TRANSFER SYSTEM INSPECTION

PROCEDURE

1. INSPECT INDICATOR LIGHT

   
   

   1. 4LO Indicator Light:

      
      

      1. Turn the ignition switch to ON.

      2. Move the shift lever to N (vehicle is stopped).

      3. for 1GR-FE, 1KD-FTV, 1GD-FTV:

         Change the transfer position switch from H4 to L4.

      4. for 2TR-FE, 5L-E:

         Change the transfer position switch from H4L to L4L.

      5. Check the 4LO indicator light.

         OK
         4LO indicator light comes on or 4LO indicator light comes on after blinking.

         If the result is not as specified, inspect the switch, 4 wheel drive control ECU and transfer shift actuator assembly.

         If the system is normal, there may be a malfunction in the CAN communication system or combination meter. In this case, first check the CAN communication system (See page ). Then check the combination meter Click here.

   2. Center Differential Lock Indicator Light:

      
      

      1. Turn the ignition switch to ON.

      2. for 1GR-FE, 1KD-FTV, 1GD-FTV:

         Change the center differential lock switch from Free to Lock.

      3. for 2TR-FE, 5L-E:

         Change the transfer position switch from H4F to H4L.

      4. Check the center differential lock indicator light.

         OK
         Center differential lock indicator light comes on

         If the result is not as specified, inspect the switches, 4 wheel drive control ECU, transfer and shift actuator.

         If the system is normal, there may be a malfunction in the CAN communication system or combination meter. In this case, first check the CAN communication system (See page ). Then check the combination meter Click here.

2. INSPECT 4 WHEEL DRIVE CONTROL ECU (POWER SUPPLY)

   
   
   1. 

      Text in Illustration

      *a	Component with harness connected (4 wheel drive control ECU)

      Measure the voltage according to the value(s) in the table below.

      Standard Voltage
      Tester Connection Switch Condition Specified Condition G54-3 (IG) - Body ground Ignition switch ON 11 to 14 V

      If the result is not as specified, inspect the harness, fuse or connector. If the harness or connector is malfunctioning, repair or replace the harness or connector. If the harness or connector is normal, replace the 4 wheel drive control ECU Click here.

   2. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition G54-4 (GND) - Body ground Always Below 1 Ω

      If the result is not as specified, repair or replace the harness or connector.

3. INSPECT 4 WHEEL DRIVE CONTROL ECU (TRANSFER POSITION SWITCH)

   
   
   1. 

      Text in Illustration

      *A	for 2TR-FE, 5L-E
      *a	Component with harness connected (4 wheel drive control ECU)

      Measure the voltage according to the value(s) in the table below.

      Standard Voltage
      for 1GR-FE, 1KD-FTV, 1GD-FTV
      Tester Connection Switch Condition Specified Condition G53-13 (LO) - Body ground Ignition switch ON Transfer position switch H4 10.5 to 14 V Ignition switch ON Transfer position switch L4 Below 1.5 V
      for 2TR-FE, 5L-E
      Tester Connection Switch Condition Specified Condition G53-11 (2-4) - Body ground Ignition switch ON Transfer position switch H4F Below 1.5 V Ignition switch ON Transfer position switch H4L Below 1.5 V Ignition switch ON Transfer position switch L4L 10.5 to 14 V G53-13 (LO) - Body ground Ignition switch ON Transfer position switch H4F 10.5 to 14 V Ignition switch ON Transfer position switch H4L Below 1.5 V Ignition switch ON Transfer position switch L4L Below 1.5 V

      If the result is not as specified, check the power supply.

      If the power supply is normal, inspect the transfer position switch Click here.

4. INSPECT 4 WHEEL DRIVE CONTROL ECU (CENTER DIFFERENTIAL LOCK SWITCH) (for 1GR-FE, 1KD-FTV, 1GD-FTV)

   
   
   1. 

      Text in Illustration

      *a	Component with harness connected (4 wheel drive control ECU)

      Measure the voltage according to the value(s) in the table below.

      Standard Voltage
      Tester Connection Switch Condition Specified Condition G53-16 (DL) - Body ground Ignition switch ON Center differential lock switch ON Below 1.5 V Ignition switch ON Center differential lock switch OFF 9.5 to 14 V

      If the result is not as specified, check the power supply.

      If the power supply is normal, inspect the center differential lock switch Click here.

5. INSPECT MULTI MODE TRANSFER SHIFT ACTUATOR

   
   

   1. Check the harness and connector between 4 wheel drive control ECU and transfer shift actuator assembly (multi mode transfer shift actuator).

