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4WD/AWD DIAGNOSIS AND REPAIR

Student Workbook
SAFETY NOTICE
This publication’s purpose is to provide technical training information to individuals in the
automotive trade. All test and repair procedures must be performed in accordance with
manufacturer’s service and diagnostic manuals. All warnings, cautions, and notes must be
observed for safety reasons. The following is a list of general guidelines:
• Proper service and repair is critical to the safe, reliable operation of all motor vehicles.
• The information in this publication has been developed for service personnel, and can help
when diagnosing and performing vehicle repairs.
• Some service procedures require the use of special tools. These special tools must be used
as recommended throughout this technical training publication, the diagnostic manual, and
the service manual.
• Special attention should be exercised when working with spring- or tension-loaded
fasteners and devices such as E-Clips, Cir-clips, snap rings, etc. Careless removal may cause
personal injury.
• Always wear safety goggles when working on vehicles or vehicle components.
• Improper service methods may damage the vehicle or render it unsafe.
• Observe all warnings to avoid the risk of personal injury.
• Observe all cautions to avoid damage to equipment and vehicles.
• Notes are intended to add clarity and should help make your job easier.
Cautions and warnings cover only the situations and procedures FCA US LLC has encountered
Ǥ ϐǡǡ
and advise the service trade of all conceivable ways in which service may be performed, or of the
Ǥǡ ϐ
undertaken any such broad service review. Accordingly, anyone who used a service procedure or
tool that is not recommended in this publication, must be certain that neither personal safety, nor
vehicle safety, is jeopardized by the service methods they select.

No part of this publication may be reproduced, stored

in a retrieval system or transmitted, in any form or
by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written
permission of FCA US LLC.
FCA US LLC reserves the right to make changes from
time to time, without notice or obligation, in prices,
ϐǡǡ
or discontinue models. See your dealer for the latest
information.

Copyright © 2018 FCA US LLC

4WD/AWD Diagnosis and Repair
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
COURSE OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ACRONYMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LESSON 1 4WD/AWD SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4WD/AWD SYSTEM TYPES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ǧ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ǧ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
ACTIVE TRANSFER CASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
ǧ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
TRANSVERSE POWERTRAIN 4WD/AWD SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
DRIVELINE COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
DRIVELINE FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
RECREATIONAL TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
THE IMPORTANCE OF TIRE SIZE AND WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
ʹǧ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
͵ ǧ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
ǧȀ ǧ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
LESSON 4 ACTIVE TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
ͷǧ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
LESSON 6 FRONT AXLE DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
MECHANICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
ELECTRICAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
LESSON 7 TRANSVERSE POWERTRAIN 4WD/AWD SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
SINGLE SPEED SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
DUAL SPEED SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

4WD/AWD Diagnosis and Repair i

DUAL SPEED SYSTEMS WITH LOCKING DIFFERENTIAL CAPABILITY. . . . . . . . . . . . . . . . . . . . . . .83
CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
ACTIVITY 1 TRANSFER CASE MECHANICAL DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
TASK ONE: NVG 241 TRANSFER CASE DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
ǣͶͶǧͶͶ
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
TASK THREE: MP2010 TRANSFER CASE INVESTIGATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
ACTIVITY 2 ACTIVE TRANSFER CASE DIAGNOSIS AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
TASK ONE: VEHICLE ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
TASK TWO: SYSTEM UNDERSTANDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
TASK THREE: VEHICLE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
͵ǧ
. . . . . . . . . . . . . 105
TASK ONE: VEHICLE ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
TASK TWO: SYSTEM UNDERSTANDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
TASK THREE: VEHICLE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
ACTIVITY 4 TRANSVERSE POWERTRAIN 4WD/AWD SYSTEM DIAGNOSIS AND REPAIR . . 111
TASK ONE: VEHICLE ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
TASK TWO: SYSTEM UNDERSTANDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
TASK THREE: VEHICLE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
CONDITIONS/SYMPTOMS RELATED TO TRANSFER CASE MALFUNCTIONS . . . . . . . . . . . . . . 117
REPLACEMENT TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

ii 4WD/AWD Diagnosis and Repair

4WD/AWD Diagnosis and Repair iii
iv 4WD/AWD Diagnosis and Repair
INTRODUCTION

COURSE OBJECTIVES
After completing this course, the technician will be able to:
• Identify part-time, full-time, active, and active on-demand transfer cases
• Identify transverse powertrain 4WD/AWD system components
• Properly diagnose and repair part-time, full-time, active, and active on-demand transfer
cases

• Properly diagnose and repair transverse powertrain 4WD/AWD systems

4WD/AWD Diagnosis and Repair 1

ACRONYMS
The following is a list of acronyms used throughout this publication:
ABS Anti-lock Brake System
APPS Accelerator Pedal Position Sensor
ATF Automatic Transmission Fluid
AWD All-wheel Drive
BCM Body Control Module
BTCM Brake Traction Control Module
BTCS Brake Traction Control System
BW Borg Warner
CAN Controller Area Network
CCN Cabin Compartment Node
DC Direct Current
DLC Data Link Connector
DMM Digital Multimeter
DTC Diagnostic Trouble Code
DTCM Drivetrain Control Module
ECC Electronically Controlled Coupling
ELSD Electronic Limited Slip Differential
ESC Electronic Stability Control
ESP Electronic Stability Program
FCM Front Control Module
FDCM Final Drive Control Module
FWD Front-wheel Drive
Gen II Second Generation
HD Heavy Duty
HDC Hill Descent Control
HSD High-side Driver
LIN Local Interconnect Network
LSD Low-side Driver
MP Magna Powertrain
NVG New Venture Gear
OR Off-road
PCM Powertrain Control Module
PDC Power Distribution Center
PTU Power Transfer Unit
PWM Pulse-width-modulation

2 4WD/AWD Diagnosis and Repair

RDM Rear Drive Module
RWD Rear-wheel Drive
TCM Transmission Control Module
2HI Two-wheel Drive High
2WD Two-wheel Drive
4WD Four-wheel Drive
4HI Four-wheel Drive High Range
4LO Four-wheel Drive Low Range

4WD/AWD Diagnosis and Repair 3

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

4 4WD/AWD Diagnosis and Repair

4WD/AWD Systems

LESSON 1 4WD/AWD SYSTEMS

0321708_001

Figure 1 Jeep Renegade 4WD

The purpose and intent of 4WD/AWD systems has always been the same: To provide engine
torque to both axles of a vehicle when commanded by the driver, or when actuated by the vehicle
control system. These systems, however, have evolved over the years to include more technology,
functionality, and system types.
Accurate 4WD/AWD system diagnosis and service is predicated on knowledge of normal system
operation. This lesson focuses on introducing the various types of 4WD/AWD systems used by
FCA.

4WD/AWD Diagnosis and Repair 5

4WD/AWD Systems

4WD/AWD SYSTEM TYPES

The following system types are found on FCA vehicles:
• Part-time
• Full-time
• Active
• Active on-demand
• Transverse powertrain
Modes and Ranges
ǡǯϐ
terminology.
Mode
Mode refers to the number of wheels receiving torque from the engine.
The typical modes of operation are 2WD, 4WD, AWD, and NEUTRAL:
• In 2WD mode, torque is directed to a single axle (two wheels).
• In 4WD mode (4HI and 4LOW), the axles are mechanically locked together and power is
split between both the front and rear axles.
• AWD is a variation of 4WD in which the front and rear axles are connected through a clutch
or center differential.
• In NEUTRAL, the input shaft and both output shafts are all mechanically released from one
another. No torque is transmitted through the transfer case.
Range
Range refers to the different output gear ratios a transfer case can produce.
Typical ranges are HI and LOW:
• 4WD with no torque multiplication is commonly referred to as 4HI.
• In 4LOW range, power is split between both the front and rear axles. However, the output
torque is increased. Transfer cases equipped with a low range contain a planetary gear
set to increase output torque to the wheels. This range is typically reserved for off-road
conditions.
• A transfer case capable of both high and low ranges is referred to as two speed.
• A transfer case capable of only high range is referred to as single speed.

6 4WD/AWD Diagnosis and Repair

4WD/AWD Systems

Figure 2 Selec-Terrain Switch

dĞƌƌĂŝŶ^ĞůĞĐƟŽŶ
Multiple vehicles are equipped with terrain selection switches (sometimes referred to as Selec-
Terrain). The switches on these systems have selections for different terrain types, such as snow,
sand, mud, etc. These various selections are typically only adjusting software parameters of the
4WD/AWD system and the transmission to maximize traction for varying conditions. For example,
the clutch apply strategy in a transfer case or rear drive module (RDM) will be adjusted. Another
example; sometimes the transmission will force a second gear start condition.

