Transfer TOYOTA SEQUOIA 2001 Service User Guide

PP434±01
± PREPARATIONSUSPENSION AND AXLE
PP±45
103 Author: Date:
2005 SEQUOIA (RM1146U)
SUSPENSION AND AXLE
SST (Special Service Tools)
09023±00101Union Nut Wrench 10mmRear axle
09213±58013Crankshaft Pully Holding ToolRear differential
09223±15020Oil Seal & Bearing ReplacerFront differential
09223±15030Oil Seal & Bearing ReplacerFront axle
09226±10010Crankshaft Front & Rear Bearing
ReplacerFront differential
09240±00020Wire Gauge SetFront drive shaft
09308±00010Oil Seal PullerFront differential
Rear axle
09308±10010Oil Seal PullerFront differential
Rear differential
09309±37010Transmission Bearing ReplacerFront differential
Front suspension
09316±12010Transfer Bearing ReplacerRear differential
09318±12010Transfer Bearing Adjusting Nut
WrenchFront axle (2WD)
09330±00021Companion Flange Holding ToolFront differential
Rear differential

SS0PX±04
SS±26
± SERVICE SPECIFICATIONSTRANSFER
168 Author: Date:
2005 SEQUOIA (RM1146U)
TRANSFER
SERVICE DATA
Transfer assembly
Planetary gear snap ring thickness Mark
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
U
2.10 to 2.15 mm (0.0827 to 0.0846 in.)
2.15 to 2.20 mm (0.0846 to 0.0866 in.)
2.20 to 2.25 mm (0.0866 to 0.0886 in.)
2.25 to 2.30 mm (0.0886 to 0.0906 in.)
2.30 to 2.35 mm (0.0906 to 0.0925 in.)
2.35 to 2.40 mm (0.0925 to 0.0945 in.)
2.40 to 2.45 mm (0.0945 to 0.0965 in.)
2.45 to 2.50 mm (0.0965 to 0.0984 in.)
2.50 to 2.55 mm (0.0984 to 0.1004 in.)
2.55 to 2.60 mm (0.1004 to 0.1024 in.)
2.60 to 2.65 mm (0.1024 to 0.1043 in.)
2.65 to 2.70 mm (0.1043 to 0.1063 in.)
2.70 to 2.75 mm (0.1063 to 0.1083 in.)
2.75 to 2.80 mm (0.1083 to 0.1102 in.)
2.80 to 2.85 mm (0.1102 to 0.1122 in.)
2.85 to 2.90 mm (0.1122 to 0.1142 in.)
2.90 to 2.95 mm (0.1142 to 0.1161 in.)
2.95 to 3.00 mm (0.1161 to 0.1181 in.)
3.00 to 3.05 mm (0.1181 to 0.1201 in.)
Rear output shaft
Drive sprocket thrust clearance Standard
Maximum
Drive sprocket radial clearance Standard
Maximum
Rear output shaft journal outer diameter
Part A Standard
Minimum
Part B Standard
Minimum
Part C Standard
Minimum
Part D Standard
Minimum
No. 1 gear shift fork claw thickness
Front drive clutch sleeve groove distance
No. 1 gear shift fork to front drive sleeve clearance
Standard
Maximum
No. 2 gear shift fork claw thickness
High and low clutch sleeve groove distance
No. 2 gear shift fork to high and low clutch sleeve clearance
Standard
Maximum0.15 to 0.24 mm (0.0059 to 0.0094 in.)
0.24 mm (0.0094 in.)
0.01 to 0.06 mm (0.0004 to 0.0024 in.)
0.06 mm (0.0024 in.)
27.98 to 27.99 mm (1.1016 to 1.1020 in.)
27.98 mm (1.1016 in.)
31.98 to 32.00 mm (1.2591 to 1.2598 in.)
31.98 mm (1.2591 in.)
34.98 to 35.00 mm (1.3772 to 1.3780 in.)
34.98 mm (1.3772 in.)
36.98 to 37.00 mm (1.4559 to 1.4567 in.)
36.98 mm (1.4559 in.)
10 mm (0.3937 in.)
10.5 mm (0.4134 in.)
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
0.84 mm (0.0331 in.)
10 mm (0.3937 in.)
10.5 mm (0.4134 in.)
0.26 to 0.84 mm (0.0102 to 0.0331 in.)
0.84 mm (0.0331 in.)

