| : | Oct 22, 2004 |

| 1 | - | Instrument cluster |
| 2 | - | Range change selection switch |
| 3 | - | Transfer box |
| 4 | - | Central junction box (CJB) |
| 5 | - | Manual transmission output shaft speed sensor |
| 6 | - | Gear position sensor (Manual transmission only) |
| 7 | - | Transfer box control module |

| 1 | - | Synchronisation spring |
| 2 | - | Differential assembly |
| 3 | - | Bolt, 6 off |
| 4 | - | Spacer ring |
| 5 | - | Shifting sleeve |
| 6 | - | Bolt, 3 off |
| 7 | - | Solenoid |
| 8 | - | Shifting element |
| 9 | - | Synchronisation spring |
| 10 | - | Circlip |
| 11 | - | Ball bearing |
| 12 | - | Rear housing |
| 13 | - | Circlip |
| 14 | - | Seal ring |
| 15 | - | Needle roller bearing |
| 16 | - | Rear output flange |
| 17 | - | Needle roller bearing |
| 18 | - | Bolt, 2 off |
| 19 | - | Selector fork position sensor |
| 20 | - | Bearing |
| 21 | - | Circlip |
| 22 | - | Transfer box motor assembly |
| 23 | - | Bolt, 4 off |
| 24 | - | Circlip |
| 25 | - | Shifting fork |
| 26 | - | Fork pin |
| 27 | - | Sliding block |
| 28 | - | Actuator assembly |
| 29 | - | Fill plug |
| 30 | - | Seal ring |
| 31 | - | Ball retention |
| 32 | - | Drain plug |
| 33 | - | Seal ring |
| 34 | - | Particle collector magnet |
| 35 | - | Sliding block |
| 36 | - | High/low shifting fork |
| 37 | - | O-ring |
| 38 | - | High/low fork pin |
| 39 | - | Circlip |
| 40 | - | Circlip |
| 41 | - | Clutch hub |
| 42 | - | Clutch friction plate, 10 off |
| 43 | - | Clutch steel plate, 10 off |
| 44 | - | Disc spring, 6 off |
| 45 | - | Clutch piston |
| 46 | - | Axial needle roller bearing |
| 47 | - | Transfer box motor lever assembly |
| 48 | - | Ball, 5 off |
| 49 | - | Transfer box motor lever assembly |
| 50 | - | Axial needle roller bearing |
| 51 | - | Needle roller bearing |
| 52 | - | Front output sprocket |
| 53 | - | Chain |
| 54 | - | Needle roller bearing |
| 55 | - | Sprocket |
| 56 | - | Circlip |
| 57 | - | Thrust washer |
| 58 | - | Spacer ring |
| 59 | - | Oil pump assembly |
| 60 | - | Needle roller bearing |
| 61 | - | Input shaft |
| 62 | - | O-ring |
| 63 | - | Circlip |
| 64 | - | Disc spring, 2 off |
| 65 | - | Bolt, 19 off |
| 66 | - | Dowel pin (2 off) |
| 67 | - | Front housing |
| 68 | - | Breather cartridge |
| 69 | - | Bearing |
| 70 | - | Circlip |
| 71 | - | Seal ring |
| 72 | - | Front output flange |
| 73 | - | Seal ring |
| 74 | - | Circlip |
| 75 | - | Bearing |

| 1 | - | Planetary gear set |
| 2 | - | Rear output flange |
| 3 | - | Centre differential assembly |
| 4 | - | Multi-plate clutch |
| 5 | - | Transfer box motor module |
| 6 | - | Rear housing assembly |
| 7 | - | Front output sprocket |
| 8 | - | Chain drive |
| 9 | - | Front output flange |
| 10 | - | Transfer box motor levers |
| 11 | - | Sprocket |
| 12 | - | Oil pump assembly |
| 13 | - | Input shaft |
| 14 | - | Front housing assembly |


| 1 | - | Motor shaft |
| 2 | - | Solenoid shift fork |
| 3 | - | Solenoid |
| 4 | - | Clutch control disc |
| 5 | - | Shifting sleeve |

| 1 | - | Motor shaft |
| 2 | - | Solenoid shift fork |
| 3 | - | Solenoid |
| 4 | - | Shifting sleeve |
| 5 | - | Actuation cam |

