Transfer Case - Suzuki Autotraining.suzukiauto.co.za/SASATrainingDocs/DS02 Driveline Axle... · The...

Transfer Case

Driveshaft/axle - Transfer Course code: DS02

Student training manual

Suzuki Online Training

Foreword A 4 Wheel Drive systems distributes driving force generated by the engine to both the front and the rear wheels to improve traction. A transfer is a supplementary gear change system for switching between 2 wheel drive, 4 wheel drive and 4 wheel drive low. In this training manual, we will study the transfer system used in the 4WD system. The Suzuki Jimny SN413 is used for description of the transfer system.

Suzuki Technician curriculum This training manual is part of the Non Suzuki Technician to Suzuki Technician curriculum. The curriculum consists of the following modules: 1. GE01 Suzuki Introduction 2. GE02 Electrical / Electronics 3. GE03 Diagnostics 4. EN02 Engine Mechanical part I 5. EN03 Engine Mechanical part II 6. EN04 Engine Mechanical part III 7. EN05 Engine Auxiliary systems 8. DS01 Driveshaft/Axle 9. DS02 Driveshaft/Axle transfer case 10. BR02 Brake control systems 11. Manual transmission / transaxle 12. CS02 Control system / body electrical 13. CS03 Communication / bus systems You are currently studying DS02 Driveshaft/Axle Transfer case. This module consists of the following courses: Transfer case DS02 practical activities

This document is intended solely for training purposes only. All vehicle repairs and adjustments must be carried out according to the procedures stipulated in current service manuals and technical bulletins.

Smart manuals Some sections of this training manual contain videos with detailed information on the topics you are studying. If you are studying this training manual on a PC, look out for the green play video symbol on any photo or picture in this manual, click on the green button to watch a video providing you with detailed information on that topic. Note: Internet connection required.

DS02 Driveshaft/Axle Transfer box 2

Table of contents Topic Page 4WD system 4 Transfer 5 Transfer control system 6 Transfer components 7 Power transmission in the transfer 8 Transfer controller/4WD control module 11 2H to 4H shift control 12 4H to 2H shift control 13 4H to 2L shift control 13 4H to 4L shift control 14 4WD indicator control 15 Description of limited shift operation 17 Basic tests of 4WD components 18 4WD on-board diagnostic system 20 DTC check 21 Fail safe table 23 Service information 24



4 Wheel Drive system

Function of 4WD system components (1) 4WD switch: Detects whether transfer shift fork shaft No.1 is at 2H or 4H/4L. (2) 4WD low switch: Detects whether transfer shift fork shaft No.1 is at 2H/4H or 4L (3) 2WD/4WD switch (figure 3 A) 2WD switch (16): Shifts transfer from 4H to 2H or from 4L

to 2H. 4WD switch (17): Shifts transfer from 2H to 4H or from 4L

to 4H. 4WD-L switch (18): Shifts transfer from 4H to 4L or from 2H

to 4L.

(4) 4WD indicator (figure 3B) Indicates whether transfer is at 4H/4L position or not. Informs what state transfer control system is. (5) 4WD-L indicator (B-20) Indicates whether transfer is at 4L position or not. Informs what state transfer control system is.

Figure 1: Location of 4WD components (Jimny SN413)

[1] 4WD low indicator [2] 4WD indicator [3] 2WD/4WD switch [4] 2WD switch [5] 4WD switch [6] 4WD-L switch [7] 4WD switch connector [8] 4WD low switch connector [9] Transfer shift actuator connector [10] Transfer shift actuator motor [11] VSS [12] 4WD control module


(6) Clutch pedal switch Detects whether clutch pedal is depressed or not. (7) Warning buzzer Warns what state transfer control system is. (8) 4WD control module Controls transfer shifting. Controls air locking hub operating Operates 4WD indicator, 4WD low indicator and warning

buzzer. Diagnoses 4WD control system components. (9) Transfer shift actuator Consists of transfer shift actuator motor and transfer shift actuator limit switch. (10) Transfer shift actuator motor Shifts transfer shift position by operating shift fork shaft No.1 through pinion gear. (11) Transfer shift actuator limit switch Detects whether transfer shift actuator motor position.

