4wd_jm

4WD SYSTEM (ITM: Interactive Torque Management)

Chonan Technical Service Training Center 1

Electronically Controlled

On-Demand 4WD System



CONTENTS

1. INTRODUCTION ----------------------------------------------------------------------

2. T/M & TRANSFER CASE ---------------------------------------------------

3. COUPLING & REAR AXLE ASSEMBLY ---------------------------------------

4. INPUTS AND OUTPUTS -------------------------------------------------------------

5. DIAGNOSIS ------------------------------------------------------------------------------

6. WIRING DIAGRAM ---------------------------------------------------------------------

7. 4WD COUPLING ASSEMBLY -------------------------------------------------------



1. INTRODUCTION

Controllability of the vehicle in all driving situations is becoming an important promotional factor for

All-Wheel-Drive. An AWD vehicle has better road handling and is safer in all driving situations.

Answering these requirements, the new Electronically Controlled On-Demand 4WD of JM offers

fully controllable torque transfer characteristics and extremely rapid activation and deactivation

automatically. SANTA FE equipped Diesel VGT (Variable Geometric Turbocharger) engine has

been already using this system since November 2002. However most parts of the system such

as T/M case, transfer case, front differential and rear differential cannot be interchangeable

between JM and SANTA FE.

The characteristics of this system is that it is in the 2WD state at constant vehicle speed but it

changes the torque distribution to rear wheels in the 4WD state according to the driving state.

ENGINE

[Transfer Case]

[Coupling & Rear Axle Assembly]

[Layout of JM 4WD System]



1.1 APPLICATION

REGION

LINE-UP

M/T

A/T

M/T

A/T

д-2.7V6

A/T

AUSEC

SO

-

-

O

- O

GENERALAREA

O -OO

O

O

в-2.0CVVT

- O

MIDDLEEAST

KOREANORTH

AMERICA

DDC 2.0DSL

O -O

OOO

- O OOO

O

O

O

O

* O: Optional Item, S; Standard Item

1.2 ADVANTAGES

Maximum performance and safety are achieved in all driving situations, as shown here:

Enhanced Vehicle Traction

- Torque transfer up to 1,200 Nm

- Full function in reverse

- Instant activation on differential speed

Enhanced Vehicle Dynamics

- Improved dynamics during acceleration and deceleration

- Rapid activation and deactivation

- Fully controllable torque transfer characteristics

Enhanced Vehicle System Compatibility

- On-line communication with the CAN system

Enhanced Vehicle Driving Comfort and Transparency

- No wind-up during tight cornering and parking

- Optimal traction during acceleration

Enhanced Optimization of Weight and Fuel Consumption

- The fully controllable torque transfer characteristic decreases the design requirements of the

complete AWD drive line, resulting in reduced weight and reduced fuel consumption



Variable Torque Control

- At Parking: Low or zero torque transfer needed for easy and comfortable maneuverability

- Acceleration: High torque transfer for maximum traction on all four wheels

- High speed driving: Reduced torque transfer, to minimum, still adding dynamic stability

- Driving on slippery/wet roads:

Swift activation of the coupling for maximum traction and safety depending on the slip of the

wheels. The coupling is in on-line communication with other safety systems in the vehicle

- Braking/ABS: Immediate deactivation on ABS signal to ensure full function of ABS system

- ESP/TCS

Immediate deactivation on ESP/TCS signal to ensure full function of ESP/TCS system.

Alternative is to communicate with the ESP/TCS system for adding the control possibility of the

new ON-Demand 4WD System to the ESP/TCS System

- Off-road: Rapid activation with high torque transfer for maximum traction



2. T/M & TRANSFER CASE

- 4WD Transfer Case: Santa Fe base modification

- T/M Case: Modification of 4WD transfer matching part

- T/M Differential for 4WD: Modification of transfer matching part



3. COUPLING & REAR AXLE ASSEMBLY

- Coupling: Same as Santa Fe

- Rear Axle: Santa Fe base modification

- Control Unit: Santa Fe base modification (Location: under the driver seat)

