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Transfer System: Inspection

  1. INSPECT INDICATOR LIGHT 
    1. Check the 4LO indicator light.
      1. Start the engine.
      2. Stop the vehicle.
      3. Move the shift lever to N.
      4. Turn the transfer position switch from H4 to L4.
      5. Check the 4LO indicator light.

        OK 

        4LO INDICATOR LIGHT POSITION

        Switch Condition Specified Condition
        Turned from H4 to L4 4LO indicator light comes on immediately or comes on after blinking

        If there is a malfunction, inspect the switch, four wheel drive control ECU and transfer shift actuator. If the system is normal, there may be a malfunction in the CAN communication system or combination meter. In that case, first check the CAN communication system (See HOW TO PROCEED WITH TROUBLESHOOTING ). Then check the combination meter (See HOW TO PROCEED WITH TROUBLESHOOTING ).

        Fig 1: Checking 4LO Indicator Light
        G05629560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Check the center differential lock indicator light.
      1. Start the engine.
      2. Push the center differential lock switch.
        NOTE:
        • Do not push the switch while the vehicle is turning.
        • Push the switch at a vehicle speed less than 100 km/h (62 mph).
      3. Check the center differential lock indicator light.

        OK 

        LOCK INDICATOR LIGHT POSITION

        Switch Condition Specified Condition
        Pushed Center differential lock indicator light comes on immediately or comes on after blinking

        If there is a malfunction, inspect the switch, four wheel drive control ECU and transfer shift actuator. If the system is normal, there may be a malfunction in the CAN communication system or combination meter. In that case, first check the CAN communication system (See HOW TO PROCEED WITH TROUBLESHOOTING ). Then check the combination meter (See HOW TO PROCEED WITH TROUBLESHOOTING ).

        Fig 2: Checking Center Differential Lock Indicator Light
        G05629561Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT FUSE 
    1. Remove the 4WD fuse from the main body ECU (cowl side junction block LH).
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      RESISTANCE SPECIFICATION

      Tester Connection Condition Specified Condition
      4WD fuse Always Below 1 Ω

      If the fuse is blown, inspect the harness connected to the fuse for a short circuit, and repair or replace the harness or replace the fuse.

  3. INSPECT TRANSFER POSITION SWITCH 
    1. Remove the transfer position switch (See REMOVAL  ).
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      RESISTANCE SPECIFICATION

      Tester Connection Switch Condition Specified Condition
      2 (2WD) - 4 (GND2) H4 position 100 kΩ or higher
      L4 position Below 1 Ω

      If there is a malfunction, replace the transfer position switch.

    3. Check the harness and connector (ECU - transfer position switch and body ground).
      1. Disconnect the A27 ECU connector.
      2. Disconnect the E48 transfer position switch connector.
        Fig 3: Identifying Transfer Position Switch Connector Terminals
        G05629562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Measure the resistance according to the value(s) in the table below.
        Fig 4: Identifying E48 And A27 Connector Terminals
        G05629563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard Resistance 

        RESISTANCE SPECIFICATION

        Tester Connection Condition Specified Condition
        E48-2 (2WD) - A27-13 (LO) Always Below 1 Ω
        E48-2 (2WD) - Body ground Always 100 kΩ or higher
        E48-4 (GND2) - Body ground Always Below 1 Ω

        If there is a malfunction, repair or replace the harness or connector.

  4. INSPECT CENTER DIFFERENTIAL LOCK SWITCH 
    1. Remove the center differential lock switch (See REMOVAL  ).
    2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance 

      RESISTANCE SPECIFICATION

      Tester Connection Switch Condition Specified Condition
      6 (L)-9 (CPU) Switch is pressed and held Below 1 Ω
      Switch is not pressed 100 kΩ or higher

      If there is a malfunction, replace the center differential lock switch.

    3. Check the harness and connector (ECU - center differential lock switch and body ground).
      1. Disconnect the A27 ECU connector.
      2. Disconnect the E49 center differential lock switch connector.
        Fig 5: Identifying Center Differential Lock Switch Connector Terminals
        G05629564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Measure the resistance according to the value(s) in the table below.
        Fig 6: Identifying E49 And A27 Connector Terminals
        G05629565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Standard Resistance 

        RESISTANCE SPECIFICATION

        Tester Connection Condition Specified Condition
        A27-12 (DL) - E49-9 (CPU) Always Below 1 Ω
        A27-12 (DL) - Body ground Always 100 kΩ or higher
        E49-6 (L) - Body ground Always Below 1 Ω

        If there is a malfunction, repair or replace the harness or connector.