Transfer The aluminum transfer case directly connected to the back of the transmission contains input shaft, counter gear, output rear shaft, output front shaft, drive chain, shift fork shaft No.1, shift fork shaft No.2 and their accompanying gears, hubs, sleeves, synchronizer ring, fork, etc. With a synchronizer installed to the front drive clutch hub sleeve, it is possible to change the shift position between the 2H position and the 4H position even while running. The front drive gear shift fork has a shift fork spring to make a smooth shift between the 4H position and the 2H position. The case has an oil receiver and an oil protect plate to provide proper lubrication even under the severe conditions of use.

Figure 2: Drivetrain layout

[1] Transfer [2] Front differential [3] Rear differential [4] Transmission

1

2

3

4


Transfer control system Instead of a transfer shift lever, the transfer position (2H, 4H and 4L) is shifted automatically by operating the 2WD switch, 4WD switch and 4WD-L switch. The 4WD control module operates the transfer shift actuator according to the 2WD switch, 4WD switch and 4WD-L switch operation. Also, the transfer control system has 4WD indicator, 4WD low indicator and warning buzzer in order to inform the transfer control system condition. The 4WD control module shifts the transfer to the selected shift position (2H, 4H, or 4L) according to the signal from the 2WD switch, 4WD switch or 4WD-L switch. The 4WD control module controls the transfer shift actuator in order to operate the shift fork shaft No.1. The 4WD control module detects the position of the transfer shift actuator motor by the signal from the transfer shift actuator limit switch. Also, the 4WD control module detects each position (2H, 4H, or 4L) of the shift fork shaft No.1 installed to the transfer assembly by the signals from the 4WD switch and the 4WD low switch as follows

Figure 3: [A] 2WD/4WD selector switch [B] 4WD indicator


Transfer components [1] Input shaft [2] Counter gear [3] Hi/Lo Clutch sleeve [4] Drive chain [5] VSS ring [6] Front output shaft [7] Front clutch hub [8] Front clutch sleeve [9] Output gear [10] Rear output shaft [11] Stationery shift shaft [12] Movable shift shaft [13] 2 4 Shift fork [14] Transfer 4WD switch [15] HI/Lo shift fork [16] Transfer L4 switch [17] Transfer actuator


Power transmission in the transfer 1) 2H position The driving force from the transmission is input to the input shaft and transmitted from the input shaft to the output gear via the drive chain. At this time, because the output gear and rear output shaft are fitted to each other, the driving force is transmitted to the rear output shaft by the high-low clutch sleeve. Note that because the front clutch hub is not fitted to the front output shaft, the driving force is not transmitted to the front output shaft.

Figure 4 [1] Input shaft [2] Counter gear [3] Hi/Lo clutch sleeve [4] Drive chain [5] VSS sensor ring [6] Front output shaft [7] Front clutch hub [8] Front clutch sleeve [9] Output gear [10] Rear output shaft [11] Stationary shift shaft [12] Movable shift shaft [13] 2 4 shift fork [14] Transfer 4WD switch (OFF) [15] HI/Lo shift fork [16] Transfer L4 switch (OFF) [17] Transfer actuator [18] 4WD/4L indicator


2) 4H position When the driver pushes the 4WD switch of the 2WD/4WD selector switch and shifts into the 4H position, the motor of the T/F actuator rotates and the movable shift shaft shifts in the direction of arrow A. The pin that is installed on the 2-4 shift fork fits into the groove of the movable shift shaft and moves the 2-4 shift fork in the same direction as the movable shift shaft. As a result, the front clutch sleeve moves in the direction of arrow B. In the same way as when in the 2H position, the driving force from the transmission is transmitted from the input shaft to the rear output shaft via the drive chain. However, because the front clutch hub is fitted to the front output shaft by the front clutch sleeve, the driving force is also transmitted to the front output shaft.

Figure 5 [1] Input shaft [2] Counter gear [3] Hi/Lo clutch sleeve [4] Drive chain [5] VSS sensor ring [6] Front output shaft [7] Front clutch hub [8] Front clutch sleeve [9] Output gear [10] Rear output shaft [11] Stationary shift shaft [12] Movable shift shaft [13] 2 4 shift fork [14] Transfer 4WD switch (ON) [15] HI/Lo shift fork [16] Transfer L4 switch (OFF) [17] Transfer actuator [18] 4WD/4L indicator [19] Pin [20] Groove


3) 4WD-L position When the driver pushes the 4WD-L switch of the 2WD/4WD selector switch and shifts into the 4L position, the motor of the T/F actuator rotates and the movable shift shaft shifts in the direction of arrow A. At this time, the snap ring that is installed on the movable shift shaft moves the high-low shift fork in the same direction as the movable shift shaft. As a result, the high-low clutch sleeve moves in the direction of arrow B. The driving force from the transmission is input to the input shaft and transmitted to the output gear via the drive chain. At this time, because the output low gear and rear output shaft are fitted to each other by the high-low clutch sleeve, the driving force is reduced with the output low gear via the counter gear, and is transmitted to the rear output shaft. In the same way as when in the 4H position, because the front clutch hub is fitted to the front output shaft by the front clutch sleeve, the driving force from the rear output shaft is transmitted to the front output shaft.