NOTE: Ȁǯϐ
ϐǤ ǡ
ͶǡͶǤ
ǡͳǤ
ͶǡʹǤ
ϐǤ

4WD/AWD Diagnosis and Repair 7

4WD/AWD Systems

WZdͳd/DdZE^&Z^

2034-358_0020

Figure 3 Part-time Transfer Case

Part-time transfer cases are all based on the following features:
• Capable of multiple modes and ranges, most commonly including 2WD, 4WD, 4LOW, and
NEUTRAL
• Front and rear axles mechanically lock together when 4WD is engaged
• Mechanically shifted with a lever and linkage or electronically shifted with a switch and
control module

8 4WD/AWD Diagnosis and Repair

4WD/AWD Systems

KƉĞƌĂƟŶŐDŽĚĞƐͬZĂŶŐĞƐ
Part-time transfer case operating modes/ranges are:
• 2HI
• 4HI
• NEUTRAL
• 4LOW
NOTE: ͶǤ

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞƉƉůŝĐĂƟŽŶƐ
Some examples of part-time transfer cases are:
• BW48-12 (Ram 1500 DT)
• BW44-45 (Ram 1500 DS)
• MP1622 (Jeep Wrangler JL)
• NVG241 (Jeep Wrangler JK)
• BW44-46 (Ram 2500 DJ)
• BW44-47 (Ram 2500 DJ)

4WD/AWD Diagnosis and Repair 9

4WD/AWD Systems

WZdͳd/DdZE^&Z^KWZd/KE

2034-358_0069

Figure 4 Part-time Transfer Case in 4HI or 4LOW

10 4WD/AWD Diagnosis and Repair

4WD/AWD Systems

&h>>ͳd/DdZE^&Z^

0321708_002

Figure 5 Full-time Transfer Case

Full-time transfer cases are all based on the following features:
• Front and rear axles are connected at all times through a center differential
• The center differential allows the front and rear axles to spin at different speeds, preventing
driveline bind up

4WD/AWD Diagnosis and Repair 11

4WD/AWD Systems

KƉĞƌĂƟŶŐDŽĚĞƐͬZĂŶŐĞƐ
Full-time transfer cases operate in an AWD mode at all times, and under all conditions. The
front and rear axles are mechanically connected together through a center differential. Vehicles
equipped with a true full-time transfer case will not have a switch or a lever to actuate the system.
The anti-lock brake System (ABS) and traction control system (TCS) play an essential part in the
operation of a full-time system. The brakes are applied as necessary at spinning wheels in effort to
transfer torque to the wheels with traction.
Part-Time/Full-Time Transfer Cases
A variation of the full-time transfer case, called “part-time/full-time” is available in certain
applications. These transfer cases contain a center differential, in addition to the components of a
typical part-time transfer case. The AWD mode is selectable either through a switch or lever.

&ƵůůͲƟŵĞdƌĂŶƐĨĞƌĂƐĞƉƉůŝĐĂƟŽŶƐ
• MP2010 (full-time in low-line Jeep Grand Cherokee)
• NVG244 (part-time/full-time)

12 4WD/AWD Diagnosis and Repair

4WD/AWD Systems

&ƵůůͲƟŵĞKƉĞƌĂƟŽŶ

2034-358_0070

Figure 6 Full-time Transfer Case in AWD

4WD/AWD Diagnosis and Repair 13

4WD/AWD Systems

ACTIVE TRANSFER CASE

0321708_003

Figure 7 Active Transfer Case

Active transfer cases are all based on the following features:
• Front and rear axles are connected through a clutch
• Clutch application is variably controlled by a control module depending on wheel speed
KƉĞƌĂƟŶŐDŽĚĞƐͬZĂŶŐĞƐ
Under ideal conditions, active transfer cases operate in a 2WD mode. AWD is only used as
necessary to control wheel slip or combat weather conditions. The front and rear axles can be
connected through a clutch in the transfer case. Vehicles equipped with an active transfer case will
not have a switch or a lever to actuate the system

ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞƉƉůŝĐĂƟŽŶƐ
• BW44-40 (Charger, 300, Challenger)
• MP3010 (SRT Grand Cherokee)

14 4WD/AWD Diagnosis and Repair

4WD/AWD Systems

ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞKƉĞƌĂƟŽŶ

2034-358_0071

Figure 8 Active Transfer Case in AWD

4WD/AWD Diagnosis and Repair 15

4WD/AWD Systems

d/sKEͳDEdZE^&Z^

0321708_004

Figure 9 Active On-demand Transfer Case

Active on-demand transfer cases are all based on the following features:
• Contain a clutch similar to an active transfer case to control 4WD AUTO mode
• Contain mechanical components similar to a part-time transfer case, such as a planetary
gear set
• Capable of multiple modes and ranges, such as 2HI, AUTO, 4HI, 4LOW, and NEUTRAL
• Mechanically shifted with a lever and linkage or electronically shifted with a switch and
control module

16 4WD/AWD Diagnosis and Repair

4WD/AWD Systems

KƉĞƌĂƟŶŐDŽĚĞƐͬZĂŶŐĞƐ
Active on-demand transfer case operating modes/ranges are:
• 2HI
• 4HI
• AUTO
• NEUTRAL
• 4LOW

ĐƟǀĞKŶͲĚĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞƉƉůŝĐĂƟŽŶƐ
Some examples of active on-demand transfer cases are:
• MP3022 (Jeep Wrangler JL)
• MP3023 (Jeep Grand Cherokee)
• BW48-11 (Ram 1500 DT)
• BW44-44. (Ram 1500 DS)

4WD/AWD Diagnosis and Repair 17

4WD/AWD Systems

ĐƟǀĞKŶͲĚĞŵĂŶĚKƉĞƌĂƟŽŶ

2034-358_0069

Figure 10 Active On-demand Transfer Case in 4LOW or 4HI

18 4WD/AWD Diagnosis and Repair

4WD/AWD Systems

2034-358_0071

Figure 11 Active On-demand Transfer Case in AUTO

4WD/AWD Diagnosis and Repair 19

4WD/AWD Systems

TRANSVERSE POWERTRAIN 4WD/AWD SYSTEMS

2034-358_0032

1 Transaxle 3 Drive Shaft

2 Power Transfer Unit 4 Rear Drive Module
Figure 12 Transverse 4WD/AWD System
Transverse powertrain 4WD/AWD systems are based on the following features:
• The engine and transaxle are transversely mounted in the vehicle
• A power transfer unit (PTU) sends transmission output torque to the drive shaft and rear
axle
• A rear drive module (RDM) is used to transmit torque to the rear wheels, typically through
a multiple disc clutch

20 4WD/AWD Diagnosis and Repair

4WD/AWD Systems

2034-358_0072

1 Electronically Controlled Coupling 3 4WD Lock Switch

2 Drivetrain Control Module
Figure 13 Transverse 4WD/AWD with Electronically Controlled Coupling (ECC)
KƉĞƌĂƟŶŐDŽĚĞƐͬZĂŶŐĞƐ
Some transverse powertrain 4WD/AWD systems are capable of multiple modes/ranges and are
selectable with a switch. Others require no driver input and are completely module controlled.
A non-selectable system operates in AUTO mode at all times.
The operating modes/ranges of a selectable system are:
• AUTO
• 4LOW
• 4LOW LOCK

4WD/AWD Diagnosis and Repair 21

4WD/AWD Systems

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƉƉůŝĐĂƟŽŶƐ
Some applications of transverse powertrain 4WD/AWD systems are:
• Jeep Cherokee
• Jeep Compass
• Jeep Renegade
• Dodge Journey
• Chrysler 200

22 4WD/AWD Diagnosis and Repair

4WD/AWD Systems

DRIVELINE COMPONENT IDENTIFICATION

6 3

2034-358_0001

1 Model Number 4 Low Range Ratio

2 Assembly Number 5 Day
3 Year 6 Month
Figure 14 ϐ
ϐǡǣ
• Model number
• Assembly number
• Manufacture date
• Gear Ratio

If the unit isn’t equipped with a tag, model information can be accessed via the vehicle sales codes
through a VIN inquiry.

4WD/AWD Diagnosis and Repair 23

4WD/AWD Systems

DRIVELINE FLUIDS

2034-358_0073

1 ϐ 3 Drain Plug

2 Fill Plug
Figure 15 Fluid Fill and Drain Plugs Example
>ĞǀĞůŚĞĐŬŝŶŐͬ&ŝůůŝŶŐ
ϐȀǤǡǡ
ϐȀǤ
dƌĂŶƐĨĞƌĂƐĞ&ůƵŝĚdǇƉĞƐ
ϐǤ
vehicles and models.

NOTE: ϐ
Ǥ

24 4WD/AWD Diagnosis and Repair

4WD/AWD Systems

RECREATIONAL TOWING
Certain 4WD/AWD vehicles have the ability to be recreationally towed. These vehicles have the
ability to achieve NEUTRAL in the 4WD/AWD system. Always refer to the owner’s manual for
recreational towing abilities and procedures.