  5. INSPECT TRANSFER SHIFT ACTUATOR ASSEMBLY (HIGH-LOW TRANSFER SHIFT ACTUATOR) 

    HINT:

    After inspecting the ECU power supply or transfer position switch, check the high-low transfer shift actuator.

    1. Check the harness and connector (ECU - high-low transfer shift actuator).
      1. Disconnect the C44 actuator connector.
      2. Disconnect the A27 and A28 ECU connectors.
      3. Measure the resistance according to the value(s) in the table below.
      Fig 7: Identifying A27 And A28 ECU Connector Terminals
      G05629566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance 

      RESISTANCE SPECIFICATION

      Tester Connection Condition Specified Condition
      A27-1 (HL1) - C44-4 (HL1) Always Below 1 Ω
      A27-1 (HL1) - Body ground Always 100 kΩ or higher
      A27-2 (HL2) - C44-6 (HL2) Always Below 1 Ω
      A27-2 (HL2) - Body ground Always 100 kΩ or higher
      A27-3 (HL3) - C44-5 (HL3) Always Below 1 Ω
      A27-3 (HL3) - Body ground Always 100 kΩ or higher
      A27-16 (NP) - C44-3 (N) Always Below 1 Ω
      A27-16 (NP) - Body ground Always 100 kΩ or higher
      A28-2 (HM1) - C44-1 (HM1) Always Below 1 Ω
      A28-2 (HM1) - Body ground Always 100 kΩ or higher
      A28-6 (HM2) - C44-2 (HM2) Always Below 1 Ω
      A28-6 (HM2) - Body ground Always 100 kΩ or higher
      C44-7 (GND) - Body ground Always Below 1 Ω

      If there is a malfunction, repair or replace the harness or connector.

    2. Check the high-low transfer shift actuator.
      1. Turn the engine switch on (IG).
      2. Stop the vehicle.
      3. Move the shift lever to N.
      4. Check that there is an operating noise from the transfer shift actuator when the transfer position switch is turned from H4 to L4, or L4 to H4.

        OK: 

        There is an operating noise. 

        HINT:

        • If the actuator fork cannot move from high to low, or low to high even though there is an operating noise, there may be a mechanical malfunction in the transfer.
        • If there is no operating noise, there may be a malfunction in the high-low transfer shift actuator. However, it may also be a result of a mechanical malfunction in the transfer, so inspect each part.
      5. Remove the transfer shift actuator assembly (See TRANSFER ASSEMBLY  ).
      6. Check the high to low switch.
        1. Connect lines via a relay as shown in the illustration (Fig 8), and check that the actuator fork moves from the high to low position.
          NOTE:
          • Make sure to perform this inspection with the actuator removed from the vehicle. If this inspection is performed with the actuator installed to the vehicle, the actuator will be damaged.
          • When inspecting the actuator, make sure to operate it with the lines connected via a relay. If the lines are not connected via a relay and battery voltage is directly applied to the actuator, the actuator will be damaged.

          HINT:

          When performing the operation described above, use the DEFOG relay.

          Fig 8: Inspecting Transfer Shift Actuator Assembly And DEFOG Relay
          G05629567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        2. After the high to low switch is complete, check the neutral position detection switch and limit switch.
          1. Measure the resistance according to the value(s) in the table below.

            Standard Resistance 

            RESISTANCE SPECIFICATION

            Tester Connection Condition Specified Condition
            3 (N) - 7 (GND) After high to low switch is complete 100 kΩ or higher
            4 (HL1) - 7 (GND) After high to low switch is complete 100 kΩ or higher
            5 (HL3) - 7 (GND) After high to low switch is complete 100 kΩ or higher
            6 (HL2) - 7 (GND) After high to low switch is complete Below 1 Ω

            If there is a malfunction, replace the transfer shift actuator assembly.

      7. Check the low to high switch.
        1. Connect lines via a relay as shown in the illustration (Fig 9), and check that the actuator fork moves from the low to high position.
          NOTE:
          • Make sure to perform this inspection with the actuator removed from the vehicle. If this inspection is performed with the actuator installed to the vehicle, the actuator will be damaged.
          • When inspecting the actuator, make sure to operate it with the lines connected via a relay. If the lines are not connected via a relay and battery voltage is directly applied to the actuator, the actuator will be damaged.

