark of drive gear with the mark of differen-
tial case, then place drive gear.
SDIA2593E
8. Apply thread locking sealant into the thread hole of drive gear.
CAUTION:
Drive gear back and threaded holes must be cleaned and
decreased sufficiently.
SDIA2594E

9. Install drive gear on the mounting bolts.
CAUTION: A
Tighten bolts in a crisscross fashion.
SDIA0247J
DLN
10. Press side bearing inner races to differential case, using the drift
(A) and the base (B).
E
A: Drift [SST: ST33230000 (J-25805-01)]
B: Base [SST: ST33061000 (J-8107-2)]
CAUTION: F
Never reuse side bearing inner race.
G
PDIA0810J
11. Press-fit side bearing outer race into side retainer with the drift H
bar (A) and the drift (B).
A: Drift bar [SST: ST30611000 (J-25742-1)]

I
B: Drift [SST: KV31103000 (J-38982)]
CAUTION:
• At first, using a hammer, tap bearing outer race until it J
becomes flat to side retainer.
• Never reuse side bearing outer race.
PDIA0811J K
12. Press-fit side bearing outer race into gear carrier with the drift
bar (A) and the drift (B).
L
A: Drift bar [SST: ST30611000 (J-25742-1)]
B: Drift [SST: KV31103000 (J-38982)]
M
CAUTION:
• At first, using a hammer, tap bearing outer race until it
becomes flat to gear carrier.
• Never reuse side bearing outer race. N
PDIA0812J
13. Place the differential case assembly into gear carrier. O

14. Measure side bearing preload. If necessary, select the appropri-
ate side bearing adjusting shim. Refer to DLN-139, "Adjust-
ment". P
PDIA0671E

15. Install selected side bearing adjusting shim . Refer to DLN-

139, "Adjustment".
: O-ring
16. Apply multi-purpose grease to O-ring, and install it to side

retainer.
CAUTION:
Never reuse O-ring.
17. Install side retainer assembly to gear carrier.
PDIA0813E
18. Install side retainer mounting bolts.
PDIA0669E
19. Using the drift (A) [SST: ST33400001 (J-26082)], press-fit side
oil seal so that its surface comes face-to-face with the end sur-
face of the side retainer.
CAUTION:
PDIA0787J
20. Using the drift (A) [SST: KV38102100 (J-25803-01)], press-fit

side oil seal so that its surface comes face-to-face with the end
surface of gear carrier.
CAUTION:
21. Apply multi-purpose grease to O-ring, and install it to gear car-
rier.
CAUTION: PDIA0788J
Never reuse O-ring.
22. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and total preload
torque. Refer to DLN-139, "Adjustment".
Recheck above items. Readjust as described above, if necessary.

23. Apply sealant to mating surface of carrier cover.
CAUTION: A
Remove old sealant adhering to mounting surfaces. Also
remove any moisture, oil, or foreign material adhering to
application and mounting surfaces.
B
PDIA0742E
DLN
24. Install carrier cover on gear carrier and tighten mounting bolts.
G
SDIA1648E
25. Set breather connector angle (A) as shown in the figure.

H
: Vehicle front
I
A : 0 – 30°
PDIA0841J
K
Adjustment INFOID:0000000011282082
TOTAL PRELOAD TORQUE L

• Before inspection and adjustment, drain gear oil.
1. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction.
M
2. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
3. Measure total preload with preload gauge (A) [SST:
ST3127S000 (J-25765-A)].
N
Total preload torque : Refer to DLN-153, "Preload
Torque".
O
NOTE:
Total preload torque = Pinion bearing preload torque + Side
bearing preload torque
• If measured value is out of the specification, disassemble it to P
check and adjust each part. Adjust the pinion bearing preload
and side bearing preload. PDIA0792J
Adjust the pinion bearing preload first, then adjust the side
bearing preload.

When the preload torque is large

On pinion bearings: Decrease the drive pinion bearing adjusting washer and drive pinion
adjusting washer thickness. For selecting adjusting washer, refer to
the latest parts information.
On side bearings: Increase the side bearing adjusting shim thickness. For selecting ad-
justing washer, refer to the latest parts information.
When the preload torque is small

On pinion bearings: Increase the drive pinion bearing adjusting washer and drive pinion
adjusting washer thickness. For selecting adjusting washer, refer to
the latest parts information.
On side bearings: Decrease the side bearing adjusting shim thickness. For selecting ad-
justing washer, refer to the latest parts information.
SIDE BEARING PRELOAD
• Before inspection and adjustment, drain gear oil.
1. Remove carrier cover and side retainer. Refer to DLN-132, "Disassembly".
2. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.
3. Place the differential case assembly into gear carrier.
PDIA0671E
4. Install side bearing adjusting shim before disassembling or shim

which thickness is the same as the one before disassembling.
5. Install side retainer assembly to gear carrier.
CAUTION:
Never install O-ring.
PDIA0678E
6. Install side retainer mounting bolts to the specified torque.
PDIA0669E

7. Measure the turning torque of the gear carrier at the drive gear
mounting bolts with a spring gauge (commercial service tool). A
Specification : 34.2 – 39.2 N (3.5 – 4.0 kg, 7.7 – 8.8 lb)

of pulling force at the drive gear bolt B
SPD194A
DLN
8. If the turning torque is outside the specification, use a thicker/
thinner side bearing adjusting shim to adjust. For selecting
adjusting shim, refer to the latest parts information.
E
If the turning torque is less than the specified range:
Decrease the side bearing adjusting shim thickness.
F
If the turning torque is greater than the specification:
Increase the side bearing adjusting shim thickness.
9. Record the total amount of shim thickness required for the cor- G
SPD772
rect carrier side bearing preload.
DRIVE GEAR RUNOUT
H
1. Remove carrier cover. Refer to DLN-132, "Disassembly".
2. Fit a dial indicator to the drive gear back face.
3. Rotate the drive gear to measure runout. I
Drive gear runout : Refer to DLN-153, "Drive Gear

Runout". J
• If the runout is outside of the repair limit, check drive gear
assembly condition; foreign material may be caught between
drive gear and differential case, or differential case or drive K
gear may be deformed, etc.
CAUTION:
SPD886
Replace drive gear and drive pinion gear as a set.
L
TOOTH CONTACT
Before inspection and adjustment, drain gear oil.
1. Remove carrier cover. Refer to DLN-132, "Disassembly". M
2. Apply red lead to drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
N
tions evenly spaced on drive gear.
P
SPD357

3. Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.
SDIA0570E
PDIA0667E

4. If tooth contact is improperly adjusted, follow the procedure
below to adjust the pinion height [dimension (X)]. A
SDIA0517E
DLN
• If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken pinion height adjusting washers to
move drive pinion closer to drive gear. E
For selecting adjusting washer, refer to the latest parts infor-
mation.
F
G
PDIA0440E
• If the tooth contact is near the flank (flank contact), or near the H
toe (toe contact), thin pinion height adjusting washers to move
drive pinion farther from drive gear.
For selecting adjusting washer, refer to the latest parts infor- I
mation.
K
PDIA0441E
BACKLASH
Before inspection and adjustment, drain gear oil. L
1. Remove carrier cover. Refer to DLN-132, "Disassembly".
2. Fit a dial indicator to the drive gear face to measure the back-
lash. M
Backlash : Refer to DLN-153, "Backlash".

