DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
4B11
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . .
Shift on the Fly System (Lever Type) . . . . . . .
Outline of Shift on the Fly System
(Lever Type) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift on the Fly Vacuum Piping and Electric
Equipment (For Lever Control Type) . . . . . .
Vacuum Piping Diagram . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
Shift on the Fly System (Push Button Type) .
Outline of Shift on the Fly System
(Push Button Type) . . . . . . . . . . . . . . . . . . . .
4B11
4B12
4B12
4B13
4B13
4B14
4B17
4B17
Service Precaution
WARNING: IF
SO
EQUIPPED
WITH
A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS),
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PERFORMING SERVICE
ON OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING, REFER TO THE SRS SERVICE
INFORMATION. FAILURE TO FOLLOW WARNINGS
COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT,
PERSONAL
INJURY,
OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
Functions of Indicator Lamp . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Axle Diagnosis . . . . . . . . . . . . . . . . . . .
Shift on the Fly Vacuum Piping and Electric
Equipment (For Push Button Type) . . . . . . . .
Vacuum Piping Diagram . . . . . . . . . . . . . . . .
Inspection and Repair . . . . . . . . . . . . . . . . . .
4WD Control Unit (For Push Button Type) . .
4WD Control Unit Associated Parts . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4B111
4B111
4B130
4B132
4B132
4B133
4B136
4B136
4B137
4B137
4B12 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Shift on the Fly System (Lever Type)
Outline of Shift on the Fly System
(Lever Type)
The shift on the fly system (Lever type) switches between
2 wheel drive (2WD) and 4 wheel drive (4WD) by drivers
shifting the transfer control lever on the floor.
This system controls below operations.
1. Connecting front wheels to, and disconnecting them
from, the front axles by vacuum actuator.
2. Indicator on instrument panel.
3. 4WD signal to Electronic Hydraulic Control Unit for
brake system (If antilock brake system is equipped).
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
4B13
Shift on the Fly Vacuum Piping and Electric Equipment
(For Lever Control Type)
Vacuum Piping Diagram
C04RW015
VSV Assembly, Actuator Assembly
412RS032
Vacuum Tank
412RS033
4B14 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Inspection and Repair
Vacuum Piping
C04RW016
1. Pull out the Hose A in figure and install a vacuum
gauge.
2. Plug up Hose B in figure to prevent the leak of
vacuum.
3. Start the engine and measure vacuum 2 or 3 minutes
afterward.
4. Repeat 1) and 2) but with Hose A plugged and Hose B
pulled out.
5. If vacuum measures 400mmHg, or if it shows a
sudden drop immediately after engine stop, inspect
the hose, tank, and pipe for damage.
Check Valve
NOTE: Be careful not to permit the entry of dust and
water during inspection.
6. Pull out Hose D in above illustration.
7. Plug Hose E in above illustration.
8. Make sure that Hose D in above illustration is under
atmospheric pressure.
9. Pull out Hose E and plug Hose D, and make sure that
Hose E is under atmospheric pressure.
10. If Check 8) or 9) has revealed stoppage, check and
see that there is no bend, foreign matter in the hose or
in the filter. If there is trouble, repair or replace.
C04RS004
1. Apply vacuum from the orange colored side(1).
Vacuum:400mmHg
2. Check leakage of vacuum.
3. Make sure that vacuum cannot be applied from the
black colored side(2).
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
4. If vacuum is not applicable as much as 400mmHg,
and if there is resistance on the intake side, replace
with a new check valve.
4B15
1. With battery not connected (Usual).
AC:There is continuity
B:Closed
VSV Assembly
2. With battery connected
Inspect the vehicle side harness as follows:
A B:There is continuity
C:Closed
3. If 1) and 2) fail, replace with a new VSV.
Axle Position Switch
412RS071
Legend
(1) Grey
(2) Blue
412RS048
1. Remove connector.
2. Shift transfer lever to 2H and start the engine.
1. With ball (1) being free
A B:There is continuity
NOTE: Do not move the vehicle while inspection.
2. With ball forced into the switch
3. Make sure that there is continuity in the vehicle side of
harness. If there is no continuity, check transfer shift
switch and wiring.