          HINT:

          When performing the operation described above, use the DEFOG relay.

          Fig 9: Inspecting Transfer Shift Actuator Assembly And DEFOG Relay
          G05629568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        2. After the low to high switch is complete, check the neutral position detection switch and limit switch.
          1. Measure the resistance according to the value(s) in the table below.

            Standard Resistance 

            RESISTANCE SPECIFICATION

            Tester Connection Condition Specified Condition
            3 (N) - 7 (GND) After low to high switch is complete 100 kΩ or higher
            4 (HL1) - 7 (GND) After low to high switch is complete Below 1 Ω
            5 (HL3) - 7 (GND) After low to high switch is complete 100 kΩ or higher
            6 (HL2) - 7 (GND) After low to high switch is complete 100 kΩ or higher

            If there is a malfunction, replace the transfer shift actuator assembly.

  6. INSPECT TRANSFER SHIFT ACTUATOR ASSEMBLY (CENTER DIFFERENTIAL LOCK ACTUATOR) 

    HINT:

    After inspecting the ECU power supply or center differential lock switch, check the center differential lock actuator.

    1. Check the harness and connector (ECU - center differential lock actuator).
      1. Disconnect the C43 actuator connector.
      2. Disconnect the A27 and A28 ECU connectors.
      3. Measure the resistance according to the value(s) in the table below.
      Fig 10: Identifying A27, A28 ECU And C43 Connector Terminals
      G05629569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Resistance 

      RESISTANCE SPECIFICATION

      Tester Connection Condition Specified Condition
      A27-6 (TL1) - C43-4 (TL1) Always Below 1 Ω
      A27-6 (TL1) - Body ground Always 100 kΩ or higher
      A27-7 (TL2) - C43-6 (TL2) Always Below 1 Ω
      A27-7 (TL2) - Body ground Always 100 kΩ or higher
      A27-8 (TL3) - C43-5 (TL3) Always Below 1 Ω
      A27-8 (TL3) - Body ground Always 100 kΩ or higher
      A27-14 (P1) - C43-3 (CDL) Always Below 1 Ω
      A27-14 (P1) - Body ground Always 100 kΩ or higher
      A28-7 (TM2) - C43-2 (TM2) Always Below 1 Ω
      A28-7 (TM2) - Body ground Always 100 kΩ or higher
      A28-8 (TM1) - C43-1 (TM1) Always Below 1 Ω
      A28-8 (TM1) - Body ground Always 100 kΩ or higher
      C43-7 (GND1) - Body ground Always Below 1 Ω

      If there is a malfunction, repair or replace the harness or connector.

    2. Check the center differential lock actuator.
      1. Turn the engine switch on (IG).
      2. Check that there is an operating noise from the transfer shift actuator when the center differential lock switch is pressed to switch from Free to Lock, or lock to free.

        OK: 

        There is an operating noise. 

        HINT:

        • If the actuator fork cannot move from free to lock, or lock to free even though there is an operating noise, there may be a mechanical malfunction in the transfer.
        • If there is no operating noise, there may be a malfunction in the center differential lock actuator. However, it may also be a result of a mechanical malfunction in the transfer, so inspect each part.
      3. Remove the transfer shift actuator assembly (See TRANSFER ASSEMBLY  ).
      4. Check the free to lock switch.
        1. Connect lines via a relay as shown in the illustration (Fig 11), and check that the actuator fork moves from the free to lock position.
          NOTE:
          • Make sure to perform this inspection with the actuator removed from the vehicle. If this inspection is performed with the actuator installed to the vehicle, the actuator will be damaged.
          • When inspecting the actuator, make sure to operate it with the lines connected via a relay. If the lines are not connected via a relay and battery voltage is directly applied to the actuator, the actuator will be damaged.

          HINT:

          When performing the operation described above, use the DEFOG relay.

          Fig 11: Identifying Transfer Shift Actuator Assembly And DEFOG Relay
          G05629570Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        2. After the free to lock switch is complete, check the center differential lock detection switch and limit switch.
          1. Measure the resistance according to the value(s) in the table below.

            Standard Resistance 

            RESISTANCE SPECIFICATION

            Tester Connection Condition Specified Condition
            3 (CDL) - 7 (GND1) After free to lock switch is complete Below 1 Ω
            4 (TL1) - 7 (GND1) After free to lock switch is complete 100 kΩ or higher
            5 (TL3) - 7 (GND1) After free to lock switch is complete 100 kΩ or higher
            6 (TL2) - 7 (GND1) After free to lock switch is complete Below 1 Ω

            If there is a malfunction, replace the transfer shift actuator assembly.