• If the backlash is outside of the specified value, change the N
thickness of side bearing adjusting washer.
When the backlash is large: O

Decrease side bearing adjusting washer thickness.
For selecting adjusting washer, refer to the latest parts SDIA0009J
information. P
When the backlash is small:
Increase side bearing adjusting washer thickness. For
selecting adjusting washer, refer to the latest parts in-
formation.


Drive Gear and Drive Pinion
• If the gear teeth never mesh or line-up correctly, determine the cause and adjust or replace as necessary.
• If the gears are worn, cracked, damaged, pitted or chipped (by friction) noticeably, replace with new drive
gear and drive pinion as a set.
Bearing
Side Gear and Pinion Mate Gear
• If any cracks or damage on the surface of the tooth is found, replace.
• If any worn or chipped mark on the contact sides of the thrust washer is found, replace.
Side Gear Thrust Washer and Pinion Mate Thrust Washer
• If it is chipped (by friction), damaged, or unusually worn, replace.
Oil Seal
• If wear, deterioration of adherence (sealing force lips), or damage is detected on the lips, replace them.
Differential Case
• If any wear or crack on the contact sides of the differential case is found, replace.

DRIVE PINION
DRIVE PINION
A
DLN
JSDIA0221GB
N
er O
Side retainer O-ring Side bearing adjusting shim P

DRIVE PINION
Side shaft bearing Extension tube retainer Side shaft oil seal

: Apply gear oil.

ucts and Sealants".
1. Remove differential case assembly. Refer to DLN-132, "Disassembly".

2. Remove drive pinion lock nut with a flange wrench (commercial
service tool).
PDIA0798J
3. Put matching mark on the end of drive pinion. The matching

mark should be in line with the matching mark on companion
flange .
CAUTION:
For matching mark, use paint. Never damage companion
flange and drive pinion.
NOTE:
The matching mark on the final drive companion flange indicates
the maximum vertical runout position.
When replacing companion flange, matching mark is not neces-
sary. PDIA0799J
4. Remove companion flange using the suitable puller.
SDIA1132E

DRIVE PINION
5. Press drive pinion assembly out of gear carrier.
CAUTION: A
Never drop drive pinion assembly.
7. Remove pinion front bearing inner race. B
8. Remove drive pinion bearing adjusting washer and drive pinion
adjusting washer.
C
PDIA0800J
DLN
9. Remove pinion rear bearing inner race and pinion height adjust-
ing washer with separator (A) (commercial service tool).
E
G
PDIA0801J
10. Tap pinion front/rear bearing outer races uniformly a brass rod or
H
equivalent to removed.
CAUTION:
Never damage gear carrier.
11. Perform inspection after disassembly. Refer to DLN-152, I
"Inspection".
PDIA0677E
K
1. Install pinion front and rear bearing outer races using drift (A) L
[SST: ST37820000 ( — )].
CAUTION:
• At first, using a hammer, tap bearing outer race until it M
• Never reuse pinion front and rear bearing outer race.
PDIA0803J O

DRIVE PINION
2. Temporarily install pinion height adjusting washer .
When hypoid gear set has been replaced
• Select pinion height adjusting washer. Refer to DLN-149,
"Adjustment".
When hypoid gear set has been reused
• Temporarily install the removed pinion height adjusting washer
or same thickness washer to drive pinion.
CAUTION:
• Pay attention to the direction of pinion height adjusting
washer. (Assemble as shown in the figure.) JSDIA0760ZZ
• Never reuse pinion rear bearing inner race.
3. Install pinion rear bearing inner race to drive pinion with the
drift (A) [SST: ST30032000 (J-26010-01)].
JSDIA0761ZZ
4. Temporarily assemble removed drive pinion adjusting washer

and drive pinion bearing adjusting washer or same thickness of
them to drive pinion.
5. Apply gear oil to pinion rear bearing, and assemble drive pinion
into gear carrier.
6. Apply gear oil to pinion front bearing, and assemble pinion front
bearing inner race to drive pinion assembly.
CAUTION:
Never reuse pinion front bearing inner race.
PDIA0681E
7. Using suitable spacer (commercial service tool), press the

pinion front bearing inner race to drive pinion as far as drive pin-
ion lock nut can be tightened.
8. Adjust pinion bearing preload. If necessary, select the appropri-
ate drive pinion adjusting washer and drive pinion bearing
adjusting washer. Refer to DLN-149, "Adjustment".
PDIA0807J

DRIVE PINION
9. Using the drifts (A and B), install front oil seal as shown in figure.
A
A: Drift [SST: ST33400001 (J-26082)]
B: Drift [SST: KV38102510 ( — )]
CAUTION: B
• Apply multi-purpose grease onto oil seal lips, and gear oil C
PDIA0808J
DLN
10. Install companion flange.
NOTE:
When reusing drive pinion, align the matching mark of drive E
pinion with the matching mark of companion flange, and then
install companion flange .
F
PDIA0799J
H
11. Apply anti-corrosion oil to the thread and seat of new drive pin-
ion lock nut, and temporarily tighten drive pinion lock nut to drive
pinion, using flange wrench (commercial service tool). I
A: Preload gauge [SST: ST3127S000 (J-25765-A)]

CAUTION: J
Never reuse drive pinion lock nut.
12. Tighten to drive pinion lock nut, while adjusting pinion bearing
preload torque, using preload gauge [SST: ST3127S000 (J- K
25765-A)].
Pinion bearing preload : Refer to DLN-153, "Pre- L

load Torque".
CAUTION:
• Adjust to the lower limit of the drive pinion lock nut tight- M
ening torque first.
• After adjustment, rotate drive pinion back and forth 2 to 3
times to check for unusual noise, rotation malfunction,
and other malfunctions. N
13. Install differential case assembly. Refer to DLN-135, "Assem-
bly".
CAUTION: PDIA0802J O
Never install carrier cover yet.
14. Check and adjust drive gear runout, tooth contact, drive gear to drive pinion backlash, and companion
flange runout. Refer to DLN-139, "Adjustment" and DLN-149, "Adjustment". P
Recheck above items. Readjust the above description, if necessary.
15. Check total preload torque. Refer to DLN-139, "Adjustment".
16. Install carrier cover. Refer to DLN-135, "Assembly".
PINION GEAR HEIGHT

DRIVE PINION
If the hypoid gear set has been replaced, select the pinion height adjusting washer.
1. Use the formula below to calculate pinion height adjusting
washer thickness.
Washer selection equation:

T = T0 + (t1− t2)
T: Correct washer thickness
T0: Removed washer thickness
t1 : Old drive pinion head letter “H × 0.01”
(“H”: machined tolerance 1/100 mm × 100)
New drive pinion head letter “H × 0.01”
SDIA0249J
t2 :
Example:
T = 3.21 + [(2 × 0.01) − (−1 × 0.01)] = 3.24
T0: 3.21
t1 : +2
t2 : −1
2. Select the proper pinion height adjusting washer. For selecting adjusting washer, refer to the latest parts
information.
If unable to find a washer of desired thickness, use a washer with thickness closest to the calculated
value.
Example:
Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm
PINION BEARING PRELOAD

Assemble the drive pinion parts if they are disassembled. Refer to DLN-147, "Assembly".
1. Make sure all parts are clean. Also, make sure the bearings are well lubricated with gear oil.
NOTE:
When reusing drive pinion, align the matching mark of drive
PDIA0799J