Inspect both VSVs as follows:
F04RS004
A B:No continuity
3. If 1) and 2) fail, replace with a new switch.
4B16 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Transfer Position Switch
412RW040
Legend
(1) Ball
1. With ball being free.
AB : There is continuity.
2. With ball forced into the switch.
AB : No continuity.
3. If 1) and 2) fail, replace with a new switch.
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
4B17
Shift on the Fly System (Push Button Type)
Outline of Shift on the Fly System (Push Button Type)
The shift on the fly system switches between 2 wheel
drive (2WD) and 4 wheel drive (4WD) electrically by
drivers pressing the 4WD switch (push button type) on
instrument panel.
This system controls below operations. (Shifting between
4H and 4L must be performed by transfer control lever
on the floor.)
1. Shifting the transfer front output gear (Connecting to,
and disconnecting from, front propeller shaft by motor
actuator).
2. Retrial of shifting the transfer front output gear.
3. Connecting front wheels to, and disconnecting them
from, the front axles by vacuum actuator.
4. Indicator on instrument panel.
5. 4WD out signal to other Electronic Hydraulic Control
Unit (If antilock brake system is equipped).
System Diagrams
412RW050
4B18 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Normal Operation
The motor actuator mounted on transfer rear case is
driven by signal from 4WD switch on instrument panel.
After complete the connecting transfer front output gear
to, or disconnecting it from, front propeller shaft, condition
of the transfer position switch changes. The vacuum
solenoid valve (VSV) is driven by the signal from transfer
position switch and the vacuum actuator connects front
wheels to, or disconnect them from, front axles.
Time Chart of Shifting Under Normal Condition
F04RW002
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
4B19
Retrial
The motor actuator starts transfer gear shifting after
signal from 4WD switch on instrument panel has been
received. But the shifting may be impossible in cold
weather or under high speed condition. When 2 seconds
have passed since transfer gear shifting started and the
transfer position switch dose not turn on (the gear
engagement is not completed), the motor reverses its
rotation for 1.2 seconds and tries again to shift transfer
gear. This procedure is repeated 3 times in maximum.
While this procedure, 4WD indicator lamp blinks by 2 Hz.
If the transfer position switch does not turn on after
aforementioned procedure has been repeated 3 times,
the gear shifting is stopped and 4WD indicator lamps
blinking changes from 2Hz to 4Hz to notify driver that the
gear shifting is stopped. This blinking of indicator lamp
continues until 4WD switch is returned from 4WD to 2WD.
Time Chart of Shifting Under Severe Condition (retrial)
F04RW003
4B110 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Warning at 4L position :In view of the shifting
mechanism of transfer, the gear shifting from 4WD to
2WD at 4L condition is impossible. Therefore, the
transfer position switch can not be turned off by 4WD
switch when vehicle is in 4L condition. In the case this
condition continues for 2 seconds, the shifting to 2WD is
stopped and the indicator lamps blinking changes from
2Hz to 4Hz to notify driver of wrong operation.
Time Chart of Shifting from 4WD to 2WD at 4L
Condition
F04RW005
4WD out signal to other Electronic Hydraulic Control
Unit : 4WDcontrol unit sends 4WD out signal to other
Electronic Hydraulic Control Unit as below.
4WD out signal
(Period)
Vehicle Condition
Transfer position switch
Front axle switch
120 ms
2WD
2WD (Open)
2WD (Open)
240 ms
4WD
4WD (Close)
4WD (Close)
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B111
Functions of Indicator Lamp
Indication of vehicle condition : Indicator lamp is
controlled by 4WD control unit and shows vehicle
conditions as below.
Indicator
Vehicle condition
4WD switch
Transfer position
switch
Front axle switch
Off
2WD
Off (Close)
2WD (Open)
2WD (Open)
On
4WD
On (Open)
4WD (Close)
4WD (Close)
Blink (2Hz)
Operating
On (Open)
4WD (Close)
2WD (Open)
Off (Close)
2WD (Open)
4WD (Close)
On (Open)
2WD (Open)
2WD (Open)
Off (Close)
4WD (Close)
4WD (Close)
Blink (4Hz)
Stop operating
Bulb check :To check the bulb of indicator lamp, the
indicator lamp comes on when ignition key is turned on,
and goes off when the engine is started.