THE IMPORTANCE OF TIRE SIZE AND WEAR

The importance of proper tire size and consistent tire wear cannot be overemphasized on a
4WD/AWD vehicle. It’s critical that all four tires on the vehicle are extremely close to the same
dimension to prevent system operation and durability concerns.
When in a 4WD or AWD mode, the front and rear axles are either mechanically locked together
or joined by a clutch mechanism. Under normal operation, if the vehicle is in motion, the front
and rear axles are turning at the same speed. This allows the internal components of the transfer
case to turn at the same speed. However, this synchronization can be upset by variances in tire
size. Ultimately, the friction between the tires and the road will dictate the speed of the driveline
components. With a variance in speed between the front and rear axles, the transfer case will
be required to compensate. In a system containing a clutch, the clutch will be forced to slip. In a
system with a mechanical locking mode, the internal components (chain and sprockets, bearings,
engagement components, etc.) will be placed under severe stress to accommodate the variance.
Either situation will ultimately result in system operation and durability concerns.
These types of situations can be caused by installing tires of different sizes or by excessive
variations in tire wear. To avoid such situations, always follow these guidelines applicable to
4WD/AWD vehicles:
• Always replace tires in complete sets where necessary
• Always replace tires with OEM tire size
• ǡϐ
• Rotate tires regularly to avoid wear variances
• Always use the OEM spare tire when necessary

4WD/AWD Diagnosis and Repair 25

4WD/AWD Systems

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

26 4WD/AWD Diagnosis and Repair

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

LESSON 2 WZdͳd/DdZE^&Z^

COMPONENTS

3
2

4
5

2034-358_0045

1 Mode Sleeve 4 Range Select Fork

2 Range Hub 5 Mode Select Fork
3 Planetary Gear Set
Figure 16 Part-time Transfer Case Components

The main components of a part-time transfer case include:

• Input and output shafts
• Chain and sprockets
• Mode select linkage
• Range select linkage
• Planetary gear set
• Lubrication system
• Shift mechanism (manual or electronic)

4WD/AWD Diagnosis and Repair 27

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

DŽĚĞ^ĞůĞĐƚ>ŝŶŬĂŐĞ
The mode sleeve, which is splined to the main shaft, engages 4WD when commanded by the driver.
2WD
When in 2WD, the mode sleeve is disengaged from the input sprocket.
4WD
When in 4WD, the mode sleeve engages the input sprocket, transferring torque through the
chain, to the front output shaft.

ZĂŶŐĞ^ĞůĞĐƚ>ŝŶŬĂŐĞ
The range select fork, which is also splined to the main shaft, engages the LOW range when
commanded by the driver. The range fork can also provide neutral.
2HI and 4HI
In 2HI and 4HI, the range select hub locks the input shaft to the main shaft. Transmission
output torque is transmitted through the transfer case.
NEUTRAL
In NEUTRAL, the range select hub disconnects the input and main shaft, ensuring that wheel
ϐǤ
4LOW
In 4LOW, the range select hub connects the rear output shaft to the planetary carrier. Torque is
transmitted through the planetary gear set, producing a gear reduction.

28 4WD/AWD Diagnosis and Repair

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

WůĂŶĞƚĂƌǇ'ĞĂƌ^Ğƚ

3
2034-358_0046

1 Sun Gear 3 Planetary Gear and Carrier Assembly

2 Annulus (ring) Gear
Figure 17 Planetary Gear Set
A planetary gear set provides low-range gear reduction. The low-range gear reduction is only
engaged when the shifter is in 4LOW. The annulus gear is held to the case, the sun gear is driven,
and the planetary carrier is the output.

4WD/AWD Diagnosis and Repair 29

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

>ƵďƌŝĐĂƟŶŐWƵŵƉ

2034-358_0044

1 Transfer Case Housing 2 Lubricating Pump and Housing

Figure 18 Lubricating Pump and Rear Case Half
ϐǡǡǤ

30 4WD/AWD Diagnosis and Repair

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

OPERATION
Most part-time transfer cases are capable of 4 modes/ranges: 2HI, 4HI, NEUTRAL, and 4LOW.

1 2

2034-358_0040

1 Range Select Fork 2 Mode Fork

Figure 19 2HI
2HI
When the manual shift control lever is in the 2HI position, shown here as 2H, the sector plate acts
against the mode fork to move the mode sleeve out of mesh with the 4WD gear. At the same time,
the range hub moves through the planetary carrier to lock the sun gear to the rear output shaft.
The input from the transmission locks to the rear output shaft in a 1:1 direct drive ratio. No power
transfers to the front output shaft.

4WD/AWD Diagnosis and Repair 31

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

4HI

1 2

2034-358_0041

1 Range Select Fork 2 Mode Fork

Figure 20 4HI
In 4HI, shown here as 4H, the sliding range hub does not change position. The mode sleeve
engages the drive sprocket, connecting the drive sprocket to the main shaft. The drive sprocket
transfers power through the drive chain to the front output shaft drive sprocket, powering the
front axle. The mode sleeve is not synchronized. Gear clash and transfer case damage may occur if
the vehicle speed is more than 5 km/h (3 mph) when shifting between 2HI and 4HI.

32 4WD/AWD Diagnosis and Repair

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

NEUTRAL

1 2

2034-358_0043

1 Range Select Fork 2 Mode Fork

Figure 21 NEUTRAL
To obtain NEUTRAL, the range hub shifts to a mid-position to disengage the input gear from the
range hub teeth. The mode sleeve simultaneously moves out of mesh with the drive sprocket,
allowing the front output shaft to spin free of the rear output shaft.

4WD/AWD Diagnosis and Repair 33

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

4LOW

1 2

2034-358_0042

1 Range Select Fork 2 Mode Fork

Figure 22 4LOW
In 4LOW, shown here as 4L, the mode sleeve remains in the same position as 4HI. The range hub is
ǡǡǡǤϐ
(ring) gear remains stationary. The sun gear drives the pinion gears. The pinion gears move
around the annulus gear to drive the planetary carrier. The planetary carrier drives the output
shaft at a slower speed than the input gear to achieve a low gear ratio.

34 4WD/AWD Diagnosis and Repair

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

CONTROLS
Part-time transfer case shift systems can include a manual shift control lever or an electronic shift
motor to actuate the internal components.
DĞĐŚĂŶŝĐĂů^ŚŝŌĞƌ

2034-358_0033

1 Transfer Case Shifter 2 Shift Cable

Figure 23 Mechanical Shifter
This part-time transfer case uses a mechanically operated shift system. The shift control lever and
cable mechanically actuate the internals of the transfer case to select the desired mode/range.

4WD/AWD Diagnosis and Repair 35

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

ůĞĐƚƌŽŶŝĐŽŶƚƌŽůƐ

358_060

Figure 24 Transfer Case Shift Selector Switch

Electronically controlled shift systems are commanded by a cabin-mounted switch. The switch
provides a request to a module, typically the body control module (BCM) on late model FCA
vehicles. The BCM then busses this information to the DTCM.
The DTCM receives switch information, along with a variety of other direct and bussed inputs,
such as wheel speed and transfer case position. The DTCM utilizes it’s internal logic to execute the
requested operation when the necessary conditions are met.

36 4WD/AWD Diagnosis and Repair

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

ůĞĐƚƌŽŶŝĐ^ŚŝŌDŽƚŽƌͬDŽĚĞ^ĞŶƐŽƌ

2034-358_0058

1 Shift Motor/Mode Sensor

Figure 25 Electronic Shift Motor/Mode Sensor
The shift motor, mounted to the transfer case, is directly controlled by the DTCM. The DTCM
commands shift motor position, while the mode sensor provides feedback to the DTCM.
The following page represents a typical electronically controlled shift system. The transfer case
switch provides a request over a local interconnect network (LIN) bus to the BCM. The DTCM
receives this information over the CAN-C bus. The DTCM is simultaneously receiving information
from other modules over the CAN-C bus, such as wheel speed from the Anti-Lock Brake System
(ABS) module. The DTCM directly controls both the shift motor position and, in this case, a front
axle disconnect as well. Both the shift motor mode sensor, and front axle disconnect provide
position feedback to the DTCM.

4WD/AWD Diagnosis and Repair 37

38
BATTERY
A0

ASSEMBLY-
POWER
DISTRIBUTION
30 RELAY- CENTER
tŝƌŝŶŐ^ĐŚĞŵĂƟĐ

RUN/
START
87 87A
FUSE FUSE
21 94 MODULE- SWITCH- MODULE- CONNECTOR-
FUSE 30A 10A SHIFT TRANSFER BODY STAR
77 BY CASE CONTROL CAN C
10A FUSED WIRE FUSED DASH
LIN LIN CAN CAN
B(+) B(+) GROUND BUS 1 BUS 1 C(+) C(-)
30 2 C3 11 C7 1 7 5 6 7 C7 1 2 C2

17 4
17 4

17 2
17 2
WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

G212
SP2284

6 C1 C C2
6 5 C1
FUSED FUSED
IGNITION CAN CAN MODULE-
B(+)
C(+) C(-) DRIVE
TRAIN
CONTROL
TRANSFER TRANSFER SWITCHED SWITCHED TRANSFER TRANSFER
DRIVETRAIN FRONT FRONT
CASE CASE SHIFT SHIFT BATTERY BATTERY CASE CASE
5 VOLT AXLE AXLE
ENCODER ENCODER MOTOR MOTOR SOLENOID SOLENOID ENCODER ENCODER
SUPPLY LOCK LOCK
SIG 0 SIG 1 CONTROL A CONTROL B SUPPLY SUPPLY SIG 3 SIG 2 CONTROL SIGNAL
GROUND
11 2 C1 B A C2 1 9 16 7 15 14 C1 D C2

A
5 10 11 26 25 9 13 12 34
5 10 11 26 25 9 13 12 34

10 4 5 1
10 4 5 1

A B C D E F G H 3 2 4 1
DRIVETRAIN TRANSFER TRANSFER SHIFT SHIFT SWITCHED TRANSFER TRANSFER ASSEMBLY- MODULE-
FUSED FRONT FRONT GROUND
5 VOLT CASE CASE MOTOR MOTOR BATTERY CASE CASE SHIFT AXLE
IGNITION AXEL AXEL
SUPPLY ENCODER ENCODER CONTROL A CONTROL B SOLENOID ENCODER ENCODER MOTOR/ DISCONNECT-
LOCK LOCK
SIG 0 SIG 1 SUPPLY SIG 3 SIG 2 MODE FRONT
CONTROL SIGNAL
SENSOR

Figure 26 Part-time Transfer Case Wiring Schematic Example

2034-358_0076

4WD/AWD Diagnosis and Repair

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

4WD/AWD Diagnosis and Repair 39

WĂƌƚͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

40 4WD/AWD Diagnosis and Repair

&ƵůůͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

LESSON 3 &h>>ͳd/DdZE^&Z^

COMPONENTS

1 2 3 4 5

7 6

2034-358_0048

1 Input Shaft 5 Rear Output Shaft

2 Drive Chain 6 Driven Sprocket
3 Drive Sprocket 7 Front Output Shaft
4 Center Differential
Figure 27 Full-time Transfer Case Components

The main components of a full-time transfer case include:

• Input and output shafts
• Chain and Sprockets
• Center differential

4WD/AWD Diagnosis and Repair 41

&ƵůůͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

ĞŶƚĞƌŝīĞƌĞŶƟĂů

2034-358_0049

1 Side Gears 2 Pinion Gears

Figure 28 Center Differential Components (MP2010 shown)
The center differential used in the full-time transfer case is a completely mechanical component
that allows power transfer between the front and rear axles without any electronic controls.