DRIVE PINION
3. Temporarily tighten removed drive pinion lock nut to drive pinion,
using flange wrench (commercial service tool). A
A: Preload gauge [SST: ST3127S000 (J-25765-A)]

NOTE: B
Use removed drive pinion lock nut only for the preload measure-
ment.
4. Rotate drive pinion at least 20 times to check for smooth opera- C
tion of the bearing.
5. Tighten to drive pinion lock nut, while adjust pinion bearing pre-
load torque, using preload gauge [SST: ST3127S000 (J-25765- DLN
A)].
Pinion bearing preload : Refer to DLN-153, "Pre-

load Torque". E
CAUTION:
• Adjust to the lower limit of the drive pinion lock nut tight-
ening torque first. F
times to check for unusual noise, rotation malfunction,
and other malfunctions. G
PDIA0802J
6. If the pinion bearing preload torque is outside the specification,
use a thicker/thinner drive pinion bearing adjusting washer and drive pinion adjusting washer to adjust.
H
When the preload torque is large:
Decrease the drive pinion bearing adjusting washer and drive pinion adjusting
washer thickness. For selecting adjusting washer, refer to the latest parts informa- I
tion.
When the preload is small:
J
Increase the drive pinion bearing adjusting washer and drive pinion adjusting
washer thickness. For selecting adjusting washer, refer to the latest parts informa-
tion.
K
7. Remove companion flange, after adjustment.
COMPANION FLANGE RUNOUT
1. Fit a dial indicator onto the companion flange face (inner side of L
the propeller shaft mounting bolt holes).
2. Rotate companion flange to check for runout.
M
Companion flange face : Refer to DLN-153,
runout "Companion Flange
Runout". N
3. Fit a test indicator to the inner side of companion flange (socket
diameter).
4. Rotate companion flange to check for runout. JSDIA0116ZZ
O
Inner side of the companion : Refer to DLN-153,

flange runout "Companion Flange P
Runout".
5. If the runout value is outside the runout limit, follow the procedure below to adjust.
a. Check for runout while changing the phase between companion flange and drive pinion by 90° step, and
search for the position where the runout is the minimum.

DRIVE PINION
b. If the runout value is still outside of the limit after the phase has been changed, possible cause will be an
assembly malfunction of drive pinion and pinion bearing and malfunction of pinion bearing. Check for
these items and repair if necessary.
c. If the runout value is still outside of the limit after the check and repair, replace companion flange.

Bearing
Oil Seal
Companion Flange
• If any chipped mark [about 0.1 mm, (0.004 in)] or other damage on the contact sides of the lips of the com-
panion flange is found, replace.

< SERVICE DATA AND SPECIFICATIONS (SDS) [FRONT FINAL DRIVE: F160A]

B
Axle AWD
C
Transmission A/T
Final drive model F160A DLN
Gear ratio 3.133
Number of teeth (Drive gear/Drive pinion) 47/15
E
Number of pinion gears 2
Drive pinion adjustment spacer type Solid
Oil capacity Refer to MA-10, "Fluids and Lubricants". F
Preload Torque INFOID:0000000011282092
Unit: N·m (kg-m, in-lb) G

Item Standard
Pinion bearing (P1) 0.78 – 1.57 (0.08 – 0.16, 7 – 13) H
Side bearing (P2) 0.78 – 1.08 (0.08 – 0.11, 7 – 9)
Side bearing to pinion bearing (Total preload)
1.56 – 2.65 (0.16 – 0.27, 14 – 23)
(Total preload = P1 + P2) I
Drive Gear Runout INFOID:0000000011282090
Unit: mm (in) J
Item Standard
Drive gear back face runout 0.05 (0.0020) or less
K
Backlash INFOID:0000000011282093
Unit: mm (in) L
Item Standard
Drive gear to drive pinion gear 0.10 – 0.15 (0.0039 – 0.0059)
M
Companion Flange Runout INFOID:0000000011282094
Unit: mm (in)
N
Item Standard
Companion flange face runout 0.18 (0.0071) or less
Inner side of the companion flange runout 0.13 (0.0051) or less O
Differential Side Gear Clearance INFOID:0000000011282091
Unit: mm (in) P
Item Standard
0.2 (0.008) or less
Side gear backlash (Clearance between side gear and differential
(Each gear should rotate smoothly without excessive resistance
case)
during differential motion.)

PRECAUTIONS
< PRECAUTION > [REAR FINAL DRIVE: R190]
PRECAUTION
PRECAUTIONS
NOTE:
occur.
NOTE:
SEF289H
detected.
NOTE:
Service Notice or Precautions for Rear Final Drive INFOID:0000000011282095
• Check for the correct installation status prior to removal or disassembly. If matching marks are required, be
certain they never interfere with the function of the parts when applied.
• Overhaul should be done in a clean work area, it is preferable to work in dustproof area.
• Before disassembly, using steam or white gasoline, completely remove sand and mud from the exterior of
the unit, preventing them from entering into the unit during disassembly or assembly.
with a new ones if necessary.
• Gaskets, seals and O-rings should be replaced any time when the unit is disassembled.
ening sequence is specified, observe it.
• When applying sealant, remove the old sealant from the mounting surface; then remove any moisture, oil,
and foreign materials from the application and mounting surfaces.
• Always use shop paper for cleaning the inside of components.
• Never use cotton gloves or shop rags to prevent entering of lint.
• During assembly, observe the specified tightening torque, and apply new gear oil, petroleum jelly, or multi-
purpose grease as specified for each vehicle, if necessary.
NOTE:
To remove rear drive shaft, it is necessary to lift down and hold rear final drive assembly.

PREPARATION
< PREPARATION > [REAR FINAL DRIVE: R190]
PREPARATION A
PREPARATION
B
Tool number C
Tool name
ST3127S000 Measuring pinion bearing preload and total DLN
(J-25765-A) preload
Preload gauge
ZZA0806D F
KV40104710 Installing front oil seal
( — )
Drift G
a: 76.3 mm (3.004 in) dia.
b: 67.9 mm (2.673 in) dia.
H
ZZA0936D
KV40104830 Installing side oil seal

( — ) I
Drift
a: 70 mm (2.76 in) dia.
b: 63.5 mm (2.50 in) dia.
J
ZZA0936D
K
ST30613000 • Removing and Installing rear cover (2 piec-
(J-25742-3) es are used.)
Drift • Removing and Installing differential case (2
a: 72 mm (2.83 in) dia. pieces are used.) L
b: 48 mm (1.89 in) dia. • Installing pinion front bearing outer race
M
ZZA1000D
ST30611000 Installing pinion front bearing outer race (Use

(J-25742-1) with ST30613000)
Drift bar N
S-NT090
ST33051001 Removing side bearing inner race P

(J-22888-20)
Puller
PDIA0747J

PREPARATION
Tool number
Tool name
KV40104920 Removing and installing side bearing inner
( — ) race
Adaptor
a: 44.7 mm (1.760 in) dia.
b: 41 mm (1.61 in) dia.
c: 15 mm (0.59 in)
ZZA1133D
KV10112100 Tightening the drive gear mounting bolt

(BT-8653-A)
Angle wrench
ZZA0120D
KV38100200 Installing side bearing inner race

(J-26233)
Drift
a: 65 mm (2.56 in) dia.
b: 49 mm (1.93 in) dia.
ZZA1143D
KV385J9010 • Checking backlash