| 1 | - | Synchronisation cup and spring |
| 2 | - | Planetary ring gear |
| 3 | - | Differential carrier |
| 4 | - | Pinion gears |
| 5 | - | Pinion gear shafts |
| 6 | - | Planetary pinion gears |
| 7 | - | Planetary pinion gear shafts |
| 8 | - | Planetary sun gear |
| 9 | - | Differential cover |
| 10 | - | Differential side gears |
| 11 | - | Multi-plate clutch basket |
| 12 | - | Dogteeth |

| A | - | High range position |
| B | - | Low range position |
| 1 | - | Dogteeth |
| 2 | - | Planetary pinion gears |
| 3 | - | Planetary ring gear |
| 4 | - | Shifting sleeve |
| 5 | - | Low range dogteeth |
| 6 | - | Rear carrier assembly |

| 1 | - | Shifting sleeve |
| 2 | - | High/low shifting fork |
| 3 | - | Shifting cam |

| 1 | - | Shifting sleeve |
| 2 | - | High/low shifting fork |
| 3 | - | Shifting cam |
| 4 | - | Motor shaft |

| 1 | - | Clutch hub |
| 2 | - | Cup springs |
| 3 | - | Clutch plates |
| 4 | - | Clutch piston |
| 5 | - | Motor levers |
| 6 | - | Ball ramp mechanism |
| 7 | - | Sprocket |


| 1 | - | Clutch piston |
| 2 | - | Motor shaft |
| 3 | - | Clutch control disc |
| 4 | - | Motor levers |
| 5 | - | Ramp mechanism balls |

| A | - | RH drive |
| B | - | LH drive |
| 1 | - | Battery Junction Box (BJB) |
| 2 | - | Battery |
| 3 | - | Engine Control Module (ECM) |
| 4 | - | Transfer box control module |
| Fault state | System response | Driver warning |
|---|---|---|
| No reduction in capability | Diagnostic Trouble Code (DTC) will be recorded but no effect on performance | Non |
| Clutch control not possible. Temporary over temperature condition | The tractive capability of the vehicle, off road, is reduced. | Driveline over temperature warning lamp or "Centre diff over temp reduce speed" on message centre |
| Clutch control not possible. Permanent fault | The tractive capability of the vehicle, off road, is reduced. | Driveline fault warning lamp or "Centre diff fault traction reduced" on message centre |
| Range change not possible | The system inhibits the driver from making a range change | Driveline fault warning lamp or "Range change inoperable" on message centre |
| Stuck in Transfer box neutral | The transfer box is stuck between high and low range resulting in no drive to wheels | Flash low range indicator plus "Park lock failure apply hand/parkbrake" message on message centre |
| Pin No. | Description | Input/output |
|---|---|---|
| 1 | Not used | - |
| 2 | Not used | - |
| 3 | CAN bus low | Data (input and output) |
| 4 | Range change selection switch - High | Input |
| 5 | Range change selection switch - Low | Input |
| 6 | CAN bus high | Data (input and output) |
| 7 | Key interlock solenoid | Output |
| 8 | LED-high | Output |
| 9 | LED-low | Output |
| Pin No. | Description | Input/output |
|---|---|---|
| 1 | CAN bus low | Data (input and output) |
| 2 | Not used | - |
| 3 | Ignition power supply | Input |
| 4 | CAN bus high | Data (input and output) |
| 5 | Ground | - |
| 6 | Permanent battery power supply | Input |
| Pin No. | Description | Input/output |
|---|---|---|
| 1 | Hall sensor signal-A | Input |
| 2 | Ground | - |
| 3 | Hall sensors supply | Output |
| 4 | Not used | - |
| 5 | Temperature sensor | Input |
| 6 | Hall sensor signal-B | Input |
| 7 | Selector position ground | - |
| 8 | 5V position sensor supply | Output |
| 9 | Selector mode solenoid ground | - |
| 10 | Selector position sensor signal | Input |
| 11 | Transmission position sensor X axis signal | Input |
| 12 | Selector mode solenoid power supply | Output |
| 13 | Transmission position sensor Y axis signal | Input |
| 14 | Manual transmission output shaft speed sensor supply | Output |
| 15 | Motor supply/ground | Input/output |
| 16 | Manual transmission output shaft speed signal | Input |
| 17 | Manual transmission output shaft speed sensor ground | - |
| 18 | Motor supply/ground | Input/output |





