Transfer Case: Service Precautions

UF1AE TRANSFER: TRANSFER SYSTEM: PRECAUTION

1. The automatic transmission with transfer is composed of highly precision-finished parts. Inspect all parts carefully before reassembly. Even a small nick could cause fluid leakage or affect the performance of the transfer system.

2. All disassembled parts should be washed clean. All fluid passages and holes should be blown through with compressed air.

3. Dry all parts with compressed air only. Never use a shop rag or piece of cloth to dry them.

4. Only recommended automatic transmission fluid or kerosene should be used for cleaning.

5. After cleaning, the parts should be arranged in their correct order for efficient inspection, repairs, and reassembly.

6. All replacement discs for the clutch must be soaked in ATF for at least 15 minutes before reassembly.

7. All seal rings, clutch discs, clutch plates, rotating parts, and sliding surfaces should be coated with ATF prior to reassembly.

8. All rubber O-rings should be replaced.

9. Make sure that the ends of a snap ring are not aligned with one of the cutouts and are installed in the groove correctly.

10. Check bearings for wear or damage. Replace them as necessary.

11. When working with FIPG material, you must observe the following:

Use a razor blade and a gasket scraper to remove all the old packing (FIPG) material from the gasket surface.

Clean all components thoroughly to remove any loose material.

Clean both sealing surfaces with a non-residue solvent.

Reassemble the parts within 5 minutes of applying fresh FIPG material. Otherwise, the packing (FIPG) material must be removed and reapplied.

Do not fill the reservoir with ATF immediately after reassembling the parts. Wait at least 1 hour before adding ATF.

12. When there is a malfunction in the contact point of the terminals or installation problems with parts, removal and installation of the suspected problem parts may return the system to the normal condition either completely or temporarily.

13. In order to determine the malfunctioning area, be sure to check the conditions at the time the malfunction occurred, such as by DTC output and record it before disconnecting each connector or removing and installing parts.

14. Since the Four Wheel Drive Control System (4WD Control System) may be influenced by a malfunction in other systems, be sure to check for DTCs in the other systems.

15. When removing and installing the 4WD control ECU and each sensor, be sure to check that the normal display is output in Test Mode inspection and in DTC output inspection after installing all the parts.

16. The CAN communication system is used for data communication between each of the ECUs and sensors. If there is trouble in the CAN communication line, the DTC of the communication line is output.

17. If the DTC of the CAN communication line is output, repair the malfunction in the communication line and troubleshoot the 4WD Control System.

18. Since the CAN communication line has its own length and route, it cannot be repaired temporarily with the bypass wire, etc.