3.1 SPECIFICATION (ITM: Interactive Torque Management)

FeatureSelf-contained, compact, light-weight, torquetransfer device for on-demand 4WD

Torque 2000 Nm

Weight 8 kg

Size 150mm Long, 140mm OD, 120mm ID

Housing Aluminum

Operating Voltage 12 volts

Operating Temperature -40 Ў Й ~ 150 Ў Й

4WD Coupling Oil Mobil Fluid – LT (0.15L)

Primary Clutch Disc (3 EA), Plate (3 EA)

Secondary Clutch Disc (10 EA), Plate (10 EA)

ITM



3.2 LOCATION

3.3 STRUCTURE

[Location of ITM Coupling]

EMC Coil Primary Clutch Apply Cam

Secondary Clutch

Back Plate

Armature

Clutch Housing Coupling Case

From Front Wheel

To Rear Wheel



3.4 COMPONENTS

Wave spring

Snap ring

Oil seal

Snap ring

Back plate Snap ring

Thrust race

Thrust washer

Base cam

Steel balls (6EA)

Disc

(10EA)

Plate

(10EA)

Disc

(3EA) Plate

(3EA)

Armature

Input shaft Nut

Spacer Oil seal

Flange

Oil seal

Snap ring

Coupling case

Electric magnetic clutch

Clutch housing

Primary clutch

Secondary clutch

214-218 (2140-2180, 158-161)

TORQUE : N⋅⋅⋅⋅m (kg⋅⋅⋅⋅cm, lb⋅⋅⋅⋅ft)



4WD ECU

[Housing] Primary Clutch [Primary Clutch]

Armature Base Cam [Base Cam]

[Armature]

Apply Cam Balls

Back Plate To rear differential EMC connector



3.5 OPERATION OF COUPLING

- Constant speed drive: almost 2WD state

- Torque distribution (4WD state) changes according to the driving state (ex: sudden start,

turning, at low-mu surface) by the ECU logic

- Basic information: Input torque (Throttle Position Sensor), Steering Angle Sensor, Wheel

Speed Sensor, Brake Signal as well as ABS signal

- EMC Coil energizes to operate the Primary Clutch

- The amount of electromagnetic force in the Primary Clutch decides displacement of a Base

Cam

- Displacement of the Base Cam increases frictional force between Inner Plates and Outer

Plates of the Secondary Clutch

- While braking: performs a different control logic to get efficient braking

·Throttle Position Sensor

·Wheel Speed Sensor

·Steering Angle Sensor

·ABS Signal

4WD ECU

Torque distributed at the

4WD coupling

Judge the driving

state

Decide an optimal

torque distribution

4WD operation

[Operating Chart]



1) MODULATING PRIMARY CLUTCH

Ошибка!

When an EMC Coil energizes, electromagnetic field is generated attracting an Armature as well as

Primary Clutch and it increase the frictional force between inner metal plates and outer metal

plates of Primary Clutch.

Higher frictional force applies bigger torque to rotate the Base Cam because the outer plates

splined to a clutch housing and the inner plates splined to a Base Cam..

PRIMARY CLUTCH

CLUTCH HOUSING

ARMATURE

Compress Primary Clutch

Primary torque in base cam

Input torque from propeller shaft

Magnetic Field

EMC COIL

Modulating Primary Clutch

Apply Force Multiplier

Secondary Wet Friction Clutch



2) APPLY FORCE AMPLIFIER

When the primary torque in the Base Cam increases, the Base Cam begins to rotates over the Ball

on the Apply Cam and it pushes the Apply Cam increasing the apply force to the Secondary Clutch.

3) SECONDARY WET FRICTION CLUTCH

The apply force from the Apply Cam compresses the Secondary Clutch and it increases the

frictional force between inner plates which is splined with a Input Shaft and outer plates which is

splined to a Clutch Housing. The more frictional force generates the higher output torque.