| 1 | - | High range LED |
| 2 | - | Low range LED |


| In order to replace the solenoid in service, the solenoid must be energized using the diagnostic tool. |

| A | - | High-line instrument cluster |
| B | - | Low-line instrument cluster |
| 1 | - | Low-range status indicator |
| 2 | - | Message centre text (high-line only) |
| 3 | - | Driveline fault lamp |
| 4 | Driveline over temperature |
| Message | Description | Chime |
|---|---|---|
| 'LOW RANGE ENGAGED' | Transfer case has engaged low range after a range change request | Single |
| 'HIGH RANGE ENGAGED' | Transfer case has engaged high range after a range change request | Single |
| 'SPEED TOO HIGH FOR RANGE CHANGE' | Range change request when vehicle speed too high | Single |
| 'SELECT NEUTRAL FOR RANGE CHANGE' | Range change request when lever not in neutral | Single |
| 'PARK LOCK FAILURE APPLY HANDBRAKE' (PARKBRAKE US/CAN) | This alerts the driver that the automatic transmission park lock function is inoperative due to transfer box out of high or low range. Transfer box control module has stopped transmitting on the CAN bus during a range change or while in neutral mode and as a result the automatic transmission park lock function is inoperative | One per second for three seconds |
| 'RANGE CHANGE INOPERABLE' | Transfer box has detected a fault inhibiting a new range change. Control unit has shut down due to thermal overload | Single |
| 'CENTRE DIFF OVER TEMP REDUCE SPEED' | Centre differential temperature is approaching the over heated threshold | Single |
| 'CENTRE DIFF FAULT – TRACTION REDUCED' | Centre differential has failed - operating as an open differential | Single |
| 'CENTRE DIFF FAULT – TRACTION REDUCED' | Transfer box control module has stopped transmitting on the CAN bus and defaults to open centre differential | Single |
| Odometer Display | Description |
|---|---|
| N | Transmission is in neutral |
| 1 | Transmission is in first gear |
| 2 | Transmission is in second gear |
| 3 | Transmission is in third gear |
| 4 | Transmission is in forth gear |
| 5 | Transmission is in fifth gear |
| 6 | Transmission is in sixth gear |
| R | Transmission is in reverse gear (Japan only) |
| Blank display | Transmission is between neutral and a gear |
| E | Transmission gear position sensor has a fault |
| Indication | Description |
|---|---|
| OFF | Transfer box is operating at normal working temperature |
| YELLOW WARNING LAMP ON | Transfer box temperature is approaching the over heated threshold |
| YELLOW WARNING LAMP ON | Transfer box has detected a fault, which affects the range change function (current range is still maintained) or the centre differential has failed to open. |
| RED WARNING LAMP ON | Transfer box has detected a fault which renders the transmission park lock function inoperative due to out of range condition, OR centre differential has failed with a non-zero locking torque |
| YELLOW WARNING LAMP ON | Transfer box control module has stopped transmitting on the CAN bus and defaults to open centre differential |
| RED WARNING LAMP ON | Transfer box control module has stopped transmitting on the CAN bus during a range change or while in neutral mode and as a result the automatic transmission park lock function is inoperative |


| 1 | - | Input shaft spline |
| On vehicles with automatic transmission, if the transmission selector lever is in the 'P' position, the range change will not take place and the 'SELECT NEUTRAL' message will not be displayed in the message centre. |

| A = Hardwired; D = CAN bus |

| 1 | - | Diagnostic socket |
| 2 | - | Instrument cluster |
| 3 | - | Terrain response™ |
| 4 | - | High/Low range selection switch |
| 5 | - | High/Low range LED |
| 6 | - | Transmission Control Module (TCM) |
| 7 | - | Engine Control Module (ECM) |
| 8 | - | Transfer box motor |
| 9 | - | Temperature sensor |
| 10 | - | Hall sensors (speed and direction) |
| 11 | - | Manual transmission gear position sensor |
| 12 | - | Output shaft speed sensor |
| 13 | - | Fuse 24 ignition feed |
| 14 | - | Fusible link permanent battery feed |
| 15 | - | Ignition switch |
| 16 | - | Solenoid |
| 17 | - | Transfer box control module |
| 18 | - | High/low position sensor |