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Transfer Case Assembly: Other Hyundai Tucson I

Transfer Case 98 illustrations ~2705 words

POWER FLOW MECHANISM

  1. Normal driving situation: 2WD base driving
  2. 4WD driving in driving situations (rapid activation, cornering etc.)

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Scheme 64
  1. Input the information from each sensor in vehicle Input torque (Throttle position sensor) Cornering situation (Steering angle sensor) Vehicle speed and different wheel speed front & rear (Wheel speed sensor) Braking situation (Brake signal and ABS signal)
  2. Distributed the required driving force after 4WD ECU operates.
  3. EMC (Electric Magnetic Clutch) operates the primary clutch.
  4. Control the cam's opening gap by operation of primary clutch.
  5. Control the slip of inner & outer plate Control variably the driving force distribution to optimize front & rear driving force.

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Scheme 65: SYSTEM SCHEMATICS
Scheme 65: SYSTEM SCHEMATICS

CONTROL ALGORITHM FLOW CHART

The base control algorithm of the ITM ECM is defined by the following flowchart

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Scheme 66: CONTROL ALGORITHM FLOW CHART
Scheme 66: CONTROL ALGORITHM FLOW CHART

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Scheme 67: LOCK MODE DESCRIPTION
Scheme 67: LOCK MODE DESCRIPTION
  1. Based on a driver request for lock mode, the system will supply a fixed torque to the ITM-I clutch.
  2. When the vehicle exceeds 30 kph the system will begin to disable lock mode by ramping down the ITM clutch torque. When the vehicle exceeds 40 KPH the ITM clutch is reduced to its minimum torque value. Lock mode is re-enabled following the same speed-to-torque map.
  3. Lock mode is activated based on part number.
  4. Lock mode will override all other system requests except for during an ABS event. During an ABS event the ITM clutch is turned off.
  5. If there is a speed sensor signal fault, the speeds are no longer considered reliable and lock mode will be disabled.

VERIFICATION OF VEHICLE REPAIR

  1. IG KEY ON, ENG ON
  2. Steering angle sensor module, 4WD ECM connector: Connect.
  3. Clear the DTC with a scan tool.
  4. Rotate the steering wheel both ways.
  5. Verify the malfunction relevant to steering angle sensor #1. Does the scan tool display any DTC relevant to steering angle sensor #1? YES : --> Go to the applicable troubleshooting procedure. NO : --> System OK.
  1. IG KEY ON, ENG ON
  2. Steering angle sensor module, 4WD ECM connector: Connect.
  3. Clear the DTC with a scan tool.
  4. Rotate the steering wheel both ways.
  5. Verify the malfunction relevant to steering angle sensor #2. Does the scan tool display any DTC relevant to steering angle sensor #2? YES : --> Go to the applicable troubleshooting procedure. NO : --> System OK.

Refer to DTC P1717 .

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Scheme 68: COMPONENT LOCATION
Scheme 68: COMPONENT LOCATION
  1. IG KEY ON, ENG OFF
  2. ECM, 4WD ECM connector: Connect.
  3. Shift to N Range.
  4. Clear the DTC with a scan tool.
  5. Verify the malfunction relevant to TPS signal. Does the scan tool display any DTC relevant to steering angle sensor center signal? YES : --> Go to the applicable troubleshooting procedure. NO : --> System OK.

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Scheme 69: COMPONENT LOCATION
Scheme 69: COMPONENT LOCATION
  1. IG KEY ON, ENG ON
  2. Electric Magnet Valve Clutch connector and 4WD ECM connector: Disconnect.
  3. Shift to N Range.
  4. Check EMC output signal and verify the malfunction. Does the scan tool display any DTC relevant to EMC signal? YES : --> Go to the applicable troubleshooting procedure. NO : --> System OK.

Refer to DTC P1728 .