± SERVICE SPECIFICATIONSTRANSFER
SS±27
169 Author: Date:
2005 SEQUOIA (RM1146U)Input shaft
Input shaft journal outer diameterMaximum
Input shaft bushing diameterMaximum47.59 mm (1.8736 in.)
48.14 mm (1.8953 in.)
Planetary gear
Pinion gear thrust clearance Standard
Maximum
Pinion gear radial clearanceStandard
Maximum
Outer bearing snap ring thickness Mark
1
2
3
4
5
Inner bearing press in depth0.11 to 0.84 mm (0.0043 to 0.0331 in.)
0.84 mm (0.0331 in.)
0.009 to 0.038 mm (0.0004 to 0.0015 in.)
0.038 mm (0.0015 in.)
1.45 to 1.50 mm (0.0571 to 0.0591 in.)
1.50 to 1.55 mm (0.0591 to 0.0610 in.)
1.55 to 1.60 mm (0.0610 to 0.0630 in.)
1.60 to 1.65 mm (0.0630 to 0.0650 in.)
1.65 to 1.70 mm (0.0650 to 0.0669 in.)
7.7 to 8.3 mm (0.303 to 0.327 in.)

SS0PY±05
SS±28
± SERVICE SPECIFICATIONSTRANSFER
170 Author: Date:
2005 SEQUOIA (RM1146U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transfer x Transfer adaptor2424518
Engine rear mounting x Transmission6566048
Crossmember x Frame7273053
Engine rear mounting x Crossmember1818513
Heat insulator x Crossmember1616412
Front suspension member bracket x Crossmember3333624
Filler plug x Transfer3737727
Rear propeller shaft x Rear differential8889765
Rear propeller shaft x Transfer8889765
Protector x Transfer1818513
Front propeller shaft x Front differential7475054
Front propeller shaft x Transfer8889765
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Center exhaust pipe4849035
Transfer case cover x Transfer front case1818413
Case plug x Transfer front case18.619014
Front bearing retainer x Transfer front case11.511 98
Front output shaft companion flange lock nut11 81,20387
Oil pump x Front case7.56966 in.´lbf
Oil separator x Front case7.56966 in.´lbf
Transfer shift actuator x Transfer case rear2020415
Front case x Transfer case rear2828621
Shift shaft stopper1919414
Drain and filler plug3737727
Transfer extension housing x Transfer case rear121229
Rear output shaft companion flange lock nut11 81,20387
Gear shift fork2424518

SS07Z±05
SS±30
± SERVICE SPECIFICATIONSPROPELLER SHAFT
172 Author: Date:
2005 SEQUOIA (RM1146U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Propeller shaft assembly (2WD)
Propeller shaft x Differential
8889765
Propeller shaft assembly (4WD)
Front propeller shaft x Front differential
Front propeller shaft x Transfer
Rear propeller shaft x Rear differential
Rear propeller shaft x Transfer
74
88
88
88750
897
897
89754
65
65
65

DI±72
± DIAGNOSTICSENGINE
266 Author: Date:
2005 SEQUOIA (RM1146U)P2445
(DI±426)
Secondary Air Injection System
Pump Stuck On Bank 1

Air pump fuse

Vacuum hose

Air pump assembly

Open in air pump circuit

Air injection system piping

Pressure sensor

Open or short in pressure sensor circuit

ECM

P2610
(DI±442)ECM/PCM Internal Engine Off
Timer Performance
ECM
P2714
(DI±656)Pressure Control Solenoid ºDº
Performance (Shift Solenoid
Valve SLT)

Electronic control automatic transmission (ECT)
P2716
(DI±662)Pressure Control Solenoid ºDº
Electrical (Shift Solenoid Valve
SLT)