      5. Check the lock to free switch.
        1. Connect lines via a relay as shown in the illustration (Fig 12), and check that the actuator fork moves from the lock to free position.
          NOTE:
          • Make sure to perform this inspection with the actuator removed from the vehicle. If this inspection is performed with the actuator installed to the vehicle, the actuator will be damaged.
          • When inspecting the actuator, make sure to operate it with the lines connected via a relay. If the lines are not connected via a relay and battery voltage is directly applied to the actuator, the actuator will be damaged.

          HINT:

          When performing the operation described above, use the DEFOG relay.

          Fig 12: Identifying Transfer Shift Actuator Assembly And DEFOG Relay
          G05629571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        2. After the lock to free switch is complete, check the center differential lock detection switch and limit switch.
          1. Measure the resistance according to the value(s) in the table below.

            Standard Resistance 

            RESISTANCE SPECIFICATION

            Tester Connection Condition Specified Condition
            3 (CDL) - 7 (GND1) After lock to free switch is complete 100 kΩ or higher
            4 (TL1) - 7 (GND1) After lock to free switch is complete 100 kΩ or higher
            5 (TL3) - 7 (GND1) After lock to free switch is complete Below 1 Ω
            6 (TL2) - 7 (GND1) After lock to free switch is complete 100 kΩ or higher

            If there is a malfunction, replace the transfer shift actuator assembly.

  7. INSPECT FOUR WHEEL DRIVE CONTROL ECU 

    HINT:

    Inspect the connectors from the back side while the connectors are connected.

    1. Check the four wheel drive control ECU.
      1. Measure the resistance and voltage according to the value(s) in the table below.
        Fig 13: Identifying A27 And A28 Connector Terminals
        G05629572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TERMINAL DESCRIPTION

        Tester Connection Terminal Description Condition Specified Condition
        A27-1 (HL1) - A28-4 (GND) High-low transfer shift actuator limit switch Engine switch on (IG) Transfer in high position Below 1.5 V
        Engine switch on (IG) Transfer in low position 11 to 14 V
        Engine switch on (IG) Transfer in neutral position 11 to 14 V
        A27-2 (HL2) - A28-4 (GND) High-low transfer shift actuator limit switch Engine switch on (IG) Transfer in high position 11 to 14 V
        Engine switch on (IG) Transfer in low position Below 1.5 V
        Engine switch on (IG) Transfer in neutral position 11 to 14 V
        A27-3 (HL3) - A28-4 (GND) High-low transfer shift actuator limit switch Engine switch on (IG) Transfer in high position 11 to 14 V
        Engine switch on (IG) Transfer in low position 11 to 14 V
        Engine switch on (IG) Transfer in neutral position Below 1.5 V
        A27-5 (TT) - A27-25 (TGND)* Temperature sensor Engine switch on (IG) 0 to 5 V
        A27-6 (TL1) - A28-4 (GND) Center differential lock actuator limit switch Engine switch on (IG) Center differential in free position 11 to 14 V
        Engine switch on (IG) Center differential in lock position 11 to 14 V
        Engine switch on (IG) Transfer in neutral position Below 1.5 V
        A27-7 (TL2) - A28-4 (GND) Center differential lock actuator limit switch Engine switch on (IG) Center differential in free position 11 to 14 V
        Engine switch on (IG) Center differential in lock position Below 1.5 V
        Engine switch on (IG) Transfer in neutral position 11 to 14 V
        A27-8 (TL3) - A28-4 (GND) Center differential lock actuator limit switch Engine switch on (IG) Center differential in free position Below 1.5 V
        Engine switch on (IG) Center differential in lock position 11 to 14 V
        Engine switch on (IG) Transfer in neutral position 11 to 14 V
        A27-12 (DL) - A28-4 (GND) Center differential lock switch Engine switch on (IG) Center differential lock switch is pressed and held Below 1.5 V
        Engine switch on (IG) Center differential lock switch is not pressed 11 to 14 V
        A27-13 (LO) - A28-4 (GND) Transfer position switch Engine switch on (IG) Transfer in high position 11 to 14 V
        Engine switch on (IG) Transfer in low position Below 1.5 V
        A27-14 (P1) - A28-4 (GND) Center differential lock detection switch Engine switch on (IG) Center differential in free position 11 to 14 V
        Engine switch on (IG) Center differential in lock position Below 1.5 V
        A27-16 (NP) - A28-4 (GND) Transfer shift actuator neutral position detection switch Engine switch on (IG) Transfer in neutral position Below 1.5 V
        Engine switch on (IG) Transfer in high or low position 11 to 14 V
        A27-19 (CAN+) - A27-20 (CAN-) CAN communication line Engine switch off 54 to 69 Ω
        A27-21 (L4) - A28-4 (GND) Transfer shift actuator Low detection switch Engine switch on (IG) Transfer position switch in H4 position 11 to 14 V
        Engine switch on (IG) Transfer position switch in L4 position Below 1.5 V
        A28-2 (HM1) - A28-4 (GND) High-low transfer shift actuator motor Engine switch on (IG) Transfer position switch H4 → L4 (During operation of high-low transfer shift actuator motor from high to low) Below 1.5 V or alternating between below 1.5 V and 11 to 14 V
        Engine switch on (IG) Transfer position switch L4 → H4 (During operation of high-low transfer shift actuator motor from low to high) 11 to 14 V
        A28-3 (IG) - A28-4 (GND) IG power Engine switch on (IG) 11 to 14 V
        A28-4 (GND) - Body ground Ground Always Below 1 Ω
        A28-6 (HM2) - A28-4 (GND) High-low transfer shift actuator motor Engine switch on (IG) Transfer position switch H4 → L4 (During operation of high-low transfer shift actuator motor from high to low) 11 to 14 V
        Engine switch on (IG) Transfer position switch L4 → H4 (During operation of high-low transfer shift actuator motor from low to high) Below 1.5 V or alternating between below 1.5 V and 11 to 14V
        A28-7 (TM2) - A28-4 (GND) Center differential lock actuator motor Engine switch on (IG) Center differential position free → lock Below 1.5 V or alternating between below 1.5 V and 11 to 14V
        Engine switch on (IG) Center differential position lock → free 11 to 14 V
        A28-8 (TM1) - A28-4 (GND) Center differential lock actuator motor Engine switch on (IG) Center differential position free → lock 11 to 14 V
        Engine switch on (IG) Center differential position lock → free Below 1.5 V or alternating between below 1.5 V and 11 to 14 V