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Scheme 70: COMPONENT LOCATION
Scheme 70: COMPONENT LOCATION
  1. IG KEY ON, ENG ON
  2. 4WD ECM connector and FLSS connector: Connect.
  3. Clear the DTC with a scan tool.
  4. Start and drive vehicle in gear and maintain vehicle speed at approx. 10 km/h or less (6mph or less).
  5. Check FLSS signal and verify the malfunction. Does the scan tool display any DTC relevant to FLSS signal? YES : --> Go to the applicable troubleshooting procedure. NO : --> System OK.

Scheme 71

Scheme 71: COMPONENT LOCATION
Scheme 71: COMPONENT LOCATION
  1. IG KEY ON, ENG ON
  2. 4WD ECM connector and FRSS connector: Connect.
  3. Clear the DTC with a scan tool.
  4. Start and drive vehicle in gear and maintain vehicle speed at approx. 10 km/h or less (6mph or less).
  5. Check FRSS signal and verify the malfunction. Does the scan tool display any DTC relevant to FRSS signal? YES : --> Go to the applicable troubleshooting procedure. NO : --> System OK.

Scheme 72

Scheme 72: COMPONENT LOCATION
Scheme 72: COMPONENT LOCATION
  1. IG KEY ON, ENG ON
  2. 4WD ECM connector and RLSS connector: Connect.
  3. Clear the DTC with a scan tool.
  4. Start and drive vehicle in gear and maintain vehicle speed at approx. 10 km/h or less (6mph or less).
  5. Check RLSS signal and verify the malfunction. Does the scan tool display any DTC relevant to RLSS signal? YES : --> Go to the applicable troubleshooting procedure. NO : --> System OK.

Scheme 73

Scheme 73: COMPONENT LOCATION
Scheme 73: COMPONENT LOCATION
  1. IG KEY ON, ENG ON
  2. 4WD ECM connector and RRSS connector: Connect.
  3. Clear the DTC with a scan tool.
  4. Start and drive vehicle in gear and maintain vehicle speed at approx. 10 km/h or less (6mph or less).
  5. Check RRSS signal and verify the malfunction. Does the scan tool display any DTC relevant to RRSS signal? YES : --> Go to the applicable troubleshooting procedure. NO : --> System OK.

Scheme 74

Scheme 74: COMPONENT LOCATION
Scheme 74: COMPONENT LOCATION

MONITOR SCANTOOL DATA

When the DTCs related to CAN communication set, use the sensor data (TCM side) to check for the ECM & TCM's communication condition. Check the data such as the engine RPM and the throttle position sensor at idle in order to inspect the signal between ECM and TCM.

  1. IG KEY ON, ENG ON
  2. TCS module connector and 4WD ECM connector: Connect.
  3. Clear the DTCs with a scan tool.
  4. Start and drive vehicle in gear and maintain vehicle speed at approx. 10km/h or less (6mph or less).
  5. Check TCS signals and verify the malfunction. Does the scan tool display any DTC relevant to this signal? YES : --> Go to the applicable troubleshooting procedure. NO : --> System OK.

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Scheme 75: COMPONENTS
Scheme 75: COMPONENTS

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Scheme 76: [2.0L]
Scheme 76: [2.0L]
  1. Remove the battery (-) terminal.
  2. Lift up the vehicle.
  3. Remove the propeller shaft (See «PROPELLER SHAFT»(ref-276698-S16211000532008011000000) ).
  4. Remove the front muffler (A).
  5. Remove the RH driveshaft (See «FRONT DRIVESHAFT ASSEMBLY»(ref-276695) ).
  6. Loosen the oil drain plug and drain the fluid.
  7. After draining, re-tighten the oil drain plug. TORQUE: 39.2~58.8 Nm (400~600 kgf.cm, 28.9~43.4 lb-ft)
  8. Support the transfer assembly with a jack.
  9. Remove the transfer assembly by loosening the mounting bolts. CAUTION: Remove the transfer bracket mounting bolts (2EA) together.