Figure 6 [1] Input shaft [2] Counter gear [3] Hi/Lo clutch sleeve [4] Drive chain [5] VSS sensor ring [6] Front output shaft [7] Front clutch hub [8] Front clutch sleeve [9] Output gear [10] Rear output shaft [11] Stationary shift shaft [12] Movable shift shaft [13] 2 4 shift fork [14] Transfer 4WD switch (ON) [15] HI/Lo shift fork [16] Transfer L4 switch (ON [17] Transfer actuator [18] 4WD/4L indicator [19] Pin [20] Groove [21] Output low gear [22] Snap ring


Transfer controller/4WD control module The transfer controller performs control of the T/F actuator and 4WD/4L indicator based on the signals from the switches, speed sensor and 4WD controller. Input and output diagram T/F shift control The transfer controller operates the T/F actuator using the switch operation that is input from the 2WD/4WD selector switch on the instrument panel as the target shift position.

The T/F actuator is made up of a motor and 3 limit switches. The movable contact point switches the limit switches depending on the motor position. The transfer controller detects the motor position from the ON/OFF condition of the limit switches.

Relationship of transfer shift position and switch In addition, the T/F 4WD switch and T/F L4 switch that detect the condition of the internal shift fork are installed on the transfer unit. These turn ON and OFF in the different shift positions (2H, 4H, 4L) as shown in the next table, inputting the position of the movable shift shaft into the transfer controller.

Figure 7: Input/output diagram for transfer controller

Figure 8: T/F actuator circuit diagram


2H 4H shift control T/F shift control (2H 4H) prohibition conditions T/F actuator limit switch: Position other than 2H Vehicle speed: Over 100 km/h


4H 2H shift control T/F shift control (4H 2H) prohibition conditions T/F actuator limit switch: Position other than 4H

4H 4L shift control


T/F shift control (4H 4L) prohibition conditions T/F actuator limit switch: Position other than 4H Vehicle speed: Over 5 km/h AT selector position (AT vehicles): Range other than "N Clutch switch (MT vehicles): OFF

4L 4H shift control T/F shift control (4L 4H) prohibition conditions T/F actuator limit switch: Position other than 4L Vehicle speed: Over 5 km/h


A/T selector position (A/T vehicles): Range other than "N" Clutch switch (MT vehicles): OFF

4WD Indicator control The transfer controller turns the 4WD (1) and the 4L (2) indicator in the combination meter on and off. While T/F shift control is being performed, the indicator that matches the input from the 2WD/4WD selector switch flashes in 0.5-second intervals. When the T/F shift control is complete, the indicator switches on or off.

The table in page 17 shows operation of the 4WD and 4WD-L indicator under different conditions. Operation of the warning buzzer is also included in the table. The warning buzzer is integrated in the 4WD controller.


Description of limited shift operation When the 4WD control module detects the following conditions in the 4WD control system, the 4WD control module limits the transfer shift operation as follows, and the limitation can be canceled by turning ignition switch to OFF position.


Basic tests of the 4WD components

1) T/F actuator check 1. Connect 2 new dry cell batteries in a series to supply a total voltage of about 3 V. 2. As shown in the figure below, connect the positive side of the power supply to terminal 1 of the T/F actuator and connect the negative side to terminal 2. Check that the motor rotates in direction A. Then connect the positive side of the power supply to terminal 2 and the negative side to terminal 1. Check that the motor rotates in direction B.

2) T/F actuator limit switch check 1. Follow the same procedure as the T/F actuator check to connect the positive side of the power supply to terminal 1 of the T/F actuator and connect the negative side to terminal 2. Rotate the motor as far as possible in direction A (direction A rotation limit). 2. Connect the positive side of the power supply to terminal 2 of the T/F actuator and connect the negative side to terminal 1. While slowly rotating the motor in direction B, check that it passes through the following conduction conditions.


