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C100 Service Training Manual :All Wheel Drive (AWD)

Participant’s Handout

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C100 Driveline All Wheel Drive


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Table Of Contents

General Description …………………………………...…….…… 5Transfer Case …...………...…...………………………....…… 6Drive Axle ………………….……………………………………… 9Propeller Shaft ……………………………...………….……. 10Rear Drive Module ……………...……………………...….…… 11Diagnosis ……………………………….…………………….… 17Wiring Diagram …………………………………………………… 18

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All Wheel Drive : General description

The C100/C105 is available with either front-wheel drive (FWD) or on-demand all-wheel drive (AWD).

The system delivers power to the front wheels during normal driving conditions on dry road surfaces, but if front wheel slippage caused by rain, snow or mud is detected, power is automatically delivered to the rear wheels as well.

The system is automatically work with no action required by the driver. While primarily intended for on-road use, the AWD system also provides excellent traction and mobility for off-road use as well.

System description

[ Active on-demand all-wheel drive (AWD) ]

Features of the Active-on demand type AWD

1. Electrical Controlled Coupling used (Electro Magnetic type).

2. Monitoring vehicle running condition and active controlling torque in real time. (Coupling engage directly)

3. Rapid convert to AWD, Many control functions, Correspond with ABS/TCS/ESP system.

4. High degree of freedom by various control factors and calibration per each vehicle configurations.

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All Wheel Drive : Transfer case

Transfer case

The Getrag 760 transfer case consists of an aluminum housing, input shaft and gear, and a ring and pinion power transfer system.The Getrag760 transfer case transfers torque/power from the input shaft through the ring and pinion assembly to the rear differential via a 1-piece propeller shaft assembly.

The on-demand rear differential and torque tube assembly distributes variable torque/power to the rear wheels via individual axle shafts.

The Getrag 760 transfer case is a single speed unit. Torque transfer is electronically controlled, dependent on the demand of the rear differential.

The power take-off unit (PTU) uses synthetic hypoid gear lubricant, which is intended for lifetime service. Full fluid level is at the bottom of the fill plug hole when the vehicle is on a level surface.

Synthetic hypoid 75W-900.8 ± 0.1L

Oil specificationOil capacity

Fill plug

Drain plug

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Transfer case exploded view -1

1. Transfer Case Drain Plug

2. Transfer Case Fill Plug

3. Transfer Case Input Shaft Seal – Left

4. Transfer Case O-Ring Seal

5. Transfer Case – Left

6. Transfer Case Vent Assembly

7. Transfer Case Half Locating Pin (Quantity: 2)

8. Front Wheel Drive Shaft Shield

9. C-Clip

10. Front Wheel Drive Retainer

11. Half Shaft Retainer

12. Front Wheel Drive Intermediate Shaft Bearing Retainer (Quantity: 2)

13. Front Wheel Drive Intermediate Shaft Bearing Assembly

14. Front Wheel Drive Intermediate Shaft

15. Transfer Case Mounting Bracket Bolt (Quantity: 6)

16. Transfer Case Mounting Bracket

17. Transfer Case Heat Shield Bolt (Quantity: 4)18. Transfer Case Heat Shield19. Transfer Case Half Bolt (Quantity: 11)20. Transfer Case – Right21. Transfer Case Seal


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Transfer case exploded view - 2

22. Transfer Case Input Shaft Seal (Right)

23. Front Drive Axle Intermediate Shaft Seal Assembly

24. Transfer Case Input Shaft

25. Transfer Case Rear Output Drive Shaft

26. Transfer Case Rear Output Drive Gear Nut

27. Transfer Case Rear Output Shaft Flange

28. Transfer Case Rear Output Shaft Oil Slinger

29. Transfer Case Rear Output Shaft Seal

30. Transfer Case Rear Output Shaft Bearing Assembly (Quantity: 2)

30. Transfer Case Rear Output Shaft Bearing Assembly (Quantity: 2)

31. Transfer Case Rear Output Drive Housing

32. Transfer Case Rear Output Shim

33. Transfer Case Rear Output Drive Shaft Housing Bolt (Quantity: 6)

34. Transfer Case Rear Output Shaft Bearing Spacer

35. Transfer Case Rear Output Shaft

36. Transfer Case Rear Output Drive Shaft Housing Seal O-Ring


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Driver axle(Front)

All Wheel Drive : Drive axle

Intermediate Shaft(FWD)

RH

LH

Intermediate Shaft(AWD)

1. Inboard Seal Kit2. Inboard Seal Kit3. Outboard Joint Kit4. Outboard Seal Kit

Driver axle (Rear)

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Propeller shaft

All Wheel Drive : Propeller shaft

The propeller shaft assembly is a 2–piece design. The front shaft consists of a plunging A–type constant velocity joint at the front and a universal joint and yoke at the rear.

The rear shaft consists of a center bearing and a center yoke, which are pressed onto the rear half of the propeller shaft and retained by a snap ring. The front and rear shafts are joined together at the yokes with a universal joint. The rear shaft attaches to the axle with a flange which is attached to the rear shaft with a universal joint.

The center bearing provides support where the front and rear shafts mate and is bolted to the underbody. The front constant velocity joint is bolted to the power take–off unit (PTU), and the rear universal joint flange is bolted to the clutch coupling assembly.