( — ) • Checking drive gear runout
Dummy cover set • Checking tooth contact
JSDIA4759ZZ
ST30720000 Installing pinion rear bearing outer race

(J-25405)
Drift
a: 77 mm (3.03 in) dia.
b: 55.5 mm (2.185 in) dia.
ZZA0811D
KV40105230 Installing pinion rear bearing outer race

( — )
Drift
a: 92 mm (3.62 in) dia.
b: 86 mm (3.39 in) dia.
c: 45 mm (1.77 in) dia.
PDIA0591E
ST38220000 Installing pinion front bearing inner race

( — )
Press stand
a: 75 mm (2.95 in) dia.
b: 63 mm (2.48 in) dia.
S-NT509

PREPARATION

Flange wrench Removing and installing drive pinion lock nut B
NT035 DLN
Puller Removing companion flange
F
ZZA0119D
Oil seal remover • Removing front oil seal

• Removing side oil seal G
JSDIA4998ZZ
I
Replacer Removing pinion rear bearing inner race
K
ZZA0700D
Drift Installing pinion rear bearing inner race

a: More than inner diameter
b: 45 – 50 mm (1.77 – 1.97 in) dia. L
ZZA0936D
Power tool Loosening bolts and nuts N
PBIC0190E P
Item Use
Red lead or equivalent Checking tooth contact

< SYSTEM DESCRIPTION > [REAR FINAL DRIVE: R190]
SYSTEM DESCRIPTION
JSDIA4742ZZ
Side gear Pinion mate shaft Side bearing

Pinion mate gear Drive pinion Pinion rear bearing
Pinion front bearing Companion flange Collapsible spacer
Drive gear Differential case

Symptom
Reference
×: Applicable
*: AWD models only

Noise
SYMPTOM DIAGNOSIS
Gear tooth rough DLN-176, "Inspection"
×
Gear contact improper DLN-173, "Adjustment"
DLN-159
Tooth surfaces worn DLN-176, "Inspection"
×
Backlash incorrect DLN-173, "Adjustment"
×
Companion flange excessive runout DLN-183, "Adjustment"
×
Gear oil improper DLN-160, "Inspection"
×
PROPELLER SHAFT NVH of FRONT* and REAR PROPELLER SHAFT in this section.
×
AXLE AND SUSPENSION NVH in FAX, RAX, FSU and RSU sections.
×
×
×
DRIVE SHAFT NVH in FAX* and RAX section.
×
×
×
[REAR FINAL DRIVE: R190]
INFOID:0000000011282100
2015 Q50
I
L
F
P
K
E
B
A
N
H
C
O
G
M
DLN
REAR DIFFERENTIAL GEAR OIL
< PERIODIC MAINTENANCE > [REAR FINAL DRIVE: R190]
PERIODIC MAINTENANCE
REAR DIFFERENTIAL GEAR OIL
OIL LEAKAGE
Make sure that oil is not leaking from final drive assembly or around it.
OIL LEVEL
• Remove filler plug and check oil level from filler plug mounting
hole as shown in the figure.
CAUTION:
Never start engine while checking oil level.
• Set a gasket on filler plug and install it on final drive assembly.
Refer to DLN-169, "Exploded View".
CAUTION:
Never reuse gasket.
JSDIA4749ZZ
1. Stop engine.
2. Remove drain plug and drain gear oil.
3. Set a gasket on drain plug and install it to final drive assembly
and tighten to the specified torque. Refer to DLN-169, "Exploded
View".
CAUTION:
Never reuse gasket.
JSDIA4748ZZ
Refilling INFOID:0000000011282103
1. Remove filler plug . Fill with new gear oil until oil level reaches
the specified level near filler plug mounting hole.
Recommended : Refer to MA-10, "Fluids and Lubri-

oil and capacity cants".
2. After refilling oil, check oil level. Set a gasket to filler plug, then
install it to final drive assembly. Refer to DLN-169, "Exploded
View".
CAUTION:
Never reuse gasket. JSDIA4749ZZ

FRONT OIL SEAL
< REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: R190]
REMOVAL AND INSTALLATION A

FRONT OIL SEAL
B
DLN
JSDIA4750GB
G
Final drive assembly Front oil seal Companion flange

H
Drive pinion lock nut
Oil seal lip
: Vehicle front I
J
: Apply gear oil.
K
L
REMOVAL
CAUTION:
Verify identification stamp of replacement frequency put in the lower part of gear carrier to determine M
replacement for collapsible spacer when replacing front oil seal. Refer to “Identification stamp of
replacement frequency of front oil seal”. If collapsible spacer replacement is necessary, remove final
drive assembly and disassemble it to replace front oil seal and collapsible spacer. Refer to DLN-178,
"Disassembly". N
NOTE:
The reuse of collapsible spacer is prohibited in principle. However, it is reusable on a one-time basis
only in cases when replacing front oil seal. O
Identification stamp of replacement frequency of front oil seal

FRONT OIL SEAL
• The diagonally shaded area in the figure shows stamping point for
replacement frequency of front oil seal.
• The following table shows if collapsible spacer replacement is
needed before replacing front oil seal.
When collapsible spacer replacement is required, disassemble
final drive assembly to replace collapsible spacer and front oil seal.
Refer to DLN-178, "Disassembly".
Stamp Collapsible spacer replacement

No stamp Not required
JSDIA4752ZZ
“0” or “0” on the far right of stamp Required
“01” or “1” on the far right of stamp Not required
CAUTION:
Make a stamping after replacing front oil seal.
• After replacing front oil seal, make a stamping on the stamping point in accordance with the table below in
order to identify replacement frequency.
CAUTION:
Make a stamping from left to right.
Stamp before stamping Stamping on the far right Stamping

No stamp 0 0
“0”
1 01
(Front oil seal was replaced once.)
“01”
0 010
(Collapsible spacer and front oil seal were replaced last time.)
“0” is on the far right.
1 ...01
(Only front oil seal was replaced last time.)
“1” is on the far right.
0 ...010
(Collapsible spacer and front oil seal were replaced last time.)
1. Make a judgment if a collapsible spacer replacement is required.
2. Drain gear oil. Refer to DLN-160, "Draining".
3. Remove final drive assembly. Refer to DLN-167, "Removal and Installation".
NOTE:
• It is necessary to separate the rear drive shaft from final drive to measure the total preload.
• It is necessary to remove final drive assembly to separate the rear drive shaft from final drive.
4. Measure the total preload with the preload gauge (A) [SST:
ST3127S000 (J-25765-A)].
NOTE:
Record the preload measurement.
JSDIA0031ZZ

FRONT OIL SEAL
5. Put matching mark on the end of the drive pinion. The match-
ing mark should be in line with the matching mark on com- A
panion flange .
CAUTION:
For matching mark, use paint. Never damage companion B
JSDIA0016ZZ
DLN
6. While holding companion flange with the flange wrench (com-
mercial service tool), remove drive pinion lock nut.
E
G
JSDIA0033ZZ
7. Remove companion flange using pullers (commercial service H

tool).
8. Remove front oil seal using oil seal remover (commercial ser-
vice tool).
I
JSDIA0034ZZ
K
INSTALLATION
1. Apply multi-purpose grease to front oil seal lips.
2. Install front oil seal using the drift (A) [SST: KV40104710 ( — L
)] as shown in figure.
CAUTION:
• Never reuse oil seal. M
• Never incline oil seal when installing.
O
JPDID0362ZZ