Retrials from 2WD to 4WD :In cold weather or under
high speed condition, the gear shifting (engagement)
sometimes does not complete by 3 trials. In such case,
the indicator lamp inform driver of this incident as
aforementioned chart (shown at Retrial in Outline of shift
on the fly system).
Diagnosis
Before Judging That Troubles Occur
(Unfaulty mode)
When Switching from 2WD to 4WD
1. In case that blinking frequency of the 4WD
indicator changes from 2Hz to 4Hz.
When heavy synchronization load is needed, the
motor actuator tries the shifting transfer gear three
times including the activation shifting. While the
motor actuator tries shifting, the indicator blinks by
2Hz. If the third shifting fails, the indicators blinking
changes from 2Hz to 4Hz at the same time that the
motor actuator shifted back to 2WD.
Heavy synchronization load occurs by:
D extremely lower temperature.
D higher speed, rotation difference of wheels during
cornering.
Solution 1: Operate again after stop the vehicle or
slow down.
2. In case that the 4WD indicator continues blinking
by 2Hz for more than 11.5 seconds.
When there is rotation difference of wheels or there
is phase difference between front wheels and axles,
it is difficult to connect front wheels to front axles. The
blinking by 2Hz shows that shifting the transfer gear
or connecting the front wheels is in the middle of
operating. In above case, the indicators blinking by
2Hz shows that connecting the front wheels is not
completed (because the indicators blinking changes
to 4Hz when the shifting transfer gear is impossible.).
And removal of rotation or phase difference make
connecting the front wheels possible.
Solution 2: When vehicle is running, drive
straight ahead while accelerating and
decelerating. When vehicle is at a stop, move the
vehicle forward and backward from 2 to 3 meters.
When switching from 4WD to 2WD
1. In case that the 4WD indicator continues blinking
by 2Hz .
The 4WD indicator continues blinking by 2Hz until
both shifting the transfer gear and disconnecting the
front wheels are completed when switching 4WD to
2WD. When driveline is loaded with torsional torque,
the shifting transfer gear and disconnecting front
wheels are impossible. In this case, removal of
torsional torque on driveline make the shifting
transfer gear and disconnecting front wheels
possible.
Solution 3: When vehicle is running, drive
straight ahead while accelerating and
decelerating. When vehicle is at a stop, move the
vehicle forward and backward from 2 to 3 meters.
2. In case that the 4WD indicators blinking changes
from 2Hz to 4Hz.
Check the position of transfer lever. Is it at 4L
position? In view of the shifting mechanism of
transfer, the gear shifting from 4WD to 2WD at 4L
condition is impossible.
Solution 4: Push the 4WD switch to 4WD, shift the
transfer lever to High position and reoperate
the 4WD switch to 2WD.
4B112 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Parts Location (LHD / Diesel Engine Model)
D08RW852
Legend
(1) I12
(2) I9
(3) H7, H8, H24, H25
(4) Fuse Box
(5) C16
(6) C94
(7) H4, H5
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
P17
P18
P19
H60
Relay & Fuse Box
H12, H16
E21
E45
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B113
Parts Location (LHD / Gasoline Engine Model)
D08RW854
Legend
(1) I12
(2) I9
(3) H7, H8, H24, H25
(4) Fuse Box
(5) C16
(6) C94
(7) H5
(8) M11, M12
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
M22
M23
M24
H10
M26
Relay & Fuse Box
H12, H16
E30
4B114 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Parts Location (RHD / Diesel Engine Model)
D08RW831
Legend
(1) I9
(2) I12
(3) E45
(4) E21
(5) H7, H9
(6) C16
(7) C94
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
H4, H5
P17
P18
P19
H60
Relay & Fuse Box
H15, H16, H25, H26, H27
Fuse Box
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B115
Parts Location (RHD / Gasoline Engine Model)
D08RW853
Legend
(1) I9
(2) I12
(3) H7, H9
(4) C16
(5) H5
(6) C94
(7) M26
(8) M11, M12
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
M22
M23
M24
H10
H12
Relay & Fuse Box
E30
H15, H16, H25, H26, H27
Fuse Box
4B116 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Wiring Diagram (LHD Model)
D08RW845
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B117
Wiring Diagram (LHD / Diesel Engine Model)
D08RW841
4B118 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Wiring Diagram (LHD / Gasoline Engine Model)
D08RW843
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B119
Wiring Diagram (RHD Model)
D08RW844
4B120 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Wiring Diagram (RHD / Diesel Engine Model)
D08RW842
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B121
Wiring Diagram (RHD / Gasoline Engine Model)
D08RW638
4B122 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Connector List
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B123
4B124 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B125
Diagnosis of the Faults Based on the
Status of 4WD Indicator Lamp, 4WD
Switch and T/F Change Lever
Diagnosis charts are shown on below. If troubles can not
be solved after every chart was traced, troubles may
occur in the 4WD control unit. In this case, replace the
4WD control unit and trace every chart again.