      
      

      1. Disconnect the C43 actuator connector.

      2. Disconnect the G53 and G54 ECU connectors.

      3. Measure the resistance according to the value(s) in the table below.

         

         Standard Resistance

         Tester Connection Condition Specified Condition G53-7 (TL2) - C43-4 (TL2) Always Below 1 Ω G53-7 (TL2) - Body ground Always 10 kΩ or higher G53-8 (TL3) - C43-5 (TL3) Always Below 1 Ω G53-8 (TL3) - Body ground Always 10 kΩ or higher G53-14 (P1) - C43-9 (CDL) Always Below 1 Ω G53-14 (P1) - Body ground Always 10 kΩ or higher G54-7 (TM2) - C43-1 (TM2) Always Below 1 Ω G54-7 (TM2) - Body ground Always 10 kΩ or higher G54-8 (TM1) - C43-2 (TM1) Always Below 1 Ω G54-8 (TM1) - Body ground Always 10 kΩ or higher C43-6 (GND1) - Body ground Always Below 1 Ω C43-10 (GND) - Body ground Always Below 1 Ω

         Text in Illustration

         *a

         Front view of wire harness connector (to 4 wheel drive control ECU)

         *b

         Front view of wire harness connector (to Transfer Shift Actuator Assembly)

         If the result is not as specified, repair or replace the harness or connector.

         If the harness or connector is normal, check the ECU output voltage.

   2. Check the 4 wheel drive control ECU (multi mode transfer shift actuator circuit).

      
      

      1. Connect the G53 and G54 ECU connectors.

      2. Connect the C43 actuator connector.

      3. 

         Text in Illustration

         *a	Component with harness connected (4 wheel drive control ECU)

         Measure the voltage according to the value(s) in the table below.

         Standard Voltage
         for 1GR-FE, 1KD-FTV, 1GD-FTV
         Tester Connection Switch Condition Specified Condition G54-8 (TM1) - G54-4 (GND) Ignition switch ON Center differential lock switch FREE → LOCK (During operation of multi mode transfer shift actuator motor from FREE to LOCK) 10 to 14 V Ignition switch ON Center differential lock switch FREE → LOCK (Multi mode transfer shift actuator motor stopped) Below 1.5 V G54-7 (TM2) - G54-4 (GND) Ignition switch ON Center differential lock switch LOCK → FREE (During operation of multi mode transfer shift actuator motor from LOCK to FREE) 10 to 14 V Ignition switch ON Center differential lock switch LOCK → FREE (Multi mode transfer shift actuator motor stopped) Below 1.5 V G53-7 (TL2) - G54-4 (GND) Ignition switch ON Center differential lock switch LOCK Below 1.5 V Ignition switch ON Center differential lock switch FREE 10.5 to 14 V G53-8 (TL3) - G54-4 (GND) Ignition switch ON Center differential lock switch LOCK 10.5 to 14 V Ignition switch ON Center differential lock switch FREE Below 1.5 V G53-14 (P1) - G54-4 (GND) Ignition switch ON Center differential lock switch FREE 9.5 to 14 V Ignition switch ON Center differential lock switch LOCK Below 1.5 V
         for 2TR-FE, 5L-E
         Tester Connection Switch Condition Specified Condition G54-8 (TM1) - G54-4 (GND) Ignition switch ON Transfer position switch H4F → H4L (During operation of multi mode transfer shift actuator motor from FREE to LOCK) 10 to 14 V Ignition switch ON Transfer position switch H4F → H4L (Multi mode transfer shift actuator motor stopped) Below 1.5 V G54-7 (TM2) - G54-4 (GND) Ignition switch ON Transfer position switch H4L → H4F (During operation of multi mode transfer shift actuator motor from LOCK to FREE) 10 to 14 V Ignition switch ON Transfer position switch H4L → H4F (Multi mode transfer shift actuator motor stopped) Below 1.5 V G53-7 (TL2) - G54-4 (GND) Ignition switch ON Transfer position switch H4L or L4L Below 1.5 V Ignition switch ON Transfer position switch H4F 10.5 to 14 V G53-8 (TL3) - G54-4 (GND) Ignition switch ON Transfer position switch H4L or L4L 10.5 to 14 V Ignition switch ON Transfer position switch H4F Below 1.5 V G53-14 (P1) - G54-4 (GND) Ignition switch ON Transfer position switch H4F 9.5 to 14 V Ignition switch ON Transfer position switch H4L or L4L Below 1.5 V

         If the result is not as specified, determine if a malfunction is on the ECU side or actuator side by disconnecting the connector of the transfer shift actuator, and then check the ECU output voltage.

   3. Check the 4 wheel drive control ECU output voltage.

      
      

      1. Disconnect the C43 actuator connector.

      2. Connect the G53 and G54 ECU connectors.

      3. 

         Text in Illustration

         *a	Front view of wire harness connector (to Transfer Shift Actuator Assembly)

         Measure the voltage according to the value(s) in the table below.