3) 2WD/4WD selector switch check Check that the conduction between the terminals is as follows when the switches of the 2WD/4WD selector switch are pressed.


4) T/F 4WD switch and T/F L4 switch check Check that there is conduction when the projection on the switches is pressed in the direction of the arrow, and that there is no conduction when it is released.

4WD On-board diagnostic system The 4WD control module has the following functions. When 4WD control module detects any malfunction, 4WD

indicator and 4WD low indicator flash continuously at the same time, and 4WD control module sets DTC and comes into fail-safe mode. For details of fail safe mode.

The DTC stored in memory of the 4WD control module is indicated by the 4WD indicator flashing in a specific pattern.

3 Driving Cycle Detection Logic The malfunction detected in the first and second driving cycle is stored in 4WD control module memory (in the form of pending DTC) but the 4WD indicator and 4WD low indicator does not flashes at this time. It flashes at the third detection of same malfunction also in the next driving cycle.

Pending DTC Pending DTC means a DTC detected and stored temporarily at 2 driving cycle of the DTC which is adopted the 3 driving cycle detection logic.


DTC check 1) Turn ignition switch to ON position with engine stop. 2) While pushing 2WD switch (1) and 4WD switch (2), push 4WD-L switch (3) 5 times within 10 seconds. 3) Read flashing pattern of 4WD indicator which represents DTC as shown in example below and write it down. When more than 2 DTCs are stored in memory, flashing for each DTC starts with the smallest DTC number in increasing order.

[A] DTC No.: 12 [B] DTC No. 23 [C] Time [a] 4WD indicator turned ON [b] 4WD indicator turned OFF

DTC table The table below shows DTCs that can be read out from the 4WD control module using the DTC check method above.


Fail safe table

Clearing DTCs 1) Performing DTC check 2) Keep pushing 2WD switch, 4WD switch and

4WD-L switch for 5 seconds or more. At the end of step 2, DTCs are cleared and 4WD indicator indicates DTC No.: 12 (normal)

3) Perform DTC Check, and confirm that normal DTC (DTC 12) is displayed.


Service information Transfer gear oil change 1) Before changing or inspecting oil, be sure to stop engine

and lift vehicle horizontally. 2) With vehicle lifted up, check oil leakage. If leakage exists,

correct or repair it. 3) Remove oil filler plug (2). 4) Remove drain plug (1), and drain old oil. 5) Tighten new oil drain plug to specified torque.

6) Pour new specified oil unit oil level reaches bottom of oil filler plug hole (3) as shown in figure.

7) Tighten new oil level/filler plug to specified torque

Gear oil specifications API GL-4, It is high recommended to use API GL-4 75 W 90 gear oil. NB: Always refer to current service literature for the most updated oil specifications:


A transfer case is installed in vehicles equipped with the 4-wheel drive system.

The transfer case distributes the driving force to both the from the rear wheels.

A mechanical lever or electronic switch is used to select the different transfer mode.

An actuator motor is installed in vehicles with automatic shift 4WD system.

Operation of the actuator motor and the 4WD indicator light in the combination meter is controlled by the 4WD control module based on information from different inputs (sensors and switches)

Diagnostic Trouble Codes of the 4WD system can be retrieved without the use of Suzuki SDT.

The 4WD indicator light is used to read out fault codes from the 4WD control module.

Reference The following abbreviations can be used in this training manual A A/B Air Bag ABDC After Bottom Dead Center ABS Anti-lock Brake System AC Alternating Current A/C Air Conditioning A-ELR Automatic-Emergency Locking Retractor A/F Air Fuel Ratio ALR Automatic Locking Retractor API American Petroleum Institute APP Accelerator Pedal Position A/T Automatic Transmission, Automatic Transaxle ATDC After Top Dead Center ATF Automatic Transmission Fluid, Automatic Transaxle Fluid AWD All Wheel Drive API American Petroleum Industry B BARO Barometric Pressure BBDC Before Bottom Dead Center BCM Body electrical Control Module BTDC Before Top Dead Center B+ Battery Positive Voltage BB+ Battery Positive Voltage for Backup

