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 clutch hub and clutch sleeve for wear and damage. If necessary, replace them.
b. Check that clutch sleeve slides smoothly on the clutch hub.





2. MEASURE SLEEVE FORK AND CLUTCH SLEEVE CLEARANCE
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 the port A. Also check that the vacuum remains constant.
If it does 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 it does not, replace the actuator.
4. INSPECT A.D.D. SOLENOIDS





a. Using an ohmmeter, measure the resistance of the solenoids.
Resistance: 37-44 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 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 continuity exists between terminals 1 and 3.
b. Using an ohmmeter, check that continuity exists between terminals 2 and 4.
c. Connect the positive (+) lead from the battery to terminal 4 and negative (-) lead from the battery to terminal 2.
d. Using an ohmmeter, check that continuity exists between terminals 3 and 5.





6. INSPECT A.D.D. SWITCH
a. Using an ohmmeter, check that continuity exists between terminals when the switch is pushed (differential connected position).
b. Using an ohmmeter, check that continuity does not exist when the switch is free (differential disconnected position).
7. INSPECT TRANSFER 4WD POSITION SWITCH