Fault on switching from 2WD to 4WD
1. In case that 4WD indicators blinking changes
from 2Hz to 4Hz after Solution 1 is carried out.
Faults occur in the motor actuator or the transfer case
assembly. Remove the motor actuator and check
function. If problem was found and it was repaired, try
Solution 1 again. After that, disassemble the
transfer case assembly for check and repair or
replace. If incident is not improved after above
mentioned actions were taken, replace the 4WD
control unit.
2. In case that 4WD indicator does not blink nor
light, when switching from 2WD to 4WD.
Action
Step
1
Yes
No
Go to Step 2
Turn on the
ignition and trace
this chart from
start.
Go to Step 3
Burning out of
indicator lamp or
disconnection of
harness wire.
Trace this chart
from the start
after repair or
replace.
Short-circuit
(body short) on
harness of the
4WD switch.
Fault of the 4WD
switch (holding
the closed
condition).
Trace this chart
from the start
after repair or
replace.
Push the 4WD
switch to 4WD.
Is ignition turned on?
2
Does the indicator light comes on when the engine is not started?
Start the engine.
Is the 4WD switch turned from 2WD to 4WD?
4B126 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
3. Case that the indicator keeps blinking by 2Hz
after aforementioned Solution 2 is carried out.
Action
Step
1
Check the air pressure and wear of all tires.
Were problems found?
Yes
No
Try Solution 2
after adjust the
air pressure and
replace worn
tires.
Go to Step 2
Go to Step 3
Disconnection of
the motor
actuator harness
wiring. Trace this
chart from the
start after repair
or replace.
Faults on the
motor actuator.
Trace this chart
from the start
after replace.
Internal faults of
transfer case.
Disassemble the
transfer case for
check. Trace this
chart from the
start after repair
or replace.
Go to Step 4
Faults on the
transfer position
switch or its
harness. Trace
this chart from
the start after
repair or replace.
Faults on the
VSV main body,
its harness or
vacuuming
system. Trace
the front axle
diagnosis chart in
this section.
After that, trace
this chart from
the start.
Internal faults on
axle switch.
Trace this chart
from the start
after replace.
Disconnection on
the axle harness.
Trace this chart
from the start
after repair or
replace.
Faults on Front
Axle ASM. Trace
the front axle
diagnosis chart in
this section.
After that, trace
this chart from
the start.
2
Can the transfer lever be operated from High to 4L or vice versa?
Pull out the hoses from vacuum actuator and operate 4WD
switch.
Is there negative pressure on either of hoses?
Check the axle switch.
Were problems found?
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B127
Fault on switching from 4WD to 2WD
1. Case that indicator does not blink nor turn out.
Step
Action
Yes
No
Go to Step 2
Short circuit of
the indicator
harness.
Disconnection on
the 4WD switch
harness or
breakdown of the
4WD switch in
open state.
Trace this chart
from the start
after repair or
replace.
Turn the 4WD
switch to 2WD
position. Trace
this chart from
the start.