[2.7L 4WD]

Note. The repair of the transfer assembly requires a special skill and furthermore an improper adjustment of the spacers may cause a severe noise and durability issue. Hypoid gear set is manufactured and controlled as a pair. Any replacement of the part is to be done as a pair, hypoid gear shaft assembly 47308-39200 and pinion shaft 47311-39000.

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Scheme 77: [2.7L 4WD]
Scheme 77: [2.7L 4WD]

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  1. Remove the battery negative (-) cable.
  2. Remove the air intake hose and air cleaner cover and then disconnect the oxygen sensor connector. (A-Engine room left side).
  3. Disconnect the oxygen sensor connector (B) and remove the oxygen sensor connector wire clamp from a bracket. (Engine room right side).
  4. Remove the wheel and tire (RH).
  5. Remove the engine side cover (A) (RH).
  6. Lift up the vehicle.
  7. Remove the lower arm ball joint mounting bolts (A).
  8. Remove the lower arm ball joint from the front axle knuckle.
  9. Remove the steering bar tie rod ball joint (A) from the knuckle.
  10. Remove the drive shaft (A) from the transfer.
  11. Remove the front exhaust pipe (A).
  12. Drain the transfer oil through drain plug hole.
  13. Remove the pinion case mounting bolts (A).
  14. Remove the alternator drive belt (A) using the tensioner and then alternator assembly (C) by loosening the mounting bolts (B).
  15. Remove the alternator wire terminal mounting nut (A) and connector (B).
  16. Remove the heat protector (A) using a hexagonal socket. NOTE: To remove the heat protector mounting bolt easily, before removing the heat protector mounting bolts (3EA), apply the mounting bolt with "WD-40® stops squeaks".
  17. Lift up the vehicle.
  18. Remove the exhaust manifold mounting nuts (7EA). NOTE: To remove the exhaust manifold mounting nut easily, before removing the exhaust manifold mounting nuts (7EA), apply the mounting nuts with "WD-40® stops squeaks".
  19. Remove the transfer mounting bracket (A).
  20. Remove the transfer mounting bolts (4EA).
  21. Using a flat head screw driver, remove the transfer from the transaxle by moving the driver to left and right directions.

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Scheme 89: DISASSEMBLY
Scheme 89: DISASSEMBLY

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  1. Drain the transfer oil through drain plug hole.
  2. Remove the pinion assembly mounting bolts (6EA) and then remove the pinion assembly (A). NOTE: This assembly can be removed with a propeller shaft assembly in REMOVAL step.
  3. Remove the transfer cover (A) with the inner drive shaft (B) assembly.
  4. Remove the transfer drive gear assembly (A) from the transfer housing.
  5. Remove the hypoid gear shaft assembly (A) from the transfer housing.
  6. Remove the oil seal (A) (47452-39000, transfer drive gear left hand side). NOTE: When reassembling the transfer, be sure to always replace the oil seal (47452-39000) with new part.
  7. Using a sliding hammer, remove the taper roller bearing outer races (A) from the transfer cover (B) and housing (C).
  8. Using the SST (09455-32200), remove the oil seal (A) from the transfer cover. NOTE: When reassembling the transfer, be sure to always replace the oil seal (47350-39010) with new part.
  9. Remove the snap ring (A) from the transfer cover.
  10. Remove the inner drive shaft assembly (A) from the transfer cover (B) by hammering.
  11. Using a sliding hammer (A), remove the other taper roller bearing outer race (B) from the transfer cover.