Back Plate

Clutch Plates

Apply Cam

Compress

Secondary Clutch

Clutch Housing

Output torque to Rear Axle

Apply Force


Ball

Apply Cam

Base Cam

Ball cam at rest




4. INPUTS AND OUTPUTS

* CAN (Controller Area Network)

4WD

CONTROL

MODULE

(ITMCM)

BATTERY & IGNITION1

STEERING ANGLE SENSOR (ESP by CAN)

WHEEL SPEED SENSOR (ABS/TCS, ESP by CAN)

ABS ACTIVE (by CAN)

4WD LOCK SWITCH

TPS (by CAN)

EMC

4WD WARNING LAMP

DIAGNOSIS

INPUTS OUTPUTS

4WD LOCK LAMP



1) STEERING ANGLE SENSOR (Refer to ESP section for detailed information)

Steering angle signals of the vehicle with ESP (Electronic Stability

Program) come to the ITMCM through the CAN BUS line. However

without ESP, steering angle signals directly come to the ITMCM from the

sensor side. With the steering angle information, the ITMCM detects the

amount of steering and it controls the EMC coil current to prevent torque

conflict between the front wheels and the rear wheels.

2) WHEEL SPEED SENSOR (Refer to ESP section for detailed information)

Wheel speed sensor signals of the vehicle with ABS/TCS, ESP come to

the ITMCM through the CAN BUS line. However vehicle with a

conventional brake system, wheel speed signals directly come to the

ITMCM from the sensor side. 4WD system always comes with ABS/TCS,

ESP or conventional brake system not with ABS only.

ITMCM varies the EMC current by the Information of the speed

difference between the front wheels and the rear wheels.

For example, if the speed difference is high, more EMC current is applied by the ITMCM to

reduce the speed gap.

� Front wheel speed = (FL Wheel Speed + FR Wheel Speed) / 2

� Rear wheel speed = (RL Wheel Speed + RR Wheel Speed) / 2

3) ABS ACTIVE SIGNAL

Vehicle is in ABS control, ITMCM does not control the EMC current. Vehicle condition is in 2WD

state.

4) TPS

ABSCM

17

10㏀

IGN

ITMCM

(NO ABS CONTROL �� 9.0V, ABS IN CONTROL �� 0.5V)

- Type : ABSCM side --- OPEN COLLECTOR TYPE

- ITMCM side --- 12V PULL UP

- PULL UP resistance = 10§ �



TPS information comes from the ECM through the CAN BUS line. TPS is an input torque data.

TPS angle suddenly increases, then the applied current to an EMC goes up. Therefore the

torque distribution to rear wheels goes up.

5) 4WD LOCK SWITCH

This switch is selected 4WD LOCK lamp comes on. The ITMCM applies maximum current to

the EMC resulting in 50 to 50 torque distribution.

6) EMC (Electro Magnetic Clutch)

The ITMCM varies the applied current to the EMC to make a torque distribution to the rear

wheels. The EMC current increases then the magnetic force increases. Stronger magnetic

force results in higher pressing force to secondary clutch.

[4WD LOCK Switch] [4WD LOCK Lamp]

[In Engine Idling] [When ‘4WD LOCK’ is selected]



7) 4WD WARNING LAMP

4WD warning lamp blinks (2Hz) when a system failure is detected.

5. DIAGNOSIS



While the ITMCM is actived it periodically monitors its inputs

and outputs. If a fault is detected the Diagnostic Bulb is

illuminated and flash at a rate of 0.25 seconds “ON”, and 0.25

seconds “OFF”. A fault code will also be stored in the ECU

memory.

The first time a fault is detected a DTC is stored in the ECU’s

Non-Volatile memory. This DTC will remain in memory until

the ITMCM is instructed to erase DTC's by the diagnostic tester.

DTC's will not be erased by disconnecting power to the ITMCM.

