DTC 42: Shift Actuator System (Short Circuit), DTC 43: Shift Actuator System (Open Circuit): Diagnosis

Required Special Tool: 

• MB991502: Scan Tool (MUT-II)

1. STEP 1. Using scan tool MB991502, check data list item 10: Shift Actuator Amperage. 
   CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502.
   1. Connect scan tool MB991502 to the data link connector.
      Fig 1: Connecting Scan Tool MB991502 To Data Link Connector

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   2. Turn the ignition switch to the "ON" position.
   3. Transmission range should be "N" range.
   4. Set scan tool MB991502 to data reading mode for item 10, Shift Actuator Amperage.
      • When the operating transfer shift lever 2H --> 4H, 4H --> 4HLc or 4HLc --> 4LLc, the display should be 0 ampere --> 0.2 - 1.5 ampere --> 0 ampere.
   5. Turn the ignition switch to the "LOCK" (OFF) position.

   Q: Is the actuator operating properly? 

   1. YES  : It can be assumed that this malfunction is intermittent. Refer to HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS - How to Cope with Intermittent Malfunction.
   2. NO  : Go to Step 2.
2. STEP 2. Measure the power supply voltage at shift actuator connector C-09. 
   1. Disconnect connector C-09 and measure at the harness side.
      Fig 2: Identifying Shift Actuator Connector C-09 Location And Terminal View

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   2. Turn the ignition switch to the "ON" position.
   3. Transmission range should be "N" range.
   4. Measure the voltage between terminal 2 and ground.
      • When the operating transfer shift lever 2H --> 4H, 4H --> 4HLc or 4HLc --> 4LLc, the voltage should measure battery positive voltage.
      Fig 3: Measuring Voltage Between Terminal 2 And Ground

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   5. Measure the voltage between terminal 1 and ground.
      • When the operating transfer shift lever 4LLc --> 4HLc, 4HLc --> 4H or 4H --> 2H, the voltage should measure battery positive voltage.
      Fig 4: Measuring Voltage Between Terminal 1 And Ground

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   6. Turn the ignition switch to the "LOCK" (OFF) position.

   Q: Is the measured voltage battery positive voltage? 

   1. YES  : Replace the shift actuator. Refer to Transfer DISASSEMBLY AND ASSEMBLY < SUPER SELECT 4WD> .
   2. NO  : Go to Step 3.
3. STEP 3. Measure the actuator output voltage at transfer-ECU connector E-109 by backprobing. 
   1. Do not disconnect connector E-109.
      Fig 5: Identifying Transfer-ECU Connector E-109 Location And Terminal View

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   2. Turn the ignition switch to the "ON" position.
   3. Transmission range should be "N" range.
   4. Measure the voltage between terminal 1 and ground by backprobing.
      • When the operating transfer shift lever 2H --> 4H, 4H --> 4HLc or 4HLc --> 4LLc, the voltage should measure 1/2 battery voltage --> battery positive voltage --> 1.0 volt or less --> 1/2 battery voltage.
      • When the operating transfer shift lever 4LLc --> 4HLc, 4HLc --> 4H or 4H --> 2H, the voltage should measure 1/2 battery voltage --> 1.0 volt or less --> 1/2 battery voltage.
      Fig 6: Measuring Voltage Between Terminal 1 And Ground By Backprobing

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   5. Measure the voltage between terminal 3 and ground by backprobing.
      • When the operating transfer shift lever 2H --> 4H, 4H --> 4HLc or 4HLc --> 4LLc, the voltage should measure 1/2 battery voltage --> 1.0 volt or less --> 1/2 battery voltage.
      • When the operating transfer shift lever 4LLc --> 4HLc, 4HLc --> 4H or 4H --> 2H, the voltage should measure 1/2 battery voltage --> battery positive voltage --> 1.0 volt or less --> 1/2 battery voltage.
      Fig 7: Measuring Voltage Between Terminal 3 And Ground By Backprobing

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   6. Turn the ignition switch to the "LOCK" (OFF) position.

   Q: Is the measured voltage within the specified range? 

   1. YES  : Go to Step  6 .
   2. NO  : Go to Step 4.
4. STEP 4. Check shift actuator connector C-09 and transfer-ECU connector E-109 for loose, corroded or damaged terminals, or terminals pushed back in the connector. 
   Fig 8: Identifying Shift Actuator Connector C-09 Location And Terminal View

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   Fig 9: Identifying Transfer-ECU Connector E-109 Location And Terminal View

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   Q: Are the connectors and terminals in good condition? 

   1. YES  : Go to Step 5.
   2. NO  : Repair or replace the damaged components. Refer to HARNESS CONNECTOR INSPECTION .
5. STEP 5. Check harnesses for short circuit to ground between shift actuator connector C-09 terminals 2, 1 and transfer-ECU connector E-109 terminals 1, 3. 
   Fig 10: Identifying Shift Actuator Connector C-09 Location And Terminal View

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   Fig 11: Identifying Transfer-ECU Connector E-109 Location And Terminal View

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   Q: Are the harnesses wire in good condition? 

   1. YES  : Go to Step  8 .
   2. NO  : Repair or replace the harness wire.
6. STEP 6. Check shift actuator connector C-09 and transfer-ECU connector E-109 for loose, corroded or damaged terminals, or terminals pushed back in the connector. 
   Fig 12: Identifying Shift Actuator Connector C-09 Location And Terminal View

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   Fig 13: Identifying Transfer-ECU Connector E-109 Location And Terminal View

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   Q: Are the connectors and terminals in good condition? 

   1. YES  : Go to Step 7.
   2. NO  : Repair or replace the damaged components. Refer to HARNESS CONNECTOR INSPECTION .
7. STEP 7. Check harnesses for open circuit between shift actuator connector C-09 terminals 2, 1 and transfer-ECU connector E-109 terminals 1, 3. 
   Fig 14: Identifying Shift Actuator Connector C-09 Location And Terminal View

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   Fig 15: Identifying Transfer-ECU Connector E-109 Location And Terminal View

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   Q: Are the harnesses wire in good condition? 

   1. YES  : Go to Step 8.
   2. NO  : Repair or replace the harness wire.
8. STEP 8. Using scan tool MB991502, check data list item 10: Shift Actuator Amperage. 
   CAUTION: To prevent damage to scan tool MB991502, always turn the ignition switch to the "LOCK" (OFF) position before connecting or disconnecting scan tool MB991502.
   1. Connect scan tool MB991502 to the data link connector.
      Fig 16: Connecting Scan Tool MB991502 To Data Link Connector

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   2. Turn the ignition switch to the "ON" position.
   3. Transmission range should be "N" range.
   4. Set scan tool MB991502 to data reading mode for item 10, Shift Actuator Amperage.
      • When the operating transfer shift lever 2H --> 4H, 4H --> 4HLc or 4HLc --> 4LLc, the display should be 0 ampere --> 0.2 - 1.5 ampere --> 0 ampere.
   5. Turn the ignition switch to the "LOCK" (OFF) position.

   Q: Is the actuator operating properly? 

   1. YES  : It can be assumed that this malfunction is intermittent. Refer to HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS - How to Cope with Intermittent Malfunction.
   2. NO  : Replace the transfer-ECU.