1
Does the indicator turn out by ignition off?
2
Is the 4WD switch on 2WD position?
4B128 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
2. Case that indicator keeps 2Hz blinking after
aforementioned Solution 3 is carried out.
Action
Step
1
Check the air pressure and wear of all tires.
Were problems found?
2
Can the transfer lever be operated from High to 4L or vice versa?
Yes
No
Try Solution 3
after adjust the
air pressure and
replace worn
tires.
Go to Step 2
Faults on the
harness wiring of
motor actuator.
Trace this chart
from the start
after repair or
replace.
Internal faults on
transfer case.
Disassemble the
transfer case for
check. Trace this
chart from the
start after repair
or replace.
Faults on the
motor actuator.
Trace this chart
from the start
after or replace.
Go to Step 3
Go to Step 4
Faults on the
transfer position
switch or its
harness. Trace
this chart from
the start after
repair or replace.
Faults on the
VSV main body,
its harness or
vacuuming
system. Trace
the front axle
diagnosis chart in
this section.
After that, trace
this chart from
the start.
Internal faults on
axle switch.
Trace this chart
from the start
after replace.
Faults on Front
Axle ASM. Trace
the front axle
diagnosis chart in
this section.
After that, trace
this chart from
the start.
Short circuit
(body short) or
disconnection of
the axle harness.
Trace this chart
from the start
after repair or
replace.
Pull out the hoses from vacuum actuator and operate 4WD
switch.
Is there negative pressure on either of hoses?
Check the axle switch.
Were problems found?
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B129
3. Case that indicators blinking changes to 4Hz
after aforementioned Solution 4 is carried out.
Step
Action
1
Can the transfer lever be operated from High to 4L or vice versa?
Yes
No
Faults on the
harness wiring of
motor actuator.
Trace this chart
from the start
after repair or
replace.
Faults on the
motor actuator.
Trace this chart
from the start
after replace.
Internal faults on
transfer case.
Disassemble the
transfer case for
check. Trace this
chart from the
start after repair
or replace.
Faults on the
4WD control unit.
Trace this chart
from the start
after replace.
4B130 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Front Axle Diagnosis
D When the 4WD switch is operated from 4H to 2H,
indicator light does not go out.
Step
1
Action
1. Check the VSV valve.
2. Check the circuit to VSV valve.
Was a problem found?
Go to Step 2
Go to Step 4
Go to Step 3
Trace this chart
from the start
after repair or
replace.
Disassemble axle
ASM for check.
Trace this chart
from the start
after repair or
replace.
Trace this chart
from the start
after repair or
replace.
Go to Step 5
Go to Step 6
Trace this chart
from the start
after repair or
replace.
Trace this chart
from the start.
Disassemble axle
ASM for check.
Trace this chart
from the start
after repair or
replace.
1. Check the actuator switch.
2. Check the circuit to indicator.
Was a problem found?
All right.
Jack up front tires.
Does the right side of front wheel rotate when the left side of front
wheel is rotated?
No
Drive slow 100 200m after a few minutes idling.
Has indicator light gone out?
Yes
Is vacuum piping all right? (tank, hose, & pipe damage or trouble)
Does actuator work all right?
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B131
D When the 4WD switch is operated from 2H to 4H,
indicator light is not actuated.
Action
Step
1
1. Check the VSV valve.
2. Check the circuit to VSV valve.
Was a problem found?
Go to Step 2
Go to Step 4
Go to Step 3
Trace this chart
from the start
after repair or
replace.
Disassemble axle
ASM for check.
Trace this chart
from the start
after repair or
replace.
Trace this chart
from the start
after repair or
replace.
Go to Step 5
Go to Step 6
Trace this chart
from the start
after repair or
replace.
Trace this chart
from the start.
Disassemble axle
ASM for check.
Trace this chart
from the start
after repair or
replace.
1. Check the actuator switch.
2. Check the circuit to indicator.
Was a problem found?
All right.
Jack up front tires.
Does not the right side of front wheel rotate when the left side of
front wheel is rotated?
No
Drive slow 100 200m after a few minutes idling.
Has indicator light actuated?