        If there is a malfunction, inspect the harnesses, connectors, transfer position switch, center differential lock switch, and transfer shift actuator assembly. If these are normal, replace the four wheel drive control ECU (See REMOVAL  ).

        HINT:

        *: w/ Temperature Sensor

  8. INSPECT NEUTRAL SWITCHING 
    1. Switch the transfer to neutral.
      1. Turn the engine switch on (IG).
      2. Move the shift lever to N.
      3. Turn the transfer position switch to H4.
      4. Make sure the center differential lock is set to the free position.
      5. Move the shift lever to P.
      6. Depress the brake pedal 3 times and do not release it on the third time.
      7. Move the shift lever to N.
      8. Depress the brake pedal 3 times.
      9. Turn the transfer position switch as follows: H4 → L4 → H4.

        HINT:

        The 4LO indicator light blinks at 2 second intervals (2 seconds on, 2 seconds off).

      10. Move the shift lever to P.
      11. Check that the transfer switches to neutral. If there is a malfunction, inspect the transfer position switch, four wheel drive control ECU and transfer shift actuator. If the system is normal, there may be a malfunction in the CAN communication system. In that case, first check the CAN communication system (See HOW TO PROCEED WITH TROUBLESHOOTING ).

        HINT:

        The 4LO indicator light blinks at 2 second intervals (2 seconds on, 2 seconds off). The A/T P indicator light turns on.

    2. Release the transfer from neutral.
      1. Turn the engine switch on (IG).
      2. Move the shift lever to N.
      3. Turn the transfer position switch as follows: H4 → L4 → H4.
      4. Check that the transfer is released from neutral.

        If there is a malfunction, inspect the transfer position switch, four wheel drive control ECU and transfer shift actuator. If the system is normal, there may be a malfunction in the CAN communication system. In that case, first check the CAN communication system (See HOW TO PROCEED WITH TROUBLESHOOTING ).

        HINT:

        The 4LO indicator light in the combination meter turns off. The release from neutral can be confirmed by checking that the A/T P indicator light does not turn on when the shift lever is moved to P.

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