FRONT OIL SEAL
3. Align the matching mark of drive pinion with the matching
mark of companion flange , and then install the companion
flange.
4. Apply anti-corrosion oil to the thread and seat of new drive pin-
ion lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
JSDIA0016ZZ

mercial service tool), tighten drive pinion lock nut within the lim-
its of specified torque so as to keep the bearing preload within a
standard values, using preload gauge (A) [SST: ST3127S000 (J-
25765-A)].
Total preload torque : A value that add 0.1 – 0.4 N·m

(0.01 – 0.04 kg-m, 0.1 –0.3 in-lb)
to the measured value before re-
moving.
CAUTION:
ening torque first.
• If the preload torque exceeds the specified value, replace
collapsible spacer and tighten it again to adjust. Never
loosen drive pinion lock nut to adjust the preload torque.
6. Make a stamping for identification of front oil seal replacement
frequency. Refer to “Identification stamp of replacement fre-
quency of front oil seal”.
CAUTION:
Make a stamping after replacing front oil seal.
7. Install final drive assembly. Refer to DLN-167, "Removal and JSDIA0035ZZ
Installation".
8. Refill gear oil to the final drive. Refer to DLN-160, "Refilling".
9. Perform inspection after installation. Refer to DLN-164, "Inspection".

Check oil level and final drive for oil leakage. Refer to DLN-160, "Inspection".

SIDE OIL SEAL
SIDE OIL SEAL
A
DLN
JSDIA4751ZZ
G
Final drive assembly Side oil seal
Oil seal lip
: Vehicle front H
: Apply gear oil.
I

J
REMOVAL
1. Remove final drive assembly. Refer to DLN-167, "Removal and Installation".
K
NOTE:
It is necessary to remove final drive assembly to remove the rear drive shaft.
2. Remove side oil seal, using oil seal remover (commercial service tool).
CAUTION: L
INSTALLATION
M
1. Apply multi-purpose grease to side oil seal lips.
2. Install side oil seal until it becomes flush with the case end,
using the drift (A) [SST: KV40104830 ( — )]. N
CAUTION:
3. Install final drive assembly. Refer to DLN-167, "Removal and O
Installation".
tion". P
JPDID0357ZZ

When oil leaks while removing, check oil level after the installation. Refer to DLN-160, "Inspection".

AIR BREATHER
AIR BREATHER
JSDIA4632ZZ
Trim clip Breather tube Plug

Hose clamp Breather connector Clip
Air breather hose
: Vehicle front
REMOVAL
1. Remove trim clip.
2. Remove clip from rear final drive.
3. Remove air breather hose and breather tube together.
4. Loosen hose clamp and remove breather tube from air breather hose.
5. Remove hose clamp and clip from air breather hose.
6. Remove plug.
7. Remove breather connector.
INSTALLATION
• Set breather connector to rear final drive with the paint mark
facing vehicle front shown as follows.
: Vehicle front
Angle : Within 15°

• When installing air breather hose, make sure there are no pinched
or restricted areas on air breather hose caused by bending or
winding.
JSDIA4634ZZ

REAR FINAL DRIVE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: R190]
UNIT REMOVAL AND INSTALLATION A

B
DLN
JSDIA4756GB
H
Upper stopper Lower stopper Washer
Rear final drive assembly
I
: Vehicle front

J
REMOVAL K
1. Remove center muffler. Refer to EX-6, "Removal and Installation".
2. Remove stabilizer bar. Refer to RSU-21, "Removal and Installation".
3. Remove rear propeller shaft from the final drive. Refer to DLN-98, "Removal and Installation" (2WD), L
DLN-108, "Removal and Installation" (AWD).
4. Remove rear suspension member stay. Refer to RSU-23, "Removal and Installation".
5. Remove rear wheel sensor. Refer to BRC-175, "REAR WHEEL SENSOR : Removal and Installation". M
6. Remove breather hose from the final drive. Refer to DLN-166, "Removal and Installation".
7. Set a suitable jack to rear final drive assembly.
CAUTION: N
Never place a jack on the rear cover (aluminum case).
8. Remove the mounting bolts and nut connecting to the suspension member.
CAUTION: O
Secure rear final drive assembly to suitable jack.
9. Separate drive shafts from final drive. Refer to RAX-13, "Removal and Installation".
NOTE: P

< UNIT REMOVAL AND INSTALLATION > [REAR FINAL DRIVE: R190]
To remove rear drive shaft, it is necessary to lift down and hold
rear final drive assembly.
JSDIA3208ZZ
10. Remove rear final drive assembly.

CAUTION:
Secure rear final drive assembly to suitable jack while
removing it.
JSDIA0026ZZ
INSTALLATION
Note the following, and installation is in the reverse order of removal.
• When install the drive shafts to final drive, remove wheel hub lock nut. Refer to RAX-8, "Removal and Instal-
lation".

When oil leaks while removing final drive assembly, check oil level after the installation. Refer to DLN-160,
"Inspection".

< UNIT DISASSEMBLY AND ASSEMBLY > [REAR FINAL DRIVE: R190]
UNIT DISASSEMBLY AND ASSEMBLY A

B
DLN
JSDIA4757GB J

Pinion front bearing Mounting insulator Gear carrier K
Collapsible spacer Pinion rear bearing Pinion height adjusting washer
Drive pinion Drive gear Differential assembly
L
Side bearing Side bearing adjusting washer Side oil seal
Rear cover Filler plug Gasket
Drain plug Stud bolt M
Oil seal lip Screw hole Comply with the assembly proce-
dure when tightening. Refer to DLN-
171, "Assembly".
N
: Select with proper thickness. O
: Apply gear oil.

P
: Apply Genuine High Strength Thread Locking Sealant or equivalent. Refer to GI-22, "Recommended Chemical Products
and Sealants".

1. Drain gear oil, if necessary.

2. Remove the side oil seal, using oil seal remover (commercial service too).
CAUTION:
Never damage gear carrier and rear cover.
3. Remove rear cover mounting bolts.
4. Set drifts (A and B) to the right and left side bearing adjusting
washers individually. Press differential assembly with side bear-
ing to remove gear carrier assembly and rear cover assembly.
A : Drift [SST: ST30613000 (J-25742-3)]

B : Drift [SST: ST30613000 (J-25742-3)]
CAUTION:
The pressure shall be as low as possible to remove gear
carrier assembly and rear cover assembly. The maximum
pressure shall be 10 kN (1 ton, 1.0 Imp ton).
NOTE: JPDID0355ZZ
Differential assembly, side bearings, and adjusting washers are

compressed and integrated in gear carrier and rear cover.
5. Remove stud bolt from rear cover.
NOTE:
It is not necessary to remove stud bolt except when it is replaced.
6. Remove side bearing adjusting washers and side bearing outer races.
CAUTION:
Mark the side bearing adjusting washers so that the original mounting positions (right/left) can be
identified later.
7. Remove side bearing inner races, using puller (A) and the adap-
tor (B).
A : Puller [SST: ST33051001 (J-22888-20)]

B : Adaptor [SST: KV40104920 ( — )]
CAUTION:
• To prevent damage to the side bearing and drive gear,
place copper plates between these parts and vise.
• To prevent damage to bearing, engage puller jaws in
groove ( ).
• It is not necessary to remove side bearing inner race
except when it is replaced.
PDIA0758J

8. For proper reinstallation, paint matching marks on one differen-
tial assembly and drive gear. A
CAUTION:
For matching marks, use paint. Never damage differential
assembly and drive gear.
B
9. Remove drive gear mounting bolts.
10. Tap drive gear off differential assembly with a soft hammer.
CAUTION:
C
Tap evenly all around to keep drive gear from bending.
"Inspection". PDIA0446E
DLN
1. Apply thread locking sealant into the thread hole of drive gear. E
CAUTION:
Clean and degrees drive gear back and threaded holes suf-
ficiently.
F
2. Install the drive gear to differential assembly.
CAUTION:
Align the matching mark of differential assembly and drive
gear. G
SDIA2594E H
3. Tighten the mounting bolts with the following procedure.

