Differential Assembly: Testing and Inspection

INSPECTION

HINT: First judge that the malfunction is found in A.D.D. control system or in 2 - 4 selector system.





1. INSPECT CLUTCH HUB AND CLUTCH SLEEVE
a. Check the wear and damage of the clutch hub and clutch sleeve.
If necessary, replace them.
b. Check that clutch sleeve slides smoothly on the clutch hub.





2. MEASURE CLEARANCE OF SLEEVE FORK AND CLUTCH SLEEVE
Using a feeler gauge, measure the clearance between the sleeve fork and clutch sleeve.
Maximum clearance: 0.35 mm (0.0138 inch)
If the clearance exceeds the maximum, replace the fork or sleeve
3. INSPECT A.D.D ACTUATOR





a. Check that the sleeve fork moves to the actuator side when a vacuum of 66.7 kPa (500 mm Hg, 19.69 inch Hg) is applied to port A. Also check that the vacuum remains constant.
If is not, replace the actuator.





b. Check that the sleeve fork moves away from the actuator when a vacuum of 66.7 kPa (500 mm Hg, 19.69 inch Hg) is applied to port B. Also check that the vacuum remains constant.
If is not, replace the actuator.
4. INSPECT A.D.D. SOLENOIDS





a. Using an ohmmeter, measure the resistance of the solenoids.
Resistance: 37 - 47 Ohms




b. Connect the battery to the solenoid. Check that air flows from the port E to port F. Check that air does not flow from the port E to the air filter.





c. Disconnect the battery positive voltage from the solenoid. Check that air flows from the port E to the air filter. Check that air does not flow from the port E to port F.





5. INSPECT A.D.D. RELAY
a. Using an ohmmeter, check that there is continuity between terminals 1 and 3.
b. Using an ohmmeter, check that there is continuity between terminals 2 and 4.
c. Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 2.
d. Using an ohmmeter, check that there is continuity between terminals 3 and 5.





6. INSPECT A.D.D. SWITCH
a. Using an ohmmeter, check that there is continuity between terminals when the switch is pushed (differential connected position).
b. Using an ohmmeter, check that there is no continuity when the switch is free (differential disconnected position).
7. INSPECT TRANSFER 4WD SWITCH