42 4WD/AWD Diagnosis and Repair

&ƵůůͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

WůĂŶĞƚĂƌǇĞŶƚĞƌŝīĞƌĞŶƟĂů

2034-358_0039

1 Differential Carrier 2 Sun Gear

Figure 29 Planetary Center Differential Carrier and Sun Gear (NVG244 shown)
There are variations in center differential design. A planetary differential style is shown above.
Overall system operation remains the same.

4WD/AWD Diagnosis and Repair 43

&ƵůůͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

ĂƌƌŝĞƌƐƐĞŵďůǇ

2
1

2034-358_0050

1 Input Shaft 3 Input Shaft Splined Internally

2 Carrier Assembly
Figure 30 Carrier Assembly
The transfer case input shaft is splined directly to the differential carrier assembly. Therefore, it is
driven at transmission output shaft speed.

44 4WD/AWD Diagnosis and Repair

&ƵůůͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

&ƌŽŶƚ^ŝĚĞ'ĞĂƌ

2034-358_0051

1 Chain Drive Sprocket 2 Front Side Gear

Figure 31 Front Side Gear
The front side gear is connected to the front output shaft by way of the drive chain and sprockets.

4WD/AWD Diagnosis and Repair 45

&ƵůůͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

ZĞĂƌ^ŝĚĞ'ĞĂƌ

2034-358_0052

1 Rear Side Gear 2 Rear Output Shaft

Figure 32 Rear Side Gear
The rear side gear is splined directly to the rear output shaft.

46 4WD/AWD Diagnosis and Repair

&ƵůůͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

OPERATION

2034-358_0056

1 Rear Driveshaft Output 2 Front Driveshaft Output

Figure 33 Full-time Center Differential Operation
Torque is split between the front and rear driveshafts, similar to an axle differential splitting
torque between the left- and right-side axle shafts.
ƌĂŬĞdƌĂĐƟŽŶŽŶƚƌŽů^ǇƐƚĞŵ
A full-time transfer case center differential works in the same manner as an open differential. It
will always direct engine torque to the wheels with the least traction if operating alone. Because
of this, full-time transfer cases rely heavily on the brake traction control system (BTCS). The BTCS
will apply the brakes at slipping wheels in order to transfer engine torque to wheels with traction.
If a rear wheel begins to slip, the BTCS will apply the brake to that wheel. Slowing that wheel will
send engine torque, by way of the differential in the axle, to the opposite wheel on that axle.
If both rear wheels begin to slip, the BTCS will apply the brakes to both rear wheels. Slowing both
rear wheels will send engine torque, by way of the center differential in the transfer case, to the
front axle.

4WD/AWD Diagnosis and Repair 47

&ƵůůͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

WZdͳd/Dͬ&h>>ͳd/DdZE^&Z^KEdZK>^

358_074

Figure 34 Full-time Transfer Case Selector Switch Example

As mentioned in Lesson 1, some transfer cases can contain a full-time center differential, while
also containing other part-time components. This type of transfer case is referred to as part-time/
full-time because they are a hybrid of the two.
Part-time full time systems are equipped with a selector switch and DTCM to control part-time
operation. In the example above, selecting AWD will engage the center differential to provide a
full-time mode. 4WD LOCK will provide a 4HI range. 4WD LOW engages a planetary gear set to
produce a low range. The NEUTRAL mode button provides a neutral range for towing.

48 4WD/AWD Diagnosis and Repair

&ƵůůͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

4WD/AWD Diagnosis and Repair 49

&ƵůůͲƟŵĞdƌĂŶƐĨĞƌĂƐĞ

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

50 4WD/AWD Diagnosis and Repair

ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞ

LESSON 4 ACTIVE TRANSFER CASE

COMPONENTS

5
2034-358_0030

1 Rear Output Shaft 4 Transfer Case Temperature Sensor

2 Drive Sprocket and Clutch Assembly 5 Driven Sprocket
3 Electromagnetic Clutch Coil 6 Front Output Shaft
Figure 35 Active Transfer Case Components

The main components of an active transfer case include:

• Input and output shafts
• Chain and Sprockets
• Multiple-disc clutch
• Clutch apply mechanism

4WD/AWD Diagnosis and Repair 51

ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞ

ůƵƚĐŚŽŵƉŽŶĞŶƚƐ

2034-358_0026

1 Clutch Rotor 2 Clutch Pack

Figure 36 Clutch Components
The clutch components consist of a clutch pack, a ball/ramp apply mechanism, and an
electromagnetic rotor and coil.
The clutch pack is a standard multiple-disc clutch assembly. The input shaft is splined to the clutch
hub, while the clutch drum is splined to the input sprocket.

52 4WD/AWD Diagnosis and Repair

ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞ

ůƵƚĐŚƉƉůǇDĞĐŚĂŶŝƐŵ

2034-358_0027

1 Clutch Rotor 2 Ball/Ramp Mechanism

Figure 37 Ball/Ramp Mechanism
A pulse-width modulated (PWM) electromagnetic clutch coil applies the clutch. The ball/ramp
mechanism engages the clutch pack. When energized, the clutch coil slows the revolution of the
clutch rotor. The unequal speed of the clutch rotor and the clutch pack causes the ball to ride up
the ramp and compress the clutch pack. The compressed clutch engages the drive sprocket to the
main shaft, and torque is transmitted through the chain, to the sprocket on the front output shaft,
providing torque to the front axle.

4WD/AWD Diagnosis and Repair 53

ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞ

OPERATION

2034-358_0071

Figure 38 Active Transfer Case in AWD

54 4WD/AWD Diagnosis and Repair

ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞ

Under ideal conditions, active transfer cases operate in a 2WD mode. The clutch remains in
an unapplied state and only the rear wheels propel the vehicle. However, the ABS system is
constantly monitoring wheel speed conditions to determine the need for clutch application.
AWD is used as necessary to control wheel slip or combat weather conditions. Torque is sent to
the front axle through the clutch in the transfer case.
Vehicles equipped with an active transfer case will not have a switch or a lever to actuate the
system.

4WD/AWD Diagnosis and Repair 55

ůĞĐƚƌŝĐĂůKƉĞƌĂƟŽŶ
As shown on the following page, the electrical system is quite simple. The DTCM controls the
application of the clutch coil. A temperature sensor is used to monitor the conditions inside the
unit.
Notice that a front axle disconnect module is also controlled by the DTCM. This module is
responsible for engaging front axle operation when AWD operation is necessary. Lesson 6 covers
front axle disconnect operation in further depth.
Operation of an active transfer case is based on inputs from other modules, Information such as
wheel speed, ambient temperature, engine throttle, and vehicle dynamics are all factored into the
calculation. Notice the CAN-C bus wires are the only input to the DTCM other than the hard-wired
temperature sensor.