CAUTION:
Apply anti-corrosion oil to the thread and seat of mounting I
bolts.
a. Tighten the bolts in a crisscross fashion to the specified torque.
J
Drive gear mounting : 78.5 N•m (8.0 kg-m, 58 ft-lb)
bolts tightening torque
K
b. Tighten the bolts additionally to the specified angle.
SDIA0247J
Drive gear mounting : 31 to 36 degree

L
bolts tightening angle
CAUTION:
Check the tightening angle using the angle wrench [SST: KV10112100 (BT-8653-A)]. Never make M
judgment by visual inspection.
4. Press side bearing inner races to differential assembly, using the
drift (A) and the adaptor (B).
N
A : Drift [SST: KV38100200 (J-26233)]
B : Adaptor [SST: KV40104920 ( — )]
O
CAUTION:
Never reuse side bearing inner race.
JSDIA2567ZZ

5. Set the drifts (A and B) to the right and left side bearing adjusting
washers individually. Compress differential assembly and side
bearing to install differential assembly to gear carrier assembly.
A : Drift [SST: ST30613000 (J-25742-3)]

B : Drift [SST: ST30613000 (J-25742-3)]
CAUTION:
• The drift shall be placed on the center of the adjusting
washers.
• The pressure shall be as low as possible to install differ-
ential assembly into gear carrier assembly. The maximum JPDID0356ZZ
pressure shall be 10 kN (1 ton, 1.0 Imp ton).

• If the adjusting washers are installed by tapping, the gear carrier may be damaged. Avoid tap-
ping.
6. Install dummy cover set [SST: KV385J9010 ( — )], check and adjust drive gear runout, tooth contact,
backlash, and total preload torque. Refer to DLN-173, "Adjustment".
7. Remove dummy cover set.
8. Install stud bolt to rear cover in the following specified length.
Length (L) : 47.3 mm (1.862 in) or less
JSDIA4766ZZ
9. Apply liquid gasket to mating surface of rear cover.

CAUTION:
• Remove old gasket adhering to the mounting surfaces.
Also remove any moisture, oil, or foreign material adher-
ing to the mounting surfaces.
• The width of sealant bead is approximately 3 mm (0.12 in).
Apply sealant evenly.
JSDIA4767ZZ
10. Set the drifts (A and B) to the right and left side bearing adjusting
washers individually. Compress differential assembly and side
bearing to install rear cover.
A : Drift [SST: ST30613000 (J-25742-3)]

B : Drift [SST: ST30613000 (J-25742-3)]
CAUTION:
• The drift shall be placed on the center of the adjusting
washers.
• The pressure shall be as low as possible to install the rear
cover. The maximum pressure shall be 10 kN (1 ton, 1.0 JPDID0355ZZ
Imp ton).
• If rear cover is forced in by tapping, rear cover may be damaged by adjusting washers. Avoid
tapping.
11. Tighten rear cover mounting bolts to the specified torque.

12. Using the drift (A) [SST: KV40104830 ( — )], drive side oil
seals until it becomes flush with the carrier end. A
CAUTION:
• Never reuse oil seals.
• When installing, do not incline oil seals.
B
C
JPDID0357ZZ
DLN
TOTAL PRELOAD TORQUE E

Before inspection and adjustment, drain gear oil.
1. Secure final drive assembly onto a suitable attachment.
2. Rotate drive pinion back and forth 2 to 3 times to check for unusual noise and rotation malfunction. F
3. Rotate drive pinion at least 20 times to check for smooth operation of the bearing.
4. While rotate drive pinion at 60 rpm, measure total preload with
the preload gauge (A) [SST: ST3127S000 (J-25765-A)]. G
Total preload torque : Refer to DLN-185, "Preload

Torque". H
NOTE:
Total preload torque = Pinion bearing preload torque + Side
bearing preload torque I
• If measured value is out of the specification, disassemble it to
check and adjust each part. Adjust the pinion bearing preload
and side bearing preload. JSDIA0031ZZ
Adjust the pinion bearing preload first, then adjust the side J
bearing preload.
When the preload torque is large K

On pinion bearings: Replace the collapsible spacer.
On side bearings: Use thinner side bearing adjusting washers by the same amount to
each side. For selecting adjusting washer, refer to the latest parts in- L
formation.
M
When the preload is small
On pinion bearings: Tighten the drive pinion lock nut.
On side bearings: Use thicker side bearing adjusting washers by the same amount to N
each side. For selecting adjusting washer, refer to the latest parts in-
formation.
DRIVE GEAR RUNOUT O
1. Remove rear cover. Refer to DLN-170, "Disassembly".
2. Using rear cover mounting bolt, install dummy cover set [SST: KV385J9010 ( — )] to gear carrier.
Refer to DLN-171, "Assembly". P
CAUTION:
Liquid gasket is not necessary. Never apply liquid gasket to rear cover.
NOTE:
The installation procedure is the same as that of rear cover.

3. Fit a dial indicator to the drive gear back face.
4. Rotate the drive gear to measure runout.
Drive gear back : Refer to DLN-185, "Drive Gear

face runout Runout".
• If the runout is outside of the repair limit, check drive gear
assembly condition; foreign material may be caught between
drive gear and differential case, or differential case or drive
gear may be deformed, etc.
CAUTION:
JSDIA4760ZZ
Replace drive gear and drive pinion as a set.
TOOTH CONTACT
Refer to DLN-171, "Assembly".
CAUTION:
NOTE:
3. Apply red lead to drive gear.
CAUTION:
Apply red lead to both the faces of 3 to 4 gears at 4 loca-
tions evenly spaced on drive gear.
JSDIA4761ZZ
4. Rotate drive gear back and forth several times, check drive pin-
ion gear to drive gear tooth contact.
CAUTION:
Check tooth contact on drive side and reverse side.
SDIA0570E

Tooth Contact Judgment Guide
A
DLN
I
SDIA0207E
5. If tooth contact is improperly adjusted, follow the procedure

below to adjust the pinion height (dimension X). J
SDIA0517E
M
• If the tooth contact is near the face (face contact), or near the
heel (heel contact), thicken drive pinion height adjusting
washer to move drive pinion closer to drive gear. N
mation.
O
P
PDIA0440E

• If the tooth contact is near the flank (flank contact), or near the
toe (toe contact), thin drive pinion height adjusting washer to
move drive pinion farther from drive gear.
mation.
PDIA0441E
BACKLASH
Refer to DLN-171, "Assembly".
CAUTION:
NOTE:
3. Fit a dial indicator to the drive gear face to measure the back-
lash.
Backlash : Refer to DLN-185, "Back-

lash".
• If the backlash is outside of the specified value, change the
thickness of side bearing adjusting washers.
When the backlash is large:

Make drive gear back side adjusting washer thicker, JSDIA4762ZZ
and drive gear tooth side adjusting washer thinner by
the same amount. For selecting adjusting washer, re-
fer to the latest parts information.
When the backlash is small:
Make drive gear back side adjusting washer thinner,
and drive gear tooth side adjusting washer thicker by
the same amount. For selecting adjusting washer, re-
fer to the latest parts information.
CAUTION:
Never change the total amount of washers as it changes the bearing preload.