Yes
Is vacuum piping all right? (tank, hose, & pipe damage or trouble)
Does actuator work all right?
4B132 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Shift on the Fly Vacuum Piping and Electric Equipment
(For Push Button Type)
Vacuum Piping Diagram
C04RW013
VSV Assembly, Actuator Assembly
412RS032
Vacuum Tank
412RS033
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B133
Inspection and Repair
Vacuum Piping
C04RW014
1. Pull out the Hose A in figure and install a vacuum
gauge.
2. Plug up Hose B in figure to prevent the leak of
vacuum.
3. Start the engine and measure vacuum 2 or 3 minutes
afterward.
4. Repeat 1) and 2) but with Hose A plugged and Hose B
pulled out.
5. If vacuum measures 400mmHg, or if it shows a
sudden drop immediately after engine stop, inspect
the hose, tank, and pipe for damage.
Check Valve
NOTE: Be careful not to permit the entry of dust and
water during inspection.
6. Pull out Hose D in above illustration.
7. Plug Hose E in above illustration.
8. Make sure that Hose D in above illustration is under
atmospheric pressure.
9. Pull out Hose E and plug Hose D, and make sure that
Hose E is under atmospheric pressure.
10. If Check 8) or 9) has revealed stoppage, check and
see that there is no bend, foreign matter in the hose or
in the filter. If there is trouble, repair or replace.
C04RS004
1. Apply vacuum from the orange colored side(1).
Vacuum:400mmHg
2. Check leakage of vacuum.
3. Make sure that vacuum cannot be applied from the
black colored side(2).
4B134 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
4. If vacuum is not applicable as much as 400mmHg,
and if there is resistance on the intake side, replace
with a new check valve.
1. With battery not connected (Usual).
AC:There is continuity
B:Closed
VSV Assembly
2. With battery connected
Inspect the vehicle side harness as follows:
A B:There is continuity
C:Closed
3. If 1) and 2) fail, replace with a new VSV.
Axle Position Switch
412RS071
Legend
(1) Grey
(2) Blue
412RS048
1. Remove connector.
2. Shift transfer lever to 2H and start the engine.
1. With ball (1) being free
A B:There is continuity
NOTE: Do not move the vehicle while inspection.
2. With ball forced into the switch
3. Make sure that there is continuity in the vehicle side of
harness. If there is no continuity, check transfer shift
switch and wiring.
Inspect both VSVs as follows:
A B:No continuity
3. If 1) and 2) fail, replace with a new switch.
Motor Actuator Assembly
Inspect the function of the motor actuator assembly as
follows:
F04RS004
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B135
1. Disassemble the motor actuator from transfer rear
case.
Shift rod of the motor actuator moves and stops
at 2WD position.
412RW037
Legend
(3) Shift Rod
(4) Connector
412RW039
Legend
(1) 2WD
(2) 4WD
(3) Shift Rod
(4) Connector
2. Connect the terminals as shown in figure.
Shift rod of the motor actuator moves and stops
at 4WD position.
4. If 2) and 3) fail, replace with a new motor actuator.
Transfer Position Switch
412RW038
Legend
(1) 2WD
(2) 4WD
(3) Shift Rod
(4) Connector
412RW040
Legend
(1) Ball
1. With ball being free.
3. Connect the terminals as shown in figure.
AB : There is continuity.
2. With ball forced into the switch.
AB : No continuity.
3. If 1) and 2) fail, replace with a new switch.
4B136 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
4WD Control Unit (For Push Button Type)
4WD Control Unit Associated Parts
412RW044
Legend
(1) Lower Cluster Assembly
(2) Front Console Assembly
(3) Harness Connector
(4) Nut
(5) 4WD Control Unit
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B137
Removal
1. Remove lower cluster assembly and front console
assembly.
Refer to Interior Trim in Body and Accessories
section.
2. Remove nut.
3. Remove 4WD control unit.
4. Disconnect harness connector (1).
412RW045
Legend
(1) Harness Connector
Installation
1. Connect harness connector, then install 4WD control
unit.
2. Install lower cluster assembly and front console
assembly.
4B138 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
MEMO