56 4WD/AWD Diagnosis and Repair

BATTERY
A0
tŝƌŝŶŐ^ĐŚĞŵĂƟĐ

ASSEMBLY-
ASSEMBLY- POWER
POWER DISTRIBUTION
FUSE DISTRIBUTION RELAY- CENTER-
85 30 MODULE-
CENTER- FUSE FUSE 30 RELAY- FRONT CONNECTOR
2 FRONT AXLE
REAR 1009 48 RUN/ STAR
60A AXLE DISCONNECT-
20A 10A START CAN C
86 87 87A DISCONNECT
87 87A FRONT FRONT FRONT FRONT
2B C2 AXLE AXLE
LOCK LOCK
59B 59A C2 CAN C (+) CAN C (-) SIGNAL CONTROL IGN RS GROUND
9B 40D 40B 40C 40A 48B 48A
4 2 C12 4 2 3 1

1
1

4WD/AWD Diagnosis and Repair

15 7

A 15 7
A

S1310

9 10 4 24
13 19 25
CAN C (+) CAN C (-) FRONT FRONT MODULE-
FUSED B(+) SMART FUSED
AXLE AXLE DRIVE
POWER IGNITION
LOCK LOCK TRAIN
RELAY RUN/
SIGNAL CONTROL CONTROL
FEED START
CONTROL
OUTPUT
SHIFT SHIFT DRIVETRAIN DRIVETRAIN
MOTOR MOTOR 5 VOLT SENSOR
CONTROL B CONTROL A SUPPLY RETURN
GROUND
12 14 7 5
11

11 23 15 9
11 23 15 9

B A C1 B A C2
ASSEMBLY-
SHIFT SHIFT DRIVETRAIN DRIVETRAIN TRANSFER
MOTOR MOTOR 5 VOLT SENSOR
CASE
CONTROL B CONTROL A SUPPLY RETURN

G901A

Figure 39 Active Transfer Case Wiring Schematic Example

2034-358_0075

57
ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞ
ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞ

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

58 4WD/AWD Diagnosis and Repair

ĐƟǀĞKŶͲĚĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞ

LESSON 5 d/sKEͳDEdZE^&Z^

COMPONENTS

1
2

5 3

2034-358_0034

1 Clutch Apply Arms 4 Planetary Gear Set

2 Oil Pump 5 Eccentric Cam
3 Clutch Pack
Figure 40 Active On-demand Transfer Case Components

4WD/AWD Diagnosis and Repair 59

ĐƟǀĞKŶͲĚĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞ

The main components of an active on-demand transfer case include:

• Input and output shafts
• Chain and sprockets
• Multiple-disc clutch
• Clutch apply mechanism
• Planetary gear set
• Mode/range select linkage
• Shift mechanism (manual or electronic)

60 4WD/AWD Diagnosis and Repair

ĐƟǀĞKŶͲĚĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞ

ůƵƚĐŚŽŵƉŽŶĞŶƚƐ

1 2

3
4

2034-358_0035

1 Clutch Drum 4 Clutch Pressure Plate

2 Bearing Spacer Plate 5 Clutch Return Spring
3 Clutch Pack
Figure 41 Clutch Pack System
The clutch pack is used to send torque through the front driveshaft, to the front axle. How
frequently the clutch is used depends on transfer case model. For example, some active on-
demand transfer cases only use the clutch in AUTO mode, while others may use the clutch in all
4WD/AWD modes/ranges to send torque to the front axle.

4WD/AWD Diagnosis and Repair 61

ĐƟǀĞKŶͲĚĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞ

ůƵƚĐŚƉƉůǇDĞĐŚĂŶŝƐŵ

2
3

5 4

2034-358_0031

1 Worm Gear 4 Clutch Pack

2 Worm Shaft 5 Eccentric Cam
3 Clutch Apply Arms
Figure 42 Clutch Apply Mechanism
Clutch apply mechanisms can vary in design. This example shown above consists of an eccentric
cam, clutch apply arms, and clutch pack assembly. When voltage is applied to the motor, the motor
turns a worm shaft. The worm shaft drives a worm gear attached to an eccentric cam. The cam
then changes the position of the clutch apply arms. As the clutch apply arms change position,
the ball and ramp mechanism varies the pressure applied to the clutch pack. Increased pressure
transmits more torque to the front axle.

62 4WD/AWD Diagnosis and Repair

ĐƟǀĞKŶͲĚĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞ

WůĂŶĞƚĂƌǇ'ĞĂƌ^Ğƚ

0322208_004

1 Planetary Gear Set

Figure 43 Planetary Gear Set
A planetary gear set is used to achieve a 4LOW ratio. The design and function is nearly identical to
that in the part-time transfer case discussed in Lesson 2.

4WD/AWD Diagnosis and Repair 63

ĐƟǀĞKŶͲĚĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞ

DŽĚĞͬZĂŶŐĞ^ĞůĞĐƚ>ŝŶŬĂŐĞ

2034-358_0036

1 Range Hub 3 Range Select Fork

2 Barrel Cam
Figure 44 Range Select Fork and Barrel Cam

Mode/range shifts are accomplished through the use of a linkage inside the transfer case. Design
of the linkage will vary depending on transfer case manufacturer and model.

64 4WD/AWD Diagnosis and Repair

ĐƟǀĞKŶͲĚĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞ

OPERATION
An active on-demand transfer case is essentially a hybrid between a part-time unit and an active
unit. It carries over the planetary gear set and mode/range select linkage from a part-time
transfer case, while utilizing a clutch and apply mechanism from an active transfer case.
2HI
Just like a part-time transfer case, torque is transferred through the transfer case to the rear
driveshaft.
Auto
Just like an active transfer case, the vehicle is in a 2WD mode, until wheel slip is detected.
When wheel slip is detected, torque is transmitted through the clutch to the front output shaft
and front axle.
4HI
Like a part-time transfer case, torque is transferred to both the front and rear output shafts. In
some transfer case designs, a mechanical dog clutch connection is used to send torque to the
front output shaft. Other designs utilize the same multiple disc clutch used in AUTO mode.
NEUTRAL
Just like a part-time transfer case, the planetary gear set is placed in an intermediate position
that interrupts torque transfer.
4LOW
Like a part-time transfer case, torque is transferred through the planetary gear set to both
the front and rear output shafts. Just like 4HI, 4LOW also may use either a dog clutch or
multiple-disc clutch to send torque to the front output shaft. Designs vary by model.

4WD/AWD Diagnosis and Repair 65

ĐƟǀĞKŶͲĚĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞ

CONTROLS

2
1

2034-358_0023

1 Encoder Sensor 2 Shift Motor

Figure 45 Electrical Operation
ůĞĐƚƌŝĐĂůKƉĞƌĂƟŽŶ
Although more commonly shifted by the DTCM, active on-demand transfer cases can also be
manually shifted by a linkage. In the example shown above, the shift motor is responsible for both
mode/range shifts, as well as clutch application in AUTO mode. This arrangement is controlled by
a dash-mounted switch.
In the case of a manually shifted unit, mode/range shifts are controlled by a lever/linkage, while
ϐǤ
either case, the DTCM controls motor operation.

The following page represents a typical switch-controlled active on-demand transfer case.
The transfer case switch output is LIN bussed to the BCM. The BCM sends this information
to the DTCM via CAN-C. Transfer case motor position is directly controlled by the DTCM. In
this application, the transfer case motor is responsible for both mode/range shifts, and clutch
application. Transfer case position is monitored by a mode sensor.

66 4WD/AWD Diagnosis and Repair

BATTERY
A0

ASSEMBLY-
POWER
DISTRIBUTION
tŝƌŝŶŐ^ĐŚĞŵĂƟĐ

CENTER
30
RELAY-
RUN/
87 87A
START
SWITCH- MODULE-
TRANSFER BODY
CAN CAN
CASE CONTROL
FUSE FUSE FUSE C (-) C (+)
SELECTOR
F77 F32 F94 LIN LIN BODY BODY
10A 30A 10A FUSED BUS BUS CONTROL CONTROL
B(+) GROUND 1 1 MODULE MODULE
30 C3 41 11 C7 7 6 5 7 C7/G 26 25 C5/E

4WD/AWD Diagnosis and Repair

6
21 6 14
21

4 8 1 2 1 C7
1 CONNECTOR-
CAN CAN
4 8 1 STAR
1 C (-) C (+) CAN CAN
BODY BODY CAN C
C (+) C (-)
CONTROL CONTROL DASH
TRANSFER TRANSFER
MODULE MODULE CASE CASE
MODULE MODULE
2 1 17
1 2 C12
2 1 17

3 30
3 30

4 C1 C C2 6 5 C1
FUSED FUSED CAN CAN MODULE-
IGNITION B(+) C (+) C (-) DRIVE
RUN/ TRANSFER TRANSFER TRAIN
SHIFT SWITCHED STEP SHIFT CONTROL
START DRIVETRAIN MODE DRIVETRAIN CASE CASE
MOTOR BATTERY MOTOR MOTOR
CONTROL 5 VOLT SENSOR SENSOR MODULE MODULE
CONTROL SOLENOID CONTROL CONTROL
OUTPUT GROUND A SUPPLY D B CUPPLY SIGNAL RETURN
D B C2 1 9 C1 A C2 11 3 10 C1

10
10
1 2 3 4 C1 1 2 3 C2

Figure 46 Active On-demand Wiring Schematic Example

SHIFT SWITCHED STEP SHIFT DRIVETRAIN MODE DRIVETRAIN MOTOR-
MOTOR BATTERY MOTOR MOTOR 5 VOLT SENSOR SENSOR TRANSFER
CONTROL SOLENOID CONTROL CONTROL CUPPLY SIGNAL RETURN CASE
A SUPPLY D B

2034-358_0077

67
ĐƟǀĞKŶͲĚĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞ
Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

68 4WD/AWD Diagnosis and Repair

Front Axle Disconnect

LESSON 6 FRONT AXLE DISCONNECT

SP2616_070

Figure 47 Front Axle Disconnect

Most modern 4WD/AWD systems are equipped with a front axle disconnect (FAD). The main
purpose of this device is to reduce the rotating mass of the system when 4WD/AWD is not active.
For example, if a transfer case is in 2WD, there is no reason to spin the front driveshaft or front
differential.
Because the wheels are spinning when the vehicle is travelling down the road, the axles are forced
to rotate. When both axles are rotating at the same speed, the differential is forced to rotate.
Through the ring and pinion gears, the front driveshaft is also forcibly rotated. So, even though
engine torque isn’t being sent through the transfer case to spin the front driveline components, the
wheels are forcing movement through the system. This results in increased rotating mass and a
decrease in fuel economy.
In effort to combat this, a FAD is used to “break” one of the front axle shafts. When one of the front
axle shafts no longer transmits wheel rotation to the differential, it will cease to spin. Instead, the
differential spider gears will just rotate on one another in the differential case. The differential,
ring and pinion gears, and driveshaft should be stationary, or very close to it.