Bearing
Oil Seal

Differential Assembly
• Clean up the disassembled parts. A
• If any wear or crack on the contact sides of the differential case is found, replace.
• If any cracks or damage on the surface of the side gear and pinion mate gear tooth is found, replace.
• If it is chipped (by friction), damaged, or unusually worn, replace.
B
• Measure and check side gear end play with the following procedure.
1. Place differential assembly straight up so that side gear to be
measured comes upward.
C
DLN
JPDID0205GB
2. Using feeler gauge, measure the clearance between side gear F

back and differential case at 3 different points, while rotating
side gear. Average the 3 readings, and then measure the clear-
ance of the other side as well. G
Side gear back clear- : Refer to DLN-185, "Differ-

ance ential Side Gear Clear- H
ance".
CAUTION:
To prevent side gear from tilting, insert feeler gauges with I
the same thickness from both sides.
• If the back clearance is outside the specification, replace dif-
ferential.
J
PDIA0576E

DRIVE PINION
DRIVE PINION
JSDIA4757GB

Pinion front bearing Mounting insulator Gear carrier
Collapsible spacer Pinion rear bearing Pinion height adjusting washer
Drive pinion Drive gear Differential assembly
Side bearing Side bearing adjusting washer Side oil seal
Rear cover Filler plug Gasket
Drain plug Stud bolt
Oil seal lip Screw hole Comply with the assembly proce-
dure when tightening. Refer to DLN-
171, "Assembly".
: Apply gear oil.

: Apply Genuine High Strength Thread Locking Sealant or equivalent. Refer to GI-22, "Recommended Chemical Products
and Sealants".
1. Remove differential assembly. Refer to DLN-170, "Disassembly".

DRIVE PINION
mercial service tool), remove drive pinion lock nut. A
JSDIA0033ZZ
DLN
3. Put matching mark on the end of drive pinion. The matching
mark should be in line with the matching mark on companion
flange . E
CAUTION:
For matching mark, use paint. Never damage companion
NOTE: F
The matching mark on the final drive companion flange indicates
the maximum vertical runout position.
When replacing companion flange, matching mark is not neces- G
sary. JSDIA0016ZZ
4. Remove companion flange using the suitable pullers (commer-

H
cial service tool).
JSDIA0034ZZ
K
5. Press drive pinion assembly out of gear carrier.
CAUTION:
Never drop drive pinion assembly. L
7. Remove pinion front bearing inner race.
8. Remove collapsible spacer. M
N
JPDID0361ZZ
9. Remove pinion rear bearing inner race and pinion height adjust- O
ing washer with the replacer (A) (commercial service tool).
PDIA0801J

DRIVE PINION
10. Tap pinion front/rear bearing outer races uniformly using a brass
rod or equivalent to remove them.
CAUTION:
"Inspection".
SDIA0817E
1. Install front bearing outer race and rear bearing outer race
using drifts (A, B and D) and drift bar (C).
A : Drift [SST: ST30720000 (J-25405)]

B : Drift [SST: KV40105230 ( — )]
C : Drift bar [SST: ST30611000 (J-25742-1)]
D : Drift [SST: ST30613000 (J-25742-3)]
CAUTION:
• At first, using a hammer, tap bearing outer race until it
• Never reuse pinion front and rear bearing outer race.
PDIA0761J
2. Temporarily install pinion height adjusting washer .

When hypoid gear set has been replaced
• Select pinion height adjusting washer. Refer to DLN-183,
"Adjustment".
When hypoid gear set has been reused
• Temporarily install the removed pinion height adjusting washer
or same thickness washer to drive pinion.
CAUTION:
Pay attention to the direction of pinion height adjusting
washer. (Assemble as shown in the figure.) JSDIA0760ZZ

DRIVE PINION
3. Install pinion rear bearing inner race to drive pinion with the
drift (A) (commercial service tool). A
CAUTION:
Never reuse pinion rear bearing inner race.
4. Check and adjust the tooth contact and back lash of drive gear B
and drive pinion following the procedure below.
a. Assemble drive pinion into gear carrier.
CAUTION: C
• Never assemble collapsible spacer.
• Apply gear oil to pinion rear bearing.
JSDIA0761ZZ
b. Assemble pinion front bearing inner race to drive pinion assem-
bly. DLN
CAUTION:
• Never reuse pinion front bearing inner race.
• Apply gear oil to pinion front bearing. E
c. Using press stand (A) [SST: ST38220000 ( — )], press the
ion lock nut can be tightened. F
H
PDIA0762J
d. Install companion flange. I

CAUTION:
Never assemble front oil seal.
NOTE:
J
When reusing drive pinion, align the matching mark of drive
e. Temporarily tighten removed drive pinion lock nut to drive pinion. K
NOTE:
Use removed drive pinion lock nut only for the preload measure-
ment. L
f. Rotate drive pinion more than 20 times to adjust bearing.
M
JSDIA0016ZZ

DRIVE PINION
g. Tighten to drive pinion lock nut holding companion flange with
the flange wrench (commercial service tool), while adjusting pin-
ion bearing preload torque using preload gauge (A) [SST:
ST3127S000 (J-25765-A)].
Pinion bearing preload : 1.0 - 1.3 N·m (0.11 – 0.13 kg-m,

(without oil seal) 9 – 11 in-lb)
CAUTION:
Drive pinion lock nut is tightened with no collapsible
spacer. Be careful not to overtighten it. While measuring the
preload, tighten it by 5° to 10°.
h. Assemble removed side bearing adjusting washer or same
thickness of it and install differential assembly. Refer to DLN-
171, "Assembly".
CAUTION:
Apply differential gear oil to the side bearings.
i. Check and adjust tooth contact, drive gear to drive pinion back-
lash. Refer to DLN-173, "Adjustment".
j. Remove differential assembly.
k. Remove companion flange.
l. Remove drive pinion assembly from gear carrier.
JSDIA0035ZZ
m. Remove pinion front bearing inner race.
5. Assemble collapsible spacer.
CAUTION:
Never reuse collapsible spacer.
6. Assemble drive pinion into gear carrier.
CAUTION:
Apply gear oil to pinion rear bearing.
7. Assemble pinion front bearing inner race to drive pinion assembly.
CAUTION:
• Never reuse pinion front bearing inner race.
• Apply gear oil to pinion front bearing.
8. Using press stand (A) [SST: ST38220000 ( — )], press the
ion lock nut can be tightened.
PDIA0762J
9. Install front oil seal until it becomes flush with the carrier end,
using the drift (A) [SST: KV40104710 ( — )] as shown in fig-
ure.
CAUTION:
JPDID0362ZZ