         Standard Voltage
         Tester Connection Switch Condition Specified Condition C43-9 (CDL) - C43-6 (GND1) Ignition switch ON 9.5 to 14 V C43-4 (TL2) - C43-6 (GND1) Ignition switch ON 10.5 to 14 V C43-5 (TL3) - C43-6 (GND1) Ignition switch ON 10.5 to 14 V

         If the result is not as specified, replace the 4 wheel drive control ECU Click here.

         If the voltage is normal, inspect the multi mode transfer shift actuator, because the voltage applied to the motor cannot be measured.

   4. Inspect the multi mode transfer shift actuator (transfer shift actuator assembly).

      
      

      1. Remove the transfer shift actuator assembly Click here.

      2. Check the LOCK to FREE switch.

         Connect lines via a relay as shown in the illustration, then check that the actuator fork moves from the LOCK to FREE position.

         Note

         
         

         • 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, 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.

         Tech Tips

         When performing the operation described above, use the DEF relay on the main body ECU (instrument panel junction block).

         

         
         

         1. After the LOCK to FREE switch is complete, inspect the center differential lock detection switch and limit switch.

            Standard Resistance
            Tester Connection Condition Specified Condition 4 (TL2) - 6 (GND1) After LOCK to FREE switch is complete 0.5 MΩ or higher 5 (TL3) - 6 (GND1) After LOCK to FREE switch is complete Below 12.5 Ω 9 (CDL) - 10 (GND) After LOCK to FREE switch is complete 0.5 MΩ or higher

            Text in Illustration

            *1	DEF Relay	-	-
            *a	Component without harness connected (Transfer Shift Actuator Assembly)	*b	LOCK to FREE

      3. Check the FREE to LOCK switch.

         Connect lines via a relay as shown in the illustration, then check that the actuator fork moves from the FREE to LOCK position.

         

         
         

         1. After the FREE to LOCK switch is complete, inspect the center differential lock detection switch and limit switch.

            Standard Resistance
            Tester Connection Condition Specified Condition 4 (TL2) - 6 (GND1) After FREE to LOCK switch is complete Below 12.5 Ω 5 (TL3) - 6 (GND1) After FREE to LOCK switch is complete 0.5 MΩ or higher 9 (CDL) - 10 (GND) After FREE to LOCK switch is complete Below 12.5 Ω

            Text in Illustration

            *1	DEF Relay	-	-
            *a	Component without harness connected (Transfer Shift Actuator Assembly)	*b	FREE to LOCK

            If the result is not as specified, replace the transfer shift actuator assembly (See page ). If the transfer shift actuator assembly is normal, replace the 4 wheel drive control ECU Click here.

6. INSPECT HIGH-LOW TRANSFER SHIFT ACTUATOR

   
   

   1. Check the harness and connector between 4 wheel drive control ECU and transfer shift actuator (high-low transfer shift actuator).

      
      

      1. Disconnect the C43 actuator connector.

      2. Disconnect the G53 and G54 ECU connector.

      3. Measure the resistance according to the value(s) in the table below.

         

         Standard Resistance

         Tester Connection Condition Specified Condition G53-1 (HL1) - C43-12 (HL1) Always Below 1 Ω G53-1 (HL1) - Body ground Always 10 kΩ or higher G53-2 (HL2) - C43-11 (HL2) Always Below 1 Ω G53-2 (HL2) - Body ground Always 10 kΩ or higher G54-2 (HM1) - C43-8 (HM1) Always Below 1 Ω G54-2 (HM1) - Body ground Always 10 kΩ or higher G54-6 (HM2) - C43-7 (HM2) Always Below 1 Ω G54-6 (HM2) - Body ground Always 10 kΩ or higher C43-10 (GND) - Body ground Always Below 1 Ω

         Text in Illustration

         *a

         Front view of wire harness connector (to 4 wheel drive control ECU)

         *b

         Front view of wire harness connector (to Transfer Shift Actuator Assembly)

         If the result is not as specified, repair or replace the harness or connector.

         If the harness or connector is normal, check the ECU output voltage.

   2. Check the 4 wheel drive control ECU (high-low transfer shift actuator circuit).

      
      

      1. Connect the G53 and G54 ECU connectors.

      2. Connect the C43 actuator connector.

      3. 

         Text in Illustration

         *a	Component with harness connected (4 wheel drive control ECU)

         Measure the voltage according to the value(s) in the table below.