CHECK FOR TRANSFER OIL

  1. Check and replenish the transfer oil every 40,000 km (24,855 miles).
  1. Install the transfer assembly to the transaxle. NOTE: To install the transfer easily, install it by moving the pinion left and right directions, and slightly rotating the inner drive shaft of transfer assembly.
  2. Install the transfer mounting bolts (4EA). TORQUE: 60.8~65.7 Nm (620~670 kgf.cm, 44.8~48.5 lb-ft)
  3. Install the transfer mounting bracket(A). TORQUE: 46.1~50.0 Nm (470~510 kgf.cm, 34.0~36.9 lb-ft) - 2EA 23.5~27.5 Nm (240~280 kgf.cm, 17.4~20.3 lb-ft) - 3EA
  4. Tighten the exhaust manifold mounting nuts (7EA). TORQUE: 29.4~34.3 Nm (300~350 kgf.cm, 21.7~25.3 lb-ft)
  5. Tighten the heat protector (A) mounting nuts (3EA). TORQUE: 11.8~14.7 Nm (120~150 kgf.cm, 8.7~10.8 lb-ft)
  6. Connect the alternator wire terminal (A) and connector (B).
  7. Install the alternator drive belt (A) using the tensioner and then alternator assembly (C) by tightening the mounting bolts (B). TORQUE: 19.6~29.4 Nm (200~300 kgf.cm, 14.5~21.7 lb-ft)
  8. Tighten the pinion case mounting bolts (6EA). TORQUE: 36.3~39.2 Nm (370~400 kgf.cm, 14.5~21.7 lb-ft)
  9. Refill the transfer oil through the filler plug.
  10. Install the front exhaust pipe (A).
  11. Install the drive shaft (RH) to the transfer assembly, lower arm ball joint mounting and steering bar tie rod ball joint.
  12. Lower the vehicle down.
  13. Install the engine side cover (RH) and the wheel and tire (RH).
  14. Connect the oxygen sensor connector (B) and insert the oxygen sensor connector wire clamp into a bracket. (Engine room right side).
  15. Install the air intake hose and air cleaner cover and then connect the oxygen sensor connector. (A-Engine room left side).
  16. Connect the battery negative (-) cable.

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Scheme 100: COMPONENTS
Scheme 100: COMPONENTS

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Scheme 101: DISASSEMBLY
Scheme 101: DISASSEMBLY

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  1. Remove the oil seal (A) from the transfer drive gear.
  2. Using the SST (09455-21000), remove the taper roller bearings (A) from the both sides of the transfer drive gear assembly.
  3. By hammering, remove the hollow shaft (A) from the transfer drive gear assembly.

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Scheme 105: REASSEMBLY
Scheme 105: REASSEMBLY
  1. Using a press machine, install the taper roller bearings (A) to the transfer drive gear.

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Scheme 106: COMPONENT
Scheme 106: COMPONENT

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Scheme 107: DISASSEMBLY
Scheme 107: DISASSEMBLY

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  1. Using the SST (09455-21000), remove the taper roller bearing (A) from the hypoid gear shaft assembly.
  2. Using the SST (09455-21000), remove the other taper roller bearing (A) from the hypoid gear shaft assembly.

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Scheme 110: REASSEMBLY
Scheme 110: REASSEMBLY

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Scheme 111
  1. Using a press machine, install the taper roller bearings (A) to the hypoid gear shaft assembly.

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Scheme 112: COMPONENT
Scheme 112: COMPONENT

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Scheme 113: DISASSEMBLY
Scheme 113: DISASSEMBLY

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  1. Remove the O-ring (A) from the pinion shaft and case assembly.
  2. Remove the spacer (A).
  3. Loosen the HEX lock nut (A).
  4. Remove the rear flange assembly (A).
  5. Using the SST (09455-32200), remove the oil seal (A) from the pinion case.
  6. Using a press machine, remove the pinion shaft (A) from the pinion case (B).
  7. Take out the taper roller bearing (A) from the pinion case (B).
  8. Using a sliding hammer (A), remove the taper roller bearing outer race (B) from the pinion case (C).

