Direct Electro-Hydraulic Coupling Repair Procedures

Inspection

All units are filled with lubricating and cooling fluid (ultra-low viscosity ATF) before shipment. Therefore, inspection, filling, and replacement of the coupling fluid is not required (lifetime fluid, no maintenance).

Removal

Coupling Service Precautions: Keep the coupling horizontal. Observe the caution level when handling (A) during coupling service (removal, installation, replacement, etc.).

1. 1
   Remove the bolts securing the 4WD coupling assembly (A-3ea) to the rear propeller shaft (B).

   Tightening torque: 49.0~69 N·m

   

2. 2
   Using a flat-blade tool, separate the propeller shaft from the 4WD coupling.
3. 3
   Disconnect the pressure sensor connector (A) and the oil hydraulic motor connector (B).

   

4. 4
   Loosen the coupling assembly mounting bolts (A-4EA).

   Tightening torque: 58.8~64 N·m

   

5. 5
   Using a flat-blade tool, separate the 4WD coupling assembly from the rear differential housing assembly.

Installation

1. 1
   Install in the reverse order of removal.

   Apply high-pressure molybdenum grease to the splines (A). When installing the coupling, be careful not to damage the oil seal (B).

2. 2
   After replacing the coupling, reset the 4WD ECU coupling learned values using GDS. (Refer to 4WD Control System - "Adjustment")