SAFARI

TRANSFER CASE

TROUBLE SHOOTING

Malfunctions of transfer case due to system elements are diagnosed by ECU and indication is given by flashing

of both 4H and 4L indicator lights. Refer self diagnosis to identify the cause detected by ECU.

Problem

Possible causes

Remedy

Electric shift problems

Faulty or damaged ECU, speed

Refer to self diagnosis

sensor, clutch or internal wiring

Damaged or worm shift cam,

Overhaul and check for wear

hub, fork and rail shaft

and damage. Replace if

necessary

No front wheel drive

Broken drive chain

Check internal parts and

when shifted to 4H or 4L

replace if necessary

Noise in 4WD operation

Oil level lower than minimum required Drain old oil and replace with

specified oil

Loosened bolts or mounting parts

Re-tighten as specified

Noisy Transfer case bearings

Disassemble bearings and

parts and check for wear or

damage. Replace if necessary

Noisy gears

Check for wear and damage

including speedometer gear

and replace if necessary

Noise in 4 H or 4L

Worn or damaged sprockets

Disassemble and check for or

drive chain

wear and damage. Replace if

necessary

Incorrect tire pressure

Adjust tire pressure

Transfer case oil leakage

Cracked transfer case

Replace the case

Leakage from other parts

Clean case and parts and

check for leakage

Breather clogging

Remove breather with

breather adapter and clean it.

Replace if necessary

Oil level higher than required

Use specified oil. Adjust oil

improper brand of oil being used

level

Loosened sealing bolts

Re-tighten

Improper brand of sealant or

Use specified sealant and

improperly applied sealant

retighten

Worm or damaged oil seal

Replace oil seal