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Scheme 121: REASSEMBLY
Scheme 121: REASSEMBLY

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Scheme 123
  1. Assemble the taper roller bearing outer races.
  2. Using a press machine, install the taper roller bearing (C) and the pinion shaft (A) in the pinion case (B).
  3. Install the oil seal and the rear flange assembly as shown below and screw down the hex lock nut (A) until an axial clearance B of 0.25 mm to 0.75 mm between pinion and pinion case results. Measurement of B Apply an additional 200N tension load F1 to the pinion head according to arrangement Y. Rotate the pinion 10 times and measure dimension C. Apply a 200N load F2 to the rear flange. Rotate the pinion 10 times and measure dimension D. B=C-D Measure dimension Ev. Tighten HEX lock nut. Measure the drag torque of the pinion assembly. Target is 180-210 Ncm. To achieve the target preload torque, it is permissible to gradually increase the tightening torque. CAUTION: If the permissible preload torque of 210 Ncm is exceeded, it is not allowed to loosen Hex lock nut. Disassemble the whole pinion assembly. Replace the collapsible spacer and repeat the mounting procedure. Measure dimension En. Check preload. A preload torque of 180 to 210 Ncm corresponds to a bearing preload of 0.12 to 0.16 mm. Ev-En-B=0.12 to 0.16 mm CAUTION: Twice use of collapsible spacer is not permitted (Permanent deformation).
  4. Assemble the O-ring and select the proper spacer later when reassembling the transfer case.

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Scheme 124: COMPONENTS
Scheme 124: COMPONENTS

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Scheme 125: REMOVAL
Scheme 125: REMOVAL

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  1. Remove the 4WD coupling bolts (A-3EA) mounted to the rear propellar shaft (B).
  2. Using a flat tool (A), separate the propellar shaft (C) from 4WD coupling (B).
  3. Remove the rear axle (B-Differential carrier) bolts mounted to the 4WD coupling (A) by a socket (C).
  4. Remove the electric magnetic clutch connector (A).
  5. Using a flat tool (A), separate the 4WD coupling assembly (B) from the rear differential carrier (C).
  6. Remove the 4WD coupling assembly (A).

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Scheme 132: DISASSEMBLY
Scheme 132: DISASSEMBLY

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  1. Remove the coupling (A) flange (B) mounting nut (C).
  2. Remove the flange spacer (A).
  3. Remove the coupling flange oil seal (A).
  4. Using a general tool, 3-way puller (A), remove the flange assembly (B) from the coupling (C).
  5. Remove the flange oil seal (A) using special tool (09432-33200).
  6. Remove the coupling case assembly (A). Remove the coupling case oil seal (A) NOTE: Insert the (-) driver between the oil seal and the clutch housing, then remove the oil seal Remove the snap ring. Remove the Electric Magnetic clutch (B) mounting nuts (A-3EA).
  7. Remove the wave spring (B) for fixing the plate (A) and the secondary clutch assembly.
  8. Remove the snap ring (A).
  9. After removing the oil seal, remove the snap ring (A).
  10. Remove the back plate and the secondary clutch (A) assembly simultaneously using special tool (09478-26100). Separate the back plate (A) from the input shaft. Remove the plates (A-10EA) and the discs (B-10EA). Remove the armature (A). Remove the input shaft (A).
  11. Remove the steel balls (A-6EA) on the base cam.
  12. Remove the base cam (A).
  13. Remove the thrust washer (A).
  14. Remove the thrust race.
  15. Remove the snap ring (A).
  16. Remove the disk (A) of the primary clutch.
  17. Remove the plate (A) of the primary clutch. NOTE: Additionally remove each 2EA discs and plates alternately.

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Scheme 156: REASSEMBLY
Scheme 156: REASSEMBLY

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  1. When reassembling the back plate oil seal (A), reassemble it using a suitable tool (B).
  2. In case of the coupling case oil seal (A), too, reassemble it using a suitable tool (B).
  3. When reassembling the 4WD coupling assembly and the flange (A), too, reassemble them using a suitable tool (B).
  4. Install the flange (A) oil seal (B) using special tool (09478-26000).

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