DRIVE PINION
NOTE:
When reusing drive pinion, align the matching mark of drive A
11. Apply anti-corrosion oil to the thread and seat of drive pinion B
lock nut, and temporarily tighten drive pinion lock nut to drive
pinion.
CAUTION:
C
JSDIA0016ZZ DLN
mercial service tool), tighten drive pinion lock nut within the lim-
E
its of specified torque so as to keep the pinion bearing preload
within a standard values, using preload gauge (A) [SST:
ST3127S000 (J-25765-A)].
F
Pinion bearing preload : Refer to DLN-185, "Pre-
load Torque".
CAUTION: G
ening torque first.
• If the preload torque exceeds the specified value, replace H
collapsible spacer and tighten it again to adjust. Never
loosen drive pinion lock nut to adjust the preload torque.
times to check for unusual noise, rotation malfunction, I
and other malfunctions.
13. Install differential assembly. Refer to DLN-171, "Assembly".
CAUTION: J
Never install rear cover at this timing.
14. Check and adjust drive gear runout, tooth contact, and drive
gear to drive pinion backlash. Refer to DLN-173, "Adjustment". JSDIA0035ZZ
K
16. Install rear cover. Refer to DLN-171, "Assembly".
L
PINION GEAR HEIGHT M

If the hypoid gear set has been replaced, select the pinion height adjusting washer.
1. Use the formula below to calculate pinion height adjusting
washer thickness.
N
Washer selection equation:
T = T0 + (t1− t2)
O
T: Correct washer thickness
T0: Removed washer thickness
Old drive pinion head letter “H × 0.01”
t1: P
New drive pinion head letter “H × 0.01”
t2:
(“H”: machined tolerance 1/100 mm × 100) SDIA0249J
Example:
T = 3.21 + [(2 × 0.01) − (−1 × 0.01)] = 3.24
T0: 3.21

DRIVE PINION
t1: +2
t2: −1
2. Select the proper pinion height adjusting washer. For selecting adjusting washer, refer to the latest parts
information.
CAUTION:
If unable to find a washer of desired thickness, use a washer with thickness closest to the calcu-
lated value.
Example:
Calculated value... T = 3.22 mm
Used washer... T = 3.21 mm

Bearing
Oil Seal
Companion Flange
• If any chipped mark [about 0.1 mm, (0.004 in)] or other damage on the contact sides of the lips of the com-
panion flange is found, replace.

< SERVICE DATA AND SPECIFICATIONS (SDS) [REAR FINAL DRIVE: R190]

B
Axle 2WD AWD

C
Transmission A/T
Final drive model R190 DLN
Gear ratio 3.133
Number of teeth (Drive gear/Drive pinion) 47/15
E
Number of pinion gears 2
Drive pinion adjustment spacer type Collapsible
Oil capacity Refer to MA-10, "Fluids and Lubricants". F
Preload Torque INFOID:0000000011282128
Unit: N·m (kg-m, in-lb) G

Item Standard
Pinion bearing (P1) 1.436 – 2.20 (0.15 – 0.22, 13 – 19) H
Side bearing (P2) 0.236 – 0.472 (0.03 – 0.04, 2 – 4)
Side bearing to pinion bearing (Total preload)
(Total preload = P1 + P2) I
1.672 – 2.672 (0.17 – 0.27, 15 – 23)
NOTE:
Rotating speed: 60 rpm
Drive Gear Runout INFOID:0000000011282126 J
Unit: mm (in)
Item Standard
K
Drive gear back face runout 0.05 (0.0020) or less
Backlash INFOID:0000000011282129
L
Unit: mm (in)
Item Standard
M
Drive gear to drive pinion gear 0.10 – 0.15 (0.0039 – 0.0059)
Differential Side Gear Clearance INFOID:0000000011282127

N
Unit: mm (in)
Item Standard
0.10 (0.004) or less O
Side gear backlash (Clearance between side gear and differential
(Each gear should rotate smoothly without excessive resistance
case)
during differential motion.)
P

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TRANSMISSION & DRIVELINE

SECTION DLN DRIVELINE

INFORMATION DISPLAY (COMBINATION C1204 AWD SOLENOID ................................... 34

Revision: 2015 January DLN-1 2015 Q50

PERIODIC MAINTENANCE ........................ 55 PRECAUTION ............................................ 84

TRANSFER FLUID ............................................ 55 PRECAUTIONS ................................................. 84

Revision: 2015 January DLN-2 2015 Q50

REMOVAL AND INSTALLATION ............... 89 PRECAUTION ............................................ 103

PRECAUTION .............................................. 93 NOISE, VIBRATION AND HARSHNESS

SYSTEM DESCRIPTION ............................. 95 REAR PROPELLER SHAFT ........................... 108

NOISE, VIBRATION AND HARSHNESS (SDS) .......................................................... 113

Revision: 2015 January DLN-3 2015 Q50

NOISE, VIBRATION AND HARSHNESS SERVICE DATA AND SPECIFICATIONS

AIR BREATHER .............................................. 125 STRUCTURE AND OPERATION ..................... 158

Revision: 2015 January DLN-4 2015 Q50

Revision: 2015 January DLN-5 2015 Q50

• Never reuse transfer fluid, once it has been drained.

Revision: 2015 January DLN-6 2015 Q50

Revision: 2015 January DLN-7 2015 Q50

KV381054S0 Removing rear oil seal

ST30720000 • Installing rear oil seal

KV40104830 Installing rear oil seal

ST33052000 Removing main shaft assembly

ST35321000 Installing main shaft assembly

Revision: 2015 January DLN-8 2015 Q50

ST33200000 Installing front drive shaft front bearing DLN

Commercial Service Tools INFOID:0000000011281939 I

Tool name Description J

Separator • Removing front drive shaft front bearing

Power tool Loosening bolts and nuts O

Lubricant or/and Sealant INFOID:0000000011281940

Revision: 2015 January DLN-9 2015 Q50

Revision: 2015 January DLN-10 2015 Q50

Instrument lower panel LH removed Transfer inside

Revision: 2015 January DLN-11 2015 Q50

AWD solenoid Refer to DLN-12, "AWD Solenoid".

AWD Control Unit INFOID:0000000011281942

• Transfer fluid temperature sensor is integrated with electric controlled coupling.

• The electrical resistance of the sensor decreases as temperature

Revision: 2015 January DLN-12 2015 Q50

Electromagnet Control clutch Cam J

POWER TRANSFER DIAGRAM L

Revision: 2015 January DLN-13 2015 Q50

Main clutch Control clutch Cam

Revision: 2015 January DLN-14 2015 Q50

Signal with Communication Line

Component parts Signal item

Revision: 2015 January DLN-15 2015 Q50

Revision: 2015 January DLN-16 2015 Q50

AWD warning (on infor- Contents of protection

Symbol Message Condition

SYNCHRONIZATION WITH MASTER WARNING LAMP

Revision: 2015 January DLN-17 2015 Q50

Revision: 2015 January DLN-18 2015 Q50

Diagnostic test mode Function C

When “PAST” is displayed on self-diagnosis result.

Revision: 2015 January DLN-19 2015 Q50

Test item Condition Description

Revision: 2015 January DLN-20 2015 Q50

Climate con- Weather Fine Cloud Rain Snow Others ( )