Transfer Case A.D.D. Control System: Inspection

INSPECT A.D.D. ACTUATOR
1. Disconnect the actuator connector.
2. Measure the resistance between the terminals 2 and 6.
  Standard resistance: 0.3 - 100 Ω
3. Measure the resistance between the terminals 2 or 6 and body ground.
  Standard resistance: More than 0.5 MΩ.
  
  If the resistance value is not as specified, replace the actuator assembly.
  
  Fig 1: Identifying Actuator Terminals
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT A.D.D. ACTUATOR OPERATION

Apply battery positive voltage between the terminal 2 or 6, and check the actuator operation by sound, A.D.D. status and continuity between the terminal 3 and 4.

A.D.D. ACTUATOR CHECK

Battery Voltage Applied Terminal	Terminals 3-4	A.D.D. Status
2 (+) - 6 (-)	Continuity	Connected
2 (-) - 6 (+)	No continuity	Disconnected

If the operation is not as specified, replace the actuator assembly.

INSPECT LIMIT SWITCH CONTINUITY

Connect the actuator connector.
Shift the transfer shift lever or switch the transfer operation switch to "H2" position.
Check the A.D.D. actuator operation by sound.
Disconnect the actuator connector.

Check the continuity between each terminal, as shown in the chart.

LIMIT SWITCH CONTINUITY (H2)

Between Terminals	Specified Condition
1 & 3	No continuity
1 & 4	No continuity
3 & 5	Continuity
4 & 5	No continuity

Fig 2: Identifying Transfer Shift Lever/Switch

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Connect the actuator connector.
Shift the transfer shift lever or switch the transfer operation switch to "H4" position.
Check the A.D.D. actuator operation by sound.
Disconnect the actuator connector.

Check the continuity between each terminal, as shown in the chart.

LIMIT SWITCH CONTINUITY (H4)

Bwetween Terminals	Specified Condition
1 & 3	Continuity
1 & 4	No continuity
3 & 5	No continuity
4 & 5	No continuity

Fig 3: Identifying H4 Position Of Transfer Shift Lever/Switch

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Connect the actuator connector.

INSPECT A.D.D. RELAY

Check the continuity between each terminal, as shown in the chart.

A.D.D. RELAY CONTINUITY CHECK

Between Terminals

Specified Condition

1 - 2

Continuity

2 - 4

Continuity

6 - 7

⁽¹⁾

⁽¹⁾	There is a diode between the terminals 6 and 7. If no continuity exists, check that continuity exists when changing the position of (+) probe for the position of negative (-) probe of tester.

Fig 4: Identifying A.D.D. Relay Terminals

Apply battery positive voltage between each terminal and check the continuity between each terminal, as shown in the chart.

TERMINALS CONTINUITY

Battery Voltage To Terminals	Measure Between Terminals	Specified Condition
6 (+) - 5 (-)	1 - 3 1 - 2	Continuity
6 (+) - 5 (-)	1 - 3 1 - 2	No Continuity
7 (+) - 2 (-)	9 - 10	No Continuity
9 (+) - 10 (-)	3-4 2-4	Continuity
9 (+) - 10 (-)	3-4 2-4	No Continuity

If continuity is not as specified, replace the relay.

INSPECT TRANSFER 4WD POSITION SWITCH
VF2A: See INSPECT SWITCH

VF2BM: See INSPECT SWITCH -1
REMOVE A.D.D. ACTUATOR (See DISASSEMBLY )
INSPECT CLUTCH HUB AND CLUTCH SLEEVE
1. Check the clutch hub and clutch sleeve for wear and damage.
  If necessary, replace them.
2. Check that clutch sleeve slides smoothly on the clutch hub.
  
  Fig 5: Checking Clutch Sleeve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 in.)

If the clearance exceeds the maximum, replace the fork or sleeve.

Fig 6: Measuring Clearance Between Sleeve Fork And Clutch Sleeve
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002