4WD/AWD Diagnosis and Repair 69

Front Axle Disconnect

MECHANICAL COMPONENTS

1 2

0322208_003

1 Disengaged Position 2 Engaged Position

Figure 48 Front Axle Disconnect Sleeve
One axle shaft (right or left depending on design) is split into two halves, both of which are splined
on the ends. An internally splined sleeve rides on the splined ends of the shafts. When 4WD/AWD
is not necessary, the sleeve is moved out of engagement. When 4WD/AWD is desired, the sleeve is
moved to engage both shafts, effectively locking them together.

70 4WD/AWD Diagnosis and Repair

Front Axle Disconnect

ELECTRICAL COMPONENTS

0322208_004

Figure 49 Front Axle Disconnect Actuator

The electrical components include the DTCM and FAD module/actuator. The operation of the
actuator is controlled by the DTCM.

4WD/AWD Diagnosis and Repair 71

Front Axle Disconnect

OPERATION

3
2034-358_0029

1 Transfer Case 3 Transfer Case Temperature Sensor

2 Front Axle Disconnect Assembly
Figure 50 4WD system with FAD
The conditions under which the DTCM will engage the FAD vary by model. Some vehicles
are as simple as 4WD/AWD being engaged by the driver. Others, such as those with an active
transfer case can be more complicated, since the system is completely reliant on the DTCM to
make commands. Some conditions that trigger the engagement of the front axle can include:
temperatures below a certain threshold, the rain sensor actuating the wipers, the electronic
stability programming (ESP) switch in the OFF position, or any other ESP event.

72 4WD/AWD Diagnosis and Repair

Front Axle Disconnect

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

4WD/AWD Diagnosis and Repair 73

Front Axle Disconnect

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

74 4WD/AWD Diagnosis and Repair

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

LESSON 7 TRANSVERSE POWERTRAIN 4WD/AWD SYSTEMS

2034-358_0032

1 Transaxle 3 Driveshaft
2 Power Transfer Unit 4 Rear Drive Module
Figure 51 Transverse Powertrain 4WD/AWD Example
Multiple 4WD/AWD systems are available on vehicles equipped with transverse mounted
powertrains. These systems typically utilize a power transfer unit (PTU) to send transaxle output
torque longitudinally to a rear drive module (RDM). The RDM transfers torque to the rear axle
shafts.
Engagement of the different modes/ranges can be controlled using sleeves, dog clutches, and
multiple-disc clutches. Depending on the system, driver input may or may not be required to
engage 4WD/AWD.

4WD/AWD Diagnosis and Repair 75

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

1 2

5 3

4 2014KL-064

1 Single-range PTU 4 Dual-range RDM

2 Dual-range PTU 5 Dual-range RDM with Locking
Differential
3 Single-range RDM
Figure 52 PTU and RDM Variations
Although there are variations, most systems can be categorized into one of the following:
• Single speed
• Dual speed
• Dual speed with locking differential capability

Most modern variations allow the PTU to completely disconnect power from the rear drive shaft.
However, certain systems propel the driveshaft whenever the vehicle is in motion.

76 4WD/AWD Diagnosis and Repair

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

SINGLE SPEED SYSTEMS

1
2

2034-358_0092

1 Output to Driveshaft 2 Transaxle Mounting Flange

Figure 53 Full-Time Single Speed PTU
^ŝŶŐůĞ^ƉĞĞĚWdh
Single speed systems are capable of sending transmission output torque to both front and rear
wheels, but only at the transmission output ratio. They have no low ratio. Single speed PTUs come
in two variations: Full-time and on-demand.
Full-Time PTU
A full-time PTU, is just as it’s name states; full-time. There is no disconnect between the
transmission and the PTU. Anytime the transmission output shaft is spinning, the PTU is
transferring torque to the driveshaft. Essentially, if the vehicle is moving, the driveshaft is also
moving.
Full time PTU systems are generally considered older technology, but still can be found on some
late-model FCA vehicles. Full -time systems are at a fuel economy disadvantage because the
driveshaft is spinning at all times, whether needed or not.

4WD/AWD Diagnosis and Repair 77

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

On-Demand PTU

2014KL-069

1 Single-range PTU Shift Collar 3 Pinion Shaft

2 Case Half Split 4 Actuator
Figure 54 Single-Speed On-Demand PTU
An on-demand PTU adds the capability to engage and disengage transmission output torque to the
driveshaft. During steady speed driving conditions, the PTU is in a normally open state, meaning
the PTU is not transferring torque to the driveshaft. The main purpose of the open state is to
ϐǤ
slip condition is detected, the PTU will engage. Other driving conditions can also cause the PTU to
engage and remain engaged. These conditions vary by vehicle model.

78 4WD/AWD Diagnosis and Repair

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

^ŝŶŐůĞ^ƉĞĞĚZD

2014KL-084

Figure 55 Single-Speed RDM

Single Speed RDMs are essentially an independent rear axle assembly, with the addition of a clutch.
The clutch is used to apply engine torque to the rear wheels when necessary.
Some units contain a hydraulically applied clutch. Hydraulic pressure originates from an
electrically driven hydraulic pump. When actuated by the DTCM, the motor will turn the pump.
Hydraulic pressure actuates the clutch. The clutch allows driveshaft torque to be sent through the
RDM to the rear axle shafts.
A mechanically applied clutch performs the same task as the hydraulically applied clutch, but the
clutch is applied by mechanical means, such as a ball and ramp mechanism. The ball and ramp
mechanism is electronically actuated by a motor.
Electromagnetic clutch mechanisms can be found on the front of certain RDMs. In these units, the
clutch resides between the driveshaft and the pinion gear.

4WD/AWD Diagnosis and Repair 79

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

DUAL SPEED SYSTEMS

1
2
5

4 3
2014KL-075

1 PTU Actuator 4 Transfer Gear Collar

2 Differential Assembly 5 Transfer Gear
3 Input Shaft Sleeve
Figure 56 Dual-range PTU Actuator in 2WD
A dual speed system works much in the same way single speed system does, but it introduces
planetary gear sets and some new engagement components. Also, a differential can be included in
the PTU, instead of the transaxle.
A planetary gear set is found in both the PTU and the RDM of dual speed systems. These planetary
gear sets provide a low output ratio to the wheels when requested by the driver.

80 4WD/AWD Diagnosis and Repair

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

ƵĂů^ƉĞĞĚWdh

2014KL-071

Figure 57 Dual-Speed PTU

When in high range, the PTU operates essentially the same as an on-demand single speed unit. The
unit will engage as necessary to send torque from the transmission to the driveshaft.
When in low range, the PTU engages the planetary gear set to provide a low range to the front
wheels.
The driveshaft, however, still receives normal PTU output. The RDM contains it’s own planetary
gear set for the rear wheels, which will be discussed shortly.

4WD/AWD Diagnosis and Repair 81

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

ƵĂů^ƉĞĞĚZD

4 2 1

2014KL-087

1 Ring Gear (splined to clutch hub) 4 Shift Collar

2 Clutch Assembly (housing splined to the 5 Differential Carrier Input Shaft
sun gear) (differential not shown)
3 Planetary Sun Gear (input to the
planetary gear set, while carrier is
output)
Figure 58 Dual Speed RDM Internals
When in high range, the RDM operates essentially the same as a single speed unit. The clutch will
engage as necessary to send torque from the driveshaft to the wheels.
When in low range, the RDM engages the planetary gear set to provide a low range to the rear
wheels. The ratio of the planetary gear set will always match that of the PTU.

82 4WD/AWD Diagnosis and Repair

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

DUAL SPEED SYSTEMS WITH LOCKING DIFFERENTIAL CAPABILITY

4 3 2 1
2014KL-088

1 Planetary Gear Set Output Gear 3 Differential Carrier Input Shaft

2 Sun Gear Output Gear 4 Differential Carrier Output Shaft (to the
right axle)
Figure 59 4WD LOW LOCK Components

Dual speed RDMs can be equipped with an optional locking differential. When the LOCK button
is pressed, the rear wheels are physically locked together by locking spider gears to differential
housing. The locking differential is for off-road conditions only, and requires the vehicle to be in
4LOW.

4WD/AWD Diagnosis and Repair 83

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

KƚŚĞƌ͞>ŽĐŬ͟DŽĚĞƐ
Some “Lock” modes are not truly locked in the traditional sense. When most people see “lock”,
they assume its a locking differential. This is not always the case. For example, the Jeep compass
has a “lock” mode. However, all this mode does is permanently lock the PTU in an engaged state to
provide faster 4WD response times when the wheel slip is detected.
Always be sure to fully understand system normal operation before attempting to diagnose a
concern.

84 4WD/AWD Diagnosis and Repair

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

CONTROLS

2014KL-067

1 Hill Descent Control Button 3 NEUTRAL Button

2 NEUTRAL Indicator LED 4 4WD LOW Button
Figure 60 4WD Selec-Terrain® Switch
A variety of different selections are available on the 4WD/AWD selector switch, including 2WD,
4WD, 4LOW, and a variety of terrain selections. It’s important to note that some of these selections
actuate physical components in the system, while others do nothing more than slightly change
system engagement and application parameters in the DTCM.
ǯϐ
information.