Electronic control automatic transmission (ECT)
P2740
(DI±666)Transmission Fluid Temperature
Sensor ºBº Circuit
Electronic control automatic transmission (ECT)
P2742
(DI±666)Transmission Fluid Temperature
Sensor ºBº Circuit Low Input
Electronic control automatic transmission (ECT)
2743
(DI±666)Transmission Fluid Temperature
Sensor ºBº Circuit High Input
Electronic control automatic transmission (ECT)
P2757
(DI±672)
Torque Converter clutch Pres-
sure Control Solenoid Perfor-
mance (Shift Solenoid Valve
SLU)

Electronic control automatic transmission (ECT)
P2759
(DI±680)Torque Converter clutch Pres-
sure Control Solenoid Electrical
(Shift Solenoid Valve SLU)

Electronic control automatic transmission (ECT)
P2772
(DI±685)Transfer L4 SW Circuit
Electronic control automatic transmission (ECT)
P2A00
(DI±451)A/F Sensor Circuit Slow Re-
sponse (Bank 1 Sensor 1)
Open or short in A/F sensor (sensor 1) circuit

A/F sensor (sensor 1)

ECM

P2A03
(DI±451)A/F Sensor Circuit Slow Re-
sponse (Bank 2 Sensor 1)
Open or short in A/F sensor (sensor 1) circuit

A/F sensor (sensor 1)

ECM

B2799
(DI±1580)Engine Immobilizer System Mal-
function
Immobilizer system±
U0001
(DI±444)High Speed CAN Communica-
tion Bus
ECM
*1: ± .... MIL does not light up.  .... MIL lights up.
*2: MIL lights up or blinks.

D14146
5 V/DIV
1 ms/DIVGND
D14147
GND
5 V/DIV
1 ms/DIV
DI±560
± DIAGNOSTICSAUTOMATIC TRANSMISSION
754 Author: Date:
2005 SEQUOIA (RM1146U)SLT+ (E7±13) ± SLT± (E7±12)
B±R ± G±YSLT solenoid signalEngine idle speedPulse generation
(See waveform 1)
SR (E7±9) ± E1 (E6±1)G±R ± BRSR solenoid signal5th gear10 to 14 V
===1st gearBelow 1 V
SL2+ (E7±17) ± SL2± (E7±16)GR ± LG±BSL2 solenoid signalEngine idle speedPulse generation
(See waveform 3)
SL1+ (E7±19) ± SL1± (E7±18)R±B ± LSL1 solenoid signalEngine idle speedPulse generation
(See waveform 4)
THO1 (E7±24) ± E2 (E8±28)G ± G±WNo.1 ATF temperature
sensor signalNo.1 ATF temperature: 115
C (239

F) or moreBelow 1.5 V
THO2 (E7±32) ± E2 (E8±28)V ± G±WNo.2 ATF temperature
sensor signalNo.2 ATF temperature: 115
C (239

F) or moreBelow 1.5 V
SP2+ (E7±34) ± SP2± (E7±26)W±R ± Y±RSpeed sensor (SP2) sig-
nalVehicle speed 20 km/h (12 mph)Pulse generation
(See waveform 6)
NT+ (E7±35) ± NT± (E7±27)B ± WSpeed sensor (NT) signalEngine idle speedPulse generation
(See waveform 5)
STAR/NSW (E7±8) ± E1 (E6±1)B ± BRPark neutral switch signalIG switch ON and shift lever P and
N positionBelow 2 V
===IG switch ON and shift lever except
P and N position10 to 14 V
L4* (E6±13) ± E1 (E6±1)L±R ± BRTransfer L position switch
signalIG switch ON and transfer L posi-
tionBelow 1 V
===IG switch ON and transfer except L
position10 to 14 V
HINT:
*: 4WD
Waveform 1
Reference:
TerminalSLT+ ± SLT±
Tool setting5V/DIV, 1ms/DIV
Vehicle conditionEngine idle speed
Waveform 2
Reference:
TerminalSLU+ ± SLU±
Tool setting5V/DIV, 1ms/DIV
Vehicle condition5th (lock±up) or 6th (lock±up) gear

± DIAGNOSTICSAUTOMATIC TRANSMISSION
DI±575
769 Author: Date:
2005 SEQUOIA (RM1146U)P2772*
(DI±685)
Transfer L4 SW Circuit
Short in transfer L4 position switch circuit
Transfer L4 position switch
4WD control ECU
ECM