         Standard Voltage
         for 1GR-FE, 1KD-FTV, 1GD-FTV
         Tester Connection Switch Condition Specified Condition G54-6 (HM2) - G54-4 (GND) Ignition switch ON Transfer position switch L4 → H4 (During operation of high-low transfer shift actuator motor from LOW to HIGH) 10 to 14 V Ignition switch ON Transfer position switch L4 → H4 (High-low transfer shift actuator motor stopped) Below 1.5 V G54-2 (HM1) - G54-4 (GND) Ignition switch ON Transfer position switch H4 → L4 (During operation of high-low transfer shift actuator motor from HIGH to LOW) 10 to 14 V Ignition switch ON Transfer position switch H4 → L4 (High-low transfer shift actuator motor stopped) Below 1.5 V G53-1 (HL1) - G54-4 (GND) Ignition switch ON Transfer position switch H4 10.5 to 14 V Ignition switch ON Transfer position switch L4 Below 1.5 V G53-2 (HL2) - G54-4 (GND) Ignition switch ON Transfer position switch H4 Below 1.5 V Ignition switch ON Transfer position switch L4 10.5 to 14 V
         for 2TR-FE, 5L-E
         Tester Connection Switch Condition Specified Condition G54-6 (HM2) - G54-4 (GND) Ignition switch ON Transfer position switch L4L → H4L (During operation of high-low transfer shift actuator motor from LOW to HIGH) 10 to 14 V Ignition switch ON Transfer position switch L4L → H4L (High-low transfer shift actuator motor stopped) Below 1.5 V G54-2 (HM1) - G54-4 (GND) Ignition switch ON Transfer position switch H4L → L4L (During operation of high-low transfer shift actuator motor from HIGH to LOW) 10 to 14 V Ignition switch ON Transfer position switch H4L → L4L (High-low transfer shift actuator motor stopped) Below 1.5 V G53-1 (HL1) - G54-4 (GND) Ignition switch ON Transfer position switch H4F or H4L 10.5 to 14 V Ignition switch ON Transfer position switch L4L Below 1.5 V G53-2 (HL2) - G54-4 (GND) Ignition switch ON Transfer position switch H4F or H4L Below 1.5 V Ignition switch ON Transfer position switch L4L 10.5 to 14 V

         If the result is not as specified, determine if the malfunction is on the ECU side or actuator side by disconnecting the connector of the transfer shift actuator, and then check the ECU output voltage.

   3. Check the 4 wheel drive control ECU output voltage.

      
      

      1. Connect the G53 and G54 ECU connectors.

      2. Disconnect the C43 actuator connector.

      3. 

         Text in Illustration

         *a	Front view of wire harness connector (to Transfer Shift Actuator Assembly)

         Measure the voltage according to the value(s) in the table below.

         Standard Voltage
         Tester Connection Switch Condition Specified Condition C43-11 (HL2) - C43-10 (GND) Ignition switch ON 10.5 to 14 V C43-12 (HL1) - C43-10 (GND) Ignition switch ON 10.5 to 14 V

         If the result is not as specified, replace the 4 wheel drive control ECU Click here.

         If the voltage is normal, inspect the high-low transfer shift actuator, because the voltage applied to the motor cannot be measured.

   4. Inspect the high-low transfer shift actuator (transfer shift actuator assembly).

      
      

      1. Remove the transfer shift actuator assembly Click here.

      2. Check the HIGH to LOW switch.

         Connect lines via a relay as shown in the illustration, then check that the actuator fork moves from the HIGH to LOW position.

         Note

         
         

         • 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, 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.

         Tech Tips

         When performing the operation described above, use the DEF relay on the main body ECU (instrument panel junction block).

         

         
         

         1. After the HIGH to LOW switch is complete, inspect the limit switch.

            Standard Resistance
            Tester Connection Condition Specified Condition 12 (HL1) - 10 (GND) After HIGH to LOW switch is complete Below 12.5 Ω 11 (HL2) - 10 (GND) After HIGH to LOW switch is complete 0.5 MΩ or higher

            Text in Illustration

            *1	DEF Relay	-	-
            *a	Component without harness connected (Transfer Shift Actuator Assembly)	*b	HIGH to LOW

      3. Check the LOW to HIGH switch.

         Connect lines via a relay as shown in the illustration, then check that the actuator fork moves from the LOW to HIGH position.

         

         
         

         1. After the LOW to HIGH switch is complete, inspect the limit switch.

            Standard Resistance
            Tester Connection Condition Specified Condition 12 (HL1) - 10 (GND) After LOW to HIGH switch is complete 0.5 MΩ or higher 11 (HL2) - 10 (GND) After LOW to HIGH switch is complete Below 12.5 Ω

            Text in Illustration

            *1	DEF Relay	-	-
            *a	Component without harness connected (Transfer Shift Actuator Assembly)	*b	LOW to HIGH

            If the result is not as specified, replace the transfer shift actuator assembly (See page ). If the transfer shift actuator assembly is normal, replace the 4 wheel drive control ECU Click here.