4WD/AWD Diagnosis and Repair 85

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

ůĞĐƚƌŝĐĂůKƉĞƌĂƟŽŶ
The following page represents a typical shift system. The transfer case switch provides a request
over a LIN bus to the BCM. The DTCM receives this information over the CAN-C bus. The DTCM
is simultaneously receiving information from other modules over the CAN-C bus, such as wheel
speed from the ABS module. Based on input data, the DTCM simultaneously controls the PTU
actuator, RDM actuator, and RDM clutch control motor. The two actuators are commanded via
private CAN networks, while the clutch motor is a direct output with feedback circuits.

86 4WD/AWD Diagnosis and Repair

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵƐ

tŝƌŝŶŐ^ĐŚĞŵĂƟĐ

0322208_005

Figure 61 Transverse Powertrain System Wiring Schematic Example

4WD/AWD Diagnosis and Repair 87

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

88 4WD/AWD Diagnosis and Repair

dƌĂŶƐĨĞƌĂƐĞDĞĐŚĂŶŝĐĂůŝĂŐŶŽƐŝƐ

ACTIVITY 1 TRANSFER CASE MECHANICAL DIAGNOSIS

TASK ONE: NVG 241 TRANSFER CASE DIAGNOSIS

Year: 2017___________________________________________________________________________
DĂŬĞĂŶĚDŽĚĞů͗:ĞĞƉtƌĂŶŐůĞƌ________________________________________________________
VIN: 1C4HJWFG5HL524889_____________________________________________________________
Customer Concern: Customer states the vehicle growls at all times when driving, and seems louder
if in 4WD or 4LOW.
1. ϐǤ
determine the source of the noise?

Contact the instructor to discuss vehicle symptoms and test procedures prior to proceeding.
2. Based on the symptoms and test results, what is the suspect component?

3. Does the suspect component need to be removed from the vehicle for further inspection?

4WD/AWD Diagnosis and Repair 89

dƌĂŶƐĨĞƌĂƐĞDĞĐŚĂŶŝĐĂůŝĂŐŶŽƐŝƐ

4. Login to DealerCONNECT and access vehicle information using the VIN.

5. Perform a VIN inquiry. What 4WD/AWD system is this vehicle equipped with?

6. ϐǫǡǫ

7. To accurately diagnose the cause of the fault, it’s critical to understand the operation of the
4WD/AWD system in the vehicle.
8. Using service information, lookup the description and operation of the transfer case.
9. What type of transfer case is the vehicle equipped with?

10. What are the operating modes/ranges of this transfer case?

11. What type of shift system is the vehicle equipped with?

12. Based on prior knowledge and the information found in your student workbook, what are
the main internal components of this transfer case?

13. List the suspected parts that could cause the customer concern in task one.

90 4WD/AWD Diagnosis and Repair

dƌĂŶƐĨĞƌĂƐĞDĞĐŚĂŶŝĐĂůŝĂŐŶŽƐŝƐ

14. The transfer case has been removed from the vehicle and is ready for inspection.
15. Following service information, disassemble the transfer case. STOP after removing the
range fork and hub.
16. Inspect the components of the transfer case to determine the root cause of the concern.
ϐǤ

17. Are any other components damaged? Is any debris visible?

18. What is the recommended repair?

4WD/AWD Diagnosis and Repair 91

dƌĂŶƐĨĞƌĂƐĞDĞĐŚĂŶŝĐĂůŝĂŐŶŽƐŝƐ

19. Identify the components in the image below.

2
1

5
4

1 4
2 5
3

92 4WD/AWD Diagnosis and Repair

dƌĂŶƐĨĞƌĂƐĞDĞĐŚĂŶŝĐĂůŝĂŐŶŽƐŝƐ

20. Identify the components in the image below.

1 2

1 3
2

21. Reassemble the transfer case to the condition it was in when you arrived at the workstation.

4WD/AWD Diagnosis and Repair 93

dƌĂŶƐĨĞƌĂƐĞDĞĐŚĂŶŝĐĂůŝĂŐŶŽƐŝƐ

d^<dtK͗tϰϰͳϰϰdZE^&Z^/'EK^/^
Year: 2018___________________________________________________________________________
DĂŬĞĂŶĚDŽĚĞů͗ZĂŵϭϱϬϬ;^Ϳ________________________________________________________
Customer Concern: Customer states 4WD LOW will not engage.
1. ϐǤϐ
actuating as commanded.
2. To accurately diagnose the cause of the fault, it’s critical to understand the operation of the
4WD/AWD system in the vehicle.
3. Login to DealerCONNECT. Using service information, lookup the description and operation
of the transfer case.
4. What type of transfer case is the vehicle equipped with?

5. What are the operating modes/ranges of this transfer case?

6. What type of shift system is the vehicle equipped with?

7. Based on prior knowledge and the information found in your student workbook, what are
the main internal components of this transfer case?

8. List the suspected parts that could cause the customer concern.

94 4WD/AWD Diagnosis and Repair

dƌĂŶƐĨĞƌĂƐĞDĞĐŚĂŶŝĐĂůŝĂŐŶŽƐŝƐ

9. The transfer case has been removed from the vehicle and is ready for inspection.
10. Following service information, disassemble the transfer case.
11. Inspect the components of the transfer case to determine the root cause of the concern.
ϐǤ

12. Are any other components damaged? Is any debris visible?

13. What is the recommended repair?

14. Reassemble the transfer case to the condition it was in when you arrived at the workstation.

4WD/AWD Diagnosis and Repair 95

dƌĂŶƐĨĞƌĂƐĞDĞĐŚĂŶŝĐĂůŝĂŐŶŽƐŝƐ
TASK THREE: MP2010 TRANSFER CASE INVESTIGATION
Year: 2018___________________________________________________________________________
DĂŬĞĂŶĚDŽĚĞů͗:ĞĞƉ'ƌĂŶĚŚĞƌŽŬĞĞ;t<Ϳ______________________________________________
1. Locate the transfer case disassembly/reassembly procedures in service information.
2. Follow the service procedures to disassemble the MP2010 transfer case.
3. Identify the components in the illustration below.

1 2 3 4 5

7 6

1 5
2 6
3 7
4

96 4WD/AWD Diagnosis and Repair

dƌĂŶƐĨĞƌĂƐĞDĞĐŚĂŶŝĐĂůŝĂŐŶŽƐŝƐ
4. Based on your observations, what type of transfer case is a MP2010?

5. What other vehicle system compliments this transfer case type, and helps shift engine
torque to the wheels with traction?

6. Reassemble the transfer case to the condition it was in when you arrived at the workstation.

4WD/AWD Diagnosis and Repair 97

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

98 4WD/AWD Diagnosis and Repair

ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

ACTIVITY 2 ACTIVE TRANSFER CASE DIAGNOSIS AND REPAIR

Year: _______________________________________________________________________________
DĂŬĞĂŶĚDŽĚĞů͗ͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺ
VIN: _______________________________________________________________________________

TASK ONE: VEHICLE ANALYSIS

Customer Concern: Customer states the Service AWD message is on the dash.
1. Attempt to verify the customer concern. Can the concern be duplicated?

2. Does the vehicle display any related symptoms?

3. Attach a Micropod to the DLC and display the vehicle in wiTECH.

4. Record any active DTCs below.

5. Login to DealerCONNECT and access vehicle information using the VIN.

6. Perform a VIN inquiry. What 4WD/AWD system is this vehicle equipped with?

7. Access TechCONNECT. Under section 28-DTC-Based Diagnostics, locate diagnostic

information for the active DTC.

4WD/AWD Diagnosis and Repair 99

ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

8. What condition will set the DTC?

9. What are the possible causes of the DTC?

TASK TWO: SYSTEM UNDERSTANDING

To accurately diagnose the cause of the fault from task one, it’s critical to understand the operation
of the 4WD/AWD system in the vehicle. Locate the transfer case on the bench.
1. Following service information, partially disassemble the transfer case. STOP after removing
the clutch assembly from the input shaft. Do not disassemble the clutch pack.
2. What are the main components of this transfer case?

3. Based on your observations, what type of transfer case are you working on?

4. Locate the transfer case wiring diagram for your vehicle.

5. What are the main components of the electrical system shown on the diagram?

100 4WD/AWD Diagnosis and Repair

ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

6. Based on the schematic, what type of shift system is the vehicle equipped with (manual or
electronic)?

TASK THREE: VEHICLE DIAGNOSIS

1. Return to the vehicle on the hoist.
2. ϐǤ
than one DTC, diagnose in order of relevance.
3. ϐǤ
4. Follow step two of the diagnostic. Record your readings below.

Contact the instructor to discuss the diagnostic process prior to proceeding.

5. If the actuator test mentioned in step two of the diagnostic was not available, what method
could be used to test the integrity of the wiring?

4WD/AWD Diagnosis and Repair 101

ĐƟǀĞdƌĂŶƐĨĞƌĂƐĞŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

6. Test the integrity of the clutch control circuit wiring using the method described above.
Record your results below.

7. Given those results, what steps could be performed to narrow down the source of the
concern?

8. Reassemble the vehicle and the transfer case to the condition they were in when you
arrived at the workstation.

102 4WD/AWD Diagnosis and Repair

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

4WD/AWD Diagnosis and Repair 103

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

104 4WD/AWD Diagnosis and Repair

ĐƟǀĞKŶͲĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

ACTIVITY 3 d/sKEͳDEdZE^&Z^/'EK^/^E
REPAIR

TASK ONE: VEHICLE ANALYSIS

Customer Concern: Customer states the Service 4WD message is on the dash.
1. Attempt to verify the customer concern. Can the concern be duplicated?