HINT:
*: 4WD

D14162
Clutch Drum
(Timing Rotor)
Input Speed Sensor NT
(Transmission Revolution Sensor NT)Output Speed Sensor SP2
(Transmission Revolution Sensor SP2)
Parking Gear
(Timing Rotor)
C13480D14149
GND
2 V/DIV
20 ms/DIV
DI±596
± DIAGNOSTICSAUTOMATIC TRANSMISSION
790 Author: Date:
2005 SEQUOIA (RM1146U)
DTC P0722 Output Speed Sensor Circuit No Signal
CIRCUIT DESCRIPTION
The speed sensor SP2 detects the rotation speed of the transmission output shaft and sends signals to the
ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the
speed sensor SP2 coil as the parking gear mounted on the rear planetary gear assy rotates, and this voltage
is sent to the ECM. The parking gear on the rear planetary gear is used as the timing rotor for this sensor.
The gear shift point and lock±up timing are controlled by the ECM based on the signals from this vehicle
speed sensor and the throttle position sensor signal.
DTC No.DTC Detection ConditionTrouble Area
P0722
All conditions below are detected 500 times or more continu-
ously (1±trip detection logic)
(a) No signal from speed sensor (SP2) is input to ECM while 4
pulses of No. 1 vehicle speed sensor signal are sent
(b) Vehicle speed is 9 km/h (6 mph) or more for at least 4 sec.
(c) Park/neutral position switch is OFF.
(d) Transfer position is except neutral (4WD).

Open or short in speed sensor (SP2) circuit

Speed sensor (SP2)

ECM

Automatic transmission (clutch, brake or gear, etc.)
Reference (Using an oscilloscope):
Check the waveform between terminals SP2+ and SP2±
of the ECM connector.
Standard: Refer to the illustration.
TerminalSP2+ ± SP2±
Tool setting2V/DIV, 20ms/DIV
Vehicle conditionVehicle speed 20 km/h (12 mph)
DIDJ9±01

± DIAGNOSTICSAUTOMATIC TRANSMISSION
DI±609
803 Author: Date:
2005 SEQUOIA (RM1146U) Shift solenoid valve SL2 circuit
Not circuit malfunction
ECT (Engine coolant temperature) sensor
circuitNot circuit malfunction
KCS sensor circuitNot circuit malfunction
ETCS (Electric throttle control system)Not system down
Transmission rangeºDº
ECT40°C (104°F) or more±
Spark advance from Max. retard timing by
KCS control0° CA or more±
EngineStarting
Transfer rangeºHIGHº*1
Transfer range ºHIGHº *1 (This condition is applied only 4WD)
*1 Following conditions met
Vehicle speed sensor circuitNot circuit malfunction
Output shaft speed sensor circuitNot circuit malfunction
Transfer output speed143 rpm or more±
NO/NOtf (Transfer input speed/Transfer
output speed)0.9 to 1.1
OFF malfunction (A)
ECM selected gear1st
Vehicle speed2 to 40 km/h (1.2 to 24.9 mph)
Throttle valve opening angle
8% or more
and 7.0% or more at 2,000 rpm
(Conditions vary with engine speed)
±
OFF malfunction (B)
Current ECM selected gear5th
Last ECM selected gear4th
Continuous time for ECM selecting 4th
gear2 sec. or more±
Actual gear when ECM selected 4th gear4th
OFF malfunction (C)
Current ECM selected gear5th
Last ECM selected gear4th
ON malfunction (A)
ECM selected gear1st
Vehicle speed2 to 40 km/h (1.2 to 24.9 mph)
Throttle valve opening angle7.0% or more at 2,000 rpm
(Conditions vary with engine speed)±
ON malfunction (B)
ECM selected gear4th
Vehicle speed2 km/h (1.2 mph) or more±
Throttle valve opening angle7.0% or more at 2,000 rpm
(Conditions vary with engine speed)±
ON malfunction (C)
ECM selected gear3rd
Vehicle speed2 km/h (1.2 mph) or more±