C CAN Controller Area Network CKP Crankshaft Position CMP Camshaft Position CO Carbon Monoxide CO2 Carbon Dioxide CPP Clutch Pedal Position CPU Central Processing Unit CVT Continuously Variable Transmission, Continuously Variable Transaxle D DC Direct Current D/C Driving Cycle DLC Data Link Connector DOHC Double Over Head Camshaft DOJ Double Offset Joint DOT Department of Transportation DPF Diesel Particulate Filter DRL Daytime Running Light DTC Diagnostic Trouble Code (Diagnostic Code) D/C Driving Cycle


E EBD Electronic Brake Force Distribution ECM Engine Control Module ECT Engine Coolant Temperature ECU Electronic Control Unit EEPROM Electrically Erasable Programmable Read Only Memory EFE Heater Early Fuel Evaporation Heater EGR Exhaust Gas Recirculation EGT Exhaust Gas Temperature ELR Emergency Locking Retractor ENG A-Stop Engine Auto Stop Start EPS Electronic Power Steering ESP Electronic Stability Program EVAP Evaporative Emission G GND Ground GPS Global Positioning System GL Gear libricant H HVAC Heating, Ventilating and Air Conditioning HC Hydrocarbons HFC Hydro Fluorocarbon HI High HO2S Heated Oxygen Sensor

I IAC Idle Air Control IAT Intake Air Temperature IMT Intake Manifold Tuning ISC Idle Speed Control ISO International Organization for Standardization J JIS Japanese Industrial Standards J/B Junction Block J/C Junction Connector L L Left LCD Liquid Crystal Display LED Light Emitting Diode LHD Left Hand Drive vehicle LIN Local Interconnect Network LO Low LSPV Load Sensing Proportioning Valve M MAF Mass Air Flow MAP Manifold Absolute Pressure Max Maximum MFI Multiport Fuel Injection Min Minimum MIL Malfunction Indicator Lamp (CHECK ENGINE Light or SERVICE ENGINE SOON Light) M/T Manual Transmission, Manual Transaxle


N NOx Nitrogen Oxides O OBD On-Board Diagnostic system OCM Occupant Classification Module OCV Oil Control Valve O/D Overdrive OHC Over Head Camshaft O2S Oxygen Sensor P PCM Powertrain Control Module PCV Positive Crankcase Ventilation PM Particulate Mater PNP Park / Neutral Position P/S Power Steering PSP Power Steering Pressure R R Right RAM Random Access Memory RHD Right Hand Drive Vehicle ROM Read Only Memory RPM Engine Speed S SAE Society of Automotive Engineers SDM Sensing and Diagnostic Module (Air Bag Controller, Air bag Control Module) SDT Smart Diagnostic Tester SFI Sequential Multiport Fuel Injection SI System International SOHC Single Over Head Camshaft SRS Supplemental Restraint System

T TCC Torque Converter Clutch TCM Transmission Control Module TCSS Traction Control Support System TDC Top Dead Center TP Throttle Position TPMS Tire Pressure Monitoring System TWC Three-Way Catalytic converter U UART Universal Asynchronous Receiver / Transmitter USB Universal Serial Bus V VFD Vacuum Fluorescent Display VIN Vehicle Identification Number VSS Vehicle Speed Sensor VVT Variable Valve Timing W WU-OC Warm Up Oxidation Catalytic converter WU-TWC Warm Up Three-Way Catalytic converter Other 2WD 2-Wheel Drive 4WD 4-Wheel Drive Note: ESP is a trademark of Daimler AG DPF is a trademark of HJS Fahrzeugtechnik GmbH & Co KG and Suzuki is the trade mark licensee.


Well done, you have now completed the DS02 Driveline/axle transfer

online training course!

Please take the online exam


Slide Number 1Slide Number 2Slide Number 3Slide Number 4Slide Number 5Slide Number 6Slide Number 7Slide Number 8Slide Number 9Slide Number 10Slide Number 11Slide Number 12Slide Number 13Slide Number 14Slide Number 15Slide Number 16Slide Number 17Slide Number 18Slide Number 19Slide Number 20Slide Number 21Slide Number 22Slide Number 23Slide Number 24Slide Number 25Slide Number 26Slide Number 27Slide Number 28Slide Number 29

Transfer Case - Suzuki Autotraining.suzukiauto.co.za/SASATrainingDocs/DS02 Driveline Axle... · The...

Documents

Transcript of Transfer Case - Suzuki Autotraining.suzukiauto.co.za/SASATrainingDocs/DS02 Driveline Axle... · The...