DTCs ITMES DESCRIPTION

P1717 Steer 1 Loss of signal out of range

P1718 Steer 2 Loss of signal out of range

P1719 Steer C Loss of signal out of range

P1726 TPS input-loss of signal Loss of signal out of range

P1728 EMC-open/short to battery Short/Open to battery

P1729 EMC-short to ground Short to ground

P1750 FLSS loss of signal Malfunction of front & left speed sensor

P1751 FRSS loss of signal Malfunction of front & right speed sensor

P1752 RLSS loss of signal Malfunction of rear & left speed sensor

P1753 RRSS loss of signal Malfunction of rear & right speed sensor

P1764 ECM-ITM CAN line, or ECM side

malfunction Malfunction of ECM-ITMCM CAN line

P1765 TCS-ITM CAN line, or ECM side

malfunction Malfunction of TCSCM-ITMCM CAN line

Input Error

Description Diagnostic

Diagnostic Lamp

Clearing Strategy

[ITM Control Module]



TPS Loss of signal

Out of range P1726 Blinking

Active P-code cleared error is

removed after 1 second

Error

Strategy A fault code from the CAN Bus, Signal lost for 1 sec. Fault code stored in memory

ECU

Action TPS=0, The ITMCM will not send current to the clutch coil.

Steer_1 Loss of signal

Out of range P1717

Blinking Active P-code cleared if error is


Steer_2 Loss of signal

Out of range P1718

Blinking Active P-code cleared if error is


Steer-C Loss of signal

Out of range P1719 Blinking

Active P-code cleared if error is


Error

Strategy Out of Range Signal : Voltage >= 4.5 vdc for greater than 1 second

ECU

Action Steering Wheel Sensor input=0. The ITMCM will not send current to the clutch coil.

FLSS P1750

(C1201)

FRSS P1751

(C1201)

RLSS P1752

(C1201)

RRSS

Loss of signal

P1753

(C1201)

Blinking

Fault cleared at ignition cycle

reset. P-code stored, and erased

by K-Line tool

Error

Strategy Measure individual wheel, if speed difference is 30kph for 30 seconds fault code

will be set. Ignition cycle reset

ECU

Action Speed sensor error will turn ITM off. ITM will not have output

Input Error

Description DTC

Diagnostic Lamp

Clearing Strategy



C.A.N

ECM-ITMCM

Communication

Line, or ECM

side malfunction

P1764 Blinking Active P-code cleared if error is

removed

Error

Strategy Loss of the following signals TPS, Transmission type.

ECU

Action The ITMCM will not send current to the clutch coil.

C.A.N

TCSCM-ITMCM

CAN Line, or

ECM side

malfunction

P1765 Blinking Active P-code cleared if error is

removed

Error

Strategy Loss of the following signals Wheel Speed No signal for greater than 1 second, and

a fault will be set.

ECU

Action Speed sensor error will turn ITM off. ITM will not have output

Short/Open to

Battery P1728 Blinking

EMC

Short to Grid P1729 Blinking

Same as Speed sensor fault

Error

Strategy 25 occurrences in a row mature

ECU

action EMC Error will turn ITM off. The ITMCM will not send current to the clutch coil

6. WIRING DIAGRAM (for CBS)



Ошибка!

[Connector-Male]



PIN DESCRIPTION

Pin No.44-50-000-093-a

(95447-39980, CBS)44-50-000-094-a

(95447-39982, ABS/TCS)44-50-000-095-a

(99447-39984, ESP)

1 EMC GND EMC GND EMC GND

2 STEERING REF GND STEERING REF GND

3 STEERING REF C STEERING REF C

4 4WD LOCK SWITCH INPUT 4WD LOCK SWITCH INPUT 4WD LOCK SWITCH INPUT

5 RRSS GND RTN

6 RLSS GND RTN

7 FRSS GND RTN

8 FLSS GND RTN

9 CAN H CAN H CAN H

10 CAN L CAN L CAN L

11 ITMCM GROUND ITMCM GROUND ITMCM GROUND

12

13 BATTERY INPUT BATTERY INPUT BATTERY INPUT

14 EMC OUTPUT EMC OUTPUT EMC OUTPUT

15 STEERING REF 5V STEERING REF 5V

16 STEERING 2 INPUT STEERING 2 INPUT

17 STEERING 1 INPUT STEERING 1 INPUT

18

19 4WD WARNING LAMP 4WD WARNING LAMP 4WD WARNING LAMP

20 RR SPEED SENSOR

21 RL SPEED SENSOR

22 FR SPEED SENSOR

23 FL SPEED SENSOR

24 4WD LOCK LAMP 4WD LOCK LAMP 4WD LOCK LAMP

25 IGNITION INPUT IGNITION INPUT IGNITION INPUT

26 K LINE K LINE K LINE

* CBS: Conventional Brake System (without ABS)

