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DAIHATSU
J100
TO INDEX
TRANSFER
DESCRIPTION ............................................. TR– 2
CENTER DIFFERENTIAL SYSTEM
......... TR– 2
OPERATION OF CENTER
DIFFERENTIAL LOCK SYSTEM
......... TR– 2
IN-VEHICLE INSPECTION .......................... TR– 4
COMPONENTS ........................................... TR– 5
REMOVAL .................................................... TR– 5
DISASSEMBLY ............................................ TR– 8
INSPECTION ............................................... TR–10
ASSEMBLY .................................................. TR–15
INSTALLATION ........................................... TR–17
SSTs ............................................................ TR–20
TIGHTENING TORQUE ............................... TR–20
JTR00001-00000
TR
NO. 9710-JE
TR–2
DESCRIPTION
A driving system equipped with a center differential is em-
ployed.
Transmission
Engine
Transfer
Center differential
Rear differential
Front differential
JTR00002-00101
CENTER DIFFERENTIAL SYSTEM
The input power from the transmission of the driving system is
always distributed to the front and rear wheels. The transfer
system employs a negative pressure-driving actuator type,
with a center differential lock mechanism.
The negative pressure which has been taken from the intake
manifold is transmitted to a diaphragm type actuator provided
inside the transfer case.
JTR00003-00102
The negative pressure is controlled by two VSV’s. For im-
proved response of the actuator, these VSV’s have been in-
stalled in the engine compartment.
JTR00004-00103
OPERATION OF CENTER DIFFERENTIAL LOCK SYSTEM
Differential lock switch
VSV2 (green)
Check valve
Indicator lamp
Chamber A
Chamber B
VSV1 (blue)
To intake
manifold
Lock
Free
Actuator for transfer
IG S/W
Differential case
Differential
clutch hub
JTR00005-00110
TR–3
1. When center differential lock switch is turned off.
(1) The VSV1 and VSV2 become unenergized. Thus, the
VSV1 is connected to the air filter side. As a result, the
transfer actuator chamber B becomes equal to the at-
mospheric pressure.
To intake
manifold
VSV2 Check
(green) valve
Differential
lock switch
Chamber B
Free
VSV1
(blue)
Chamber A
JTR00006-00111
(2) On the other hand, the intake manifold negative pres-
sure is transmitted to the check valve, VSV2, and then,
transfer actuator chamber A. Consequently, the differ-
ential clutch hub assembly of the transfer moves back-
ward. In this way, the center differential is switched to
a free state.
To intake
manifold
VSV2 Check
(green) valve
Differential
lock switch
Chamber B
Free
VSV1
(blue)
Chamber A
JTR00007-00112
2. When center differential lock switch is turned on.
(1) A electric current flows into the VSV1 and VSV2. Thus,
the intake manifold negative pressure is transmitted to
the check valve, VSV1, and then, transfer actuator
chamber B.
To intake
manifold
VSV2 Check
(green) valve
Differential
lock switch
Chamber B
Lock
VSV1
(blue)
Chamber A
JTR00008-00113
(2) On the other hand, the VSV2 is connected to the air fil-
ter. As a result, the transfer actuator chamber A be-
comes equal to the atmospheric pressure.
Consequently, the differential clutch hub assembly of
the transfer moves forward, thus engaging with the dif-
ferential case subassembly. In this way, the center dif-
ferential becomes in a locked state.
To intake
manifold
Check
VSV2
(green) valve
Differential
lock switch
Chamber B
Lock
VSV1
(blue)
Chamber A
JTR00009-00114
TR–4
IN-VEHICLE INSPECTION
1. Turn the ignition switch to the “ON” position.
2. Check to see if the indicator will illuminate when the differ-
ential lock switch is turned on.
NOTE:
•
If not, check the indicator valve.
3. Turns off the differential lock switch.
JTR00010-00201
4. Disconnect the pipe A. Then, Connect a MityVac to the
pipe A.
5. Start the engine.
6. Check to see if the MityVac indicates a negative pressure
while keeping the engine revolution speed at idling.
Pipe A
JTR00011-00202
7. Connect the MityVac to the diaphragm with a suitable
pipe.
8. Set the MityVac to –200 mmHg manually.
9. Hold the negative pressure of the MityVac at –200 mmHg
for about 10 seconds.
NOTE:
•
If the diaphragm exhibits damage, deterioration and so
forth, the negative pressure will rapidly return to posi-
tive pressure.
JTR00012-00203
10.
11.
12.
13.
Disconnect the pipe B.
Connect the MityVac to the pipe B.
Start the engine. Turns on the differential lock switch.
Check to see if the MityVac indicates a negative pressure
while keeping the engine revolution speed at idling.
Pipe A
Pipe B
JTR00013-00204
14. Connect the MityVac to the diaphragm with a suitable
pipe.
15. Set the MityVac to –200 mmHg manually.
16. Hold the negative pressure of the MityVac at –200 mmHg
for about 10 seconds.
NOTE:
•
If the diaphragm exhibits damage, deterioration and so
forth, the negative pressure will rapidly return to posi-
tive pressure.
JTR00014-00205
TR–5
COMPONENTS
Transfer oil
supply right pipe
Transfer No. 2
oil plate
Transfer oil
supply left pipe
B
K type
T type
oil seal5
oil seal5
Hanger
T type oil seal5
Diaphragm cylinder cover
B
B
Filler plug
Tube
Transfer shift shaft
sub-assembly
E ring Slotted
pin5
O ring5
Front drive
shift link lever Slotted
Drain plug sub-assembly pin5
5
E ring5
Ball
Transfer fork
Compression
Hale snap
shaft
spring
B
ring
Transfer gear
Transfer rear case
Transfer oil plate
shift head
Shaft snap
Transfer diff. rock
ring
shift fork
Transfer control
Transfer case
Compression
shaft washer
spring
Needle roller
Differential case
Differential pinion
bearing
sub-assembly
Transfer
thrust washer
clutch hub
Differential
T type oil seal5
pinion
Radial ball
Transfer output
bearing
rear shaft
Speedometer
Transfer front drive
Shaft snap
drive gear
gear bearing
ring5
inner race
Lock nut5
Bearing
Needle roller
B
Differential
Radial ball
bearing
side gear
bearing
Differential
pinion shaft
Differential No. 2 case
Transfer output
Differential
Transfer front
sub-assembly
front shaft
side gear
drive gear
Differential
Transfer front
Radial ball
side gear thrust washer
drive chain
: Non-reusable parts
bearing
Oil seal5
B
Gasket
JTR00015-00301
REMOVAL
1. Remove the transmission & transfer assembly from the ve-
hicle. Refer to MT and AT section of the service manual.
2. Remove the transfer from the transmission by removing
the attaching bolts.
NOTE:
•
Never reuse the removed gasket.
JTR00016-00401
3. Drive off the slotted pin of the transfer fork shaft.
JTR00017-00402

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