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All Wheel Drive : Rear Drive Module

[ Rear Drive Module]

1. DescriptionThe rear drive module (RDM) in this vehicle consists of a coupling control module and an aluminum housing which contains a clutch coupling assembly and a differential.The on–demand system operates as follows:1) Only when front wheel slippage is encountered torque/power

is proportioned to the rear wheels.2) As long as there is no front–to–rear speed difference; there

is no torque/power to the rear wheels.3) When front–to–rear wheel slippage does occur, the coupling

control module receive the information from the ECM, BCM, EBCM and the coupling control module sends a signal to the clutch coupling assembly to actuate the clutch coupling pack which then distributes torque/power to the rear wheels. Rear axle output torque is controlled from 0 Nm ~ 2,530 Nm depending on various road condition such as asphalt, sand,snow and ice.

4) The torque distribution ratio of front/rear axle is controlled continuously to have optimized value between 100/0 ~ 50/50 in real time depend on vehicle driving status & road condition.

5) The system has an integral protection device that reduces rear wheel torque when excessive heat is generated, thus protecting the rear wheel drive module (RDM).

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2. Specification

6 EANumber of ball

Main clutch : 12 EA,Pilot clutch:1 EA

Number of multi-disk clutch

1.9 ± 0.2ΩCoil resistance

200 (impossible of oil replacement)Oil capacity

0.6 ± 0.1 ℓOil capacity

Oil specification

Max. torque

Gear ratio

Torque capacity

Operating voltage

Operating temperature

Synthetic hypoid 75W-90

2,530 N·m

2.53 : 1

Rear axle

1,000 N·m

9V ~ 16V

-40 ~ 100

Coupling

GetragManufacturer

SpecificationItem

1

2

3

45

67

8910

11

1. Side bracket 2. Differential assy’ 3. Side cover

4. CCM (Coupling Control Module) 5 .Drive shaft seal

6. Side cover seal 7. Pinion gear seal 8. Clutch couple assy’

9. Couple housing 10. Pinion flange 11. Nut

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3. AWD torque flow

Torque to rear diff’

Torque through propeller

shaft

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4. Operation of Active coupling

[Ball ramp system working mechanism]

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5. Control system

CCMCCM

Magnetic coilMagnetic coil

Power supply(B+)Power supply(B+)

Wheel speed sensorSteering angle sensorABS operation signalAPP sensorEngine RPMParking brake S/WSystem power modePNP S/W

Wheel speed sensorSteering angle sensorABS operation signalAPP sensorEngine RPMParking brake S/WSystem power modePNP S/W

Temperature sensor

Temperature sensor

GMLANGMLAN

AWD warning lampAWD warning lamp

InputInput

Operation signalOperation signal

ClusterCluster

BCMBCM

OutputOutputCoupling statusTransfer statusTemperature status

Coupling statusTransfer statusTemperature status

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6. Functions1) Tight Corner Judgment : Low or zero torque transfer

enables easy and comfortable maneuvering in parking situations.

2) Acceleration : High torque transfer for maximum traction, instantly, on all four wheels.

3) Off-road : Instant activation with high torque transfer for maximum traction without driver’s operation of separate AWD lock switch.

4) Driving on slippery / wet roads : Swift activation of the coupling for maximum traction and safety depending on the slip of the wheels. The coupling communicates on-line with other safety systems in the vehicle.

5) Pre-Torque for Handling Enhancement : Proper Pre-Torque applied to rear wheel for enhanced handling and vehiclestability.

6) Steady Driving Judgment : Reduce rear wheel torque for better fuel economy at steady driving condition not to need AWD.

7) Braking / ABS : ABS braking overrules the coupling to ensure full function of the ABS system.

8) ESP : Communicates with the ESP system to add the rear wheel torque for Yaw control.

9) Mini Tire Detection : An algorithm in the CCM detects differences in the diameters of the tires and compensates the characteristics accordingly.

10) Self Protecting : Algorithm to reduce torque transfer for protecting coupling itself at certain temperature of RDM inside due to the abnormal input condition.

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All Wheel Drive : Diagnosis

Diagnosis

AWD warning lamp

Lost Communication With Anti–Lock Brake System(ABS) Control ModuleBlinkingU0121

Lost Communication With Body Control ModuleBlinkingU0140

Blinking

Blinking

Blinking

ON

ON

ON

ON

ON

ON

Lamp

Lost Communication With Engine Control ModuleU0100

Devicesingle or 1 Voltage LowC0899

System Permanently disabled Information StoredC0561

Calibration Data Not Programmed/LearnedC0558

Electronic Control Unit(ECU) Performance(Wiring)

Electronic Control Unit(ECU) Performance(ROM)C0550

Rear Axle Coupling Solenoid Temperature Sensor CircuitC0394

Rear Axle Coupling Solenoid Control Circuit (Wiring)

Rear Axle Coupling Solenoid Control Circuit(Over Current)

C0393

DescriptionDTC

If the AWD system has a malfunction, AWD warning lamp comes On or blinking and only FWD can be available in this condition.

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All Wheel Drive : Wiring diagram

Wiring diagram

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