7. 4WD COUPLING ASSEMBLY



7.1 SPECAL TOOLS

TOOLS

(PART NUMBER & NAME) ILLUSTRATION USE

09432-33200

Bearing removing plate

Removal of 4WD coupling

flange oil seal

09478-26000

Flange oil seal installer

Installation of 4WD coupling

flange oil seal

09478-26100

Back plate remover

Removal of 4WD coupling

back plate

7.2 TORQUE

ITEMS N⋅⋅⋅⋅m kg⋅⋅⋅⋅cm lb⋅⋅⋅⋅ft

Coupling flange lock nut 214-218 2140-2180 158-161

EMC (Electric Magnetic Clutch) mounting nuts

(3EA) 8-11 80-110 6-8

Rear propellar shaft to 4WD coupling mounting

bolts (3EA) 100-120 1000-1200 74-88

4WD coupling to rear differential carrier bolts 60-65 600-650 44-48



7.3 REMOVAL AND INSTALLATION

1. Remove the 4WD coupling bolts (3EA)

mounted to the rear propellar shaft.

2. Using a flat tool, separate the propellar shaft

from 4WD coupling.

Connecting

bolts (3EA)

Coupling

assembly

Flat tool

Rear propellar

shaft

Coupling assembly



3. Remove the rear axle (Differential carrier)

bolts mounted to the 4WD coupling.

4. Remove the electric magnetic clutch

connector.

5. Using a flat tool, separate the 4WD coupling

assembly from the rear differential carrier.

6. Remove the 4WD coupling assembly.

7. Installation is the reverse of the removal.

Socket

Coupling

assembly Rear differential

carrier

Magnetic clutch connector

Flat tool

Rear differential carrier

Coupling assembly



7.4 DISASSEMBLY

1. Remove the coupling flange mounting nut.

2. Remove the flange spacer.

3. Remove the coupling flange oil seal.

Nut

Flange

Spacer

Oil seal



4. Using a general tool, 3-way puller, remove

the flange assembly.

5. Remove the flange oil seal using special tool

(09432-33200).

6. Remove the coupling case assembly.

1) Remove the coupling case oil seal.

NOTE

Insert the (-) driver between the oil seal

and the clutch housing, then remove the oil

seal.

3-way puller

Flange

Suitable tool

09432-33200

Oil seal

Press

�

Coupling

case

Clutch housing

Oil seal



2) Remove the snap ring.

3) Remove the Electric Magnetic clutch

mounting nuts (3EA).

7. Remove the wave spring for fixing the back

plate and the secondary clutch assembly.

8. Remove the snap ring.

Snap ring

Magnetic

clutch

Wave

spring

Back plate

Snap

ring



9. After removing the oil seal, remove the snap

ring.

10. Remove the back plate and the secondary

clutch assembly simultaneously using

special tool (09478-26100).

1) Separate the back plate from the input

shaft.

2) Remove the plates (10EA) and the discs

(10EA).

09478-26100

Back plate &

secondary

clutch

Back

plate

Plate

Disc



3) Remove the armature.

4) Remove the input shaft.

11. Remove the steel balls (6EA) on the base

cam.

12. Remove the base cam.

Armature

Input shaft

Steel ball

Base cam



13. Remove the thrust washer.

14. Remove the thrust race.

15. Remove the clutch of the primary clutch.

16. Remove the plate of the primary clutch.

NOTE

Additionally remove each 2EA discs and

plates alternately.

Thrust

washer

Thrust race

Snap ring

Plate



7.5 REASSEMBLY

1. When reassembling the back plate oil seal,

reassemble it using a suitable tool.

2. In case of the coupling case oil seal, too,

reassemble it using a suitable tool.

3. When reassembling the 4WD coupling

assembly and the flange, too, reassemble

them using a suitable tool.

4. Install the flange oil seal using special tool.

Suitable tool

Oil seal

Suitable tool

Coupling case oil seal

Suitable tool Flange

09478-2600

Flange

Oil seal

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