2. Does the vehicle display any related symptoms?

3. Attach a Micropod to the DLC and display the vehicle in wiTECH.

4. Record any active DTCs below.

5. Login to DealerCONNECT and access vehicle information using the VIN.

6. Perform a VIN inquiry. What 4WD/AWD system is this vehicle equipped with?

7. Access TechCONNECT. Under section 28-DTC-Based Diagnostics, locate diagnostic

information for the active DTC.

4WD/AWD Diagnosis and Repair 105

ĐƟǀĞKŶͲĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

8. What condition will set the DTC?

9. What are the possible causes of the DTC?

TASK TWO: SYSTEM UNDERSTANDING

To accurately diagnose the cause of the fault from task one, it’s critical to understand the operation
of the 4WD/AWD system in the vehicle. Locate the transfer case on the bench.
1. Following service information, partially disassemble the transfer case. STOP after removing
the clutch apply piston.
2. What are the main components of this transfer case?

3. Based on your observations, what type of transfer case are you working on?

4. Locate the transfer case wiring diagram for your vehicle.

106 4WD/AWD Diagnosis and Repair

ĐƟǀĞKŶͲĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

5. What are the main components of the electrical system shown on the diagram?

6. Based on the schematic, what type of shift system is the vehicle equipped with (manual or
electronic)?

TASK THREE: VEHICLE DIAGNOSIS

1. Return to the vehicle on the hoist.
2. ϐǤ
than one DTC, diagnose in order of relevance.
3. ϐǤ
4. Follow step two of the diagnostic. Record your readings below.

5. What are you instructed to do next?

6. ϐǤ

4WD/AWD Diagnosis and Repair 107

ĐƟǀĞKŶͲĞŵĂŶĚdƌĂŶƐĨĞƌĂƐĞŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

7. What did this test verify?

8. Perform the next diagnostic test. Record your results below.

9. Based on these results, what are you instructed to do next?

10. Perform this step and record your results below.

11. What is the proper repair for the concern?

12. Reassemble the vehicle and the transfer case to the condition they were in when you
arrived at the workstation.

108 4WD/AWD Diagnosis and Repair

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

4WD/AWD Diagnosis and Repair 109

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

110 4WD/AWD Diagnosis and Repair

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

ACTIVITY 4 TRANSVERSE POWERTRAIN 4WD/AWD SYSTEM DIAGNOSIS

AND REPAIR

TASK ONE: VEHICLE ANALYSIS

Customer Concern: Customer states the Service 4WD message is on the dash.
1. Attempt to verify the customer concern. Can the concern be duplicated?

2. Does the vehicle display any related symptoms?

3. Attach a Micropod to the DLC and display the vehicle in wiTECH.

4. Record any active DTCs below.

5. Login to DealerCONNECT and access vehicle information using the VIN.

6. Perform a VIN inquiry. What 4WD/AWD system is this vehicle equipped with?

7. Access TechCONNECT. Under section 28-DTC-Based Diagnostics, locate diagnostic

information for the active DTCs.

4WD/AWD Diagnosis and Repair 111

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

8. What document are you directed to follow?

TASK TWO: SYSTEM UNDERSTANDING

To accurately diagnose the cause of the fault from task one, it’s critical to understand the operation
of the 4WD/AWD system in the vehicle.
1. Based on your observations, what type of system are you working on?

2. Locate the transfer case wiring diagram for your vehicle.

3. What are the main components of the electrical system shown on the diagram?

4. Based on the schematic, what type of shift system is the vehicle equipped with (manual or
electronic)?

TASK THREE: VEHICLE DIAGNOSIS

1. Return to the vehicle on the hoist.
2. Ǥϐ
Ǥ ϐ
diagnostic steps.

Contact the instructor to discuss your diagnostic plan prior to proceeding.

112 4WD/AWD Diagnosis and Repair

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

3. ǡϐ
the concern?

4. Perform these tests. Record your results below.

5. What do these results indicate?

6. What steps should be taken to locate the root cause of the fault?

4WD/AWD Diagnosis and Repair 113

dƌĂŶƐǀĞƌƐĞWŽǁĞƌƚƌĂŝŶϰtͬt^ǇƐƚĞŵŝĂŐŶŽƐŝƐĂŶĚZĞƉĂŝƌ

Contact the instructor to discuss the results of your testing.

7. What is the root cause of the fault?

8. Reassemble the vehicle to the condition it was in when you arrived at the workstation.

114 4WD/AWD Diagnosis and Repair

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

4WD/AWD Diagnosis and Repair 115

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

116 4WD/AWD Diagnosis and Repair

APPENDIX

CONDITIONS/SYMPTOMS RELATED TO TRANSFER CASE MALFUNCTIONS

The tables on the following pages show the most common mechanical malfunctions related to
mechanically and electronically shifted transfer cases. Refer to appropriate service information for
correct application.
Table 1 Mechanically Shifted Transfer Case Mechanical Concerns
Condition Correction
Transfer case Vehicle speed too great to permit Stop vehicle and shift into desired
ϐ shifting range, or reduce speed to below 3–5
does not shift into km/h (2–3 mph) before attempting
desired range the shift
If vehicle was operated for an Stop vehicle and shift the
extended period in 4HI on a dry transmission into NEUTRAL; shift
paved surface, the driveline torque the transfer case to 2WD and operate
load may be causing a bind the vehicle in 2WD on dry paved
surfaces
Transfer case external shift linkage Lubricate, repair, or replace
binding linkage bushings; or tighten loose
components as necessary

ϐ ϐ
quantity of the correct lubricant
Internal components binding, worn Disassemble the transfer case
or damaged and replace worn or damaged
components as necessary
Transfer case noisy ϐ ϐϐ
in all drive modes with correct lubricant
Note: If the unit is still noisy after
ϐǡ
inspection may be required to locate
source of noise

4WD/AWD Diagnosis and Repair 117

Table 2 Mechanically Shifted Transfer Case Mechanical Concerns (Continued)
Condition Correction
Noisy in, or jumps Transfer case not completely With the transmission in NEUTRAL
out of, 4LOW engaged in 4LOW position (or the clutch depressed on
vehicles equipped with a manual
transmission), and the vehicle
moving under 3–5 km/h (2–3 mph),
shift the transfer case to NEUTRAL
and then shift into the 4LOW
position
Shift linkage out of adjustment Adjust linkage
Shift linkage loose or binding Tighten, lubricate, or repair as
necessary

Range fork damaged, inserts worn, Disassemble the unit and repair as
or fork is binding on shift rail necessary

Low range gear worn or damaged Disassemble and repair as necessary

Lubricant leaking ϐ Drain lubricant to correct level
from output shaft Vent closed or restricted Clear or replace vent as necessary
seals or from vent
Output shaft seals damaged or Replace seal as necessary Check
installed incorrectly to ensure that another component
(the propeller shaft slip yoke, for
example) is not causing damage to
the seal
Abnormal tire wear Extended operation on hard, dry Operate vehicle in the 2WD position
surface in the 4HI position on hard, dry surfaces

118 4WD/AWD Diagnosis and Repair

Table 3 Electronically Shifted Transfer Case Mechanical Concerns
Condition Correction
Transfer case Transfer case electronically Verify proper operation per the
ϐ controlled shift system malfunction appropriate diagnostic manual
does not shift into If vehicle was operated for an Drive the vehicle in a straight
desired range extended period in 4HI on a dry, line and momentarily release the
paved surface, the driveline torque accelerator The transfer case can
load may be causing a bind then be shifted to the desired mode
ϐ ϐ
quantity of the correct lubricant
Internal components binding, worn, Disassemble the transfer case
or damaged and replace worn or damaged
components as necessary
Transfer case noisy ϐ ϐϐ
in all drive modes with correct lubricant
Internal transfer case components Repair or replace components as
binding, worn, or damaged necessary
Table 4 Electronically Shifted Transfer Case Mechanical Concerns (Continued)
Condition Correction
Noisy in, or jumps Transfer case not completely While rolling 3–5 km/h (2–3
out of 4LOW engaged in 4LOW position mph) and the transmission in
NEUTRAL (or clutch depressed on
vehicles equipped with a manual
transmission), shift transfer case to
the 2WD or 4HI position, and then
back into the 4LOW position

Range fork damaged, inserts worn, Disassemble unit and repair as

or fork is binding on shift rail necessary
Low range gear worn or damaged Disassemble and repair as necessary
Lubricant leaking ϐ Drain lubricant to correct level
from output shaft Vent closed or restricted Clean or replace the vent as
seals or from vent necessary
Seals damaged or installed Replace the seal as necessary; check
incorrectly to ensure that another component
(the propeller shaft slip yoke, for
example) is not causing damage to
the seal
Abnormal tire wear Extended operation on hard, dry Operate vehicle in the 2WD position
surface in the 4HI position on hard, dry surfaces

4WD/AWD Diagnosis and Repair 119

NOTE:
Ǥ

REPLACEMENT TIRES
Tire size is important for proper performance of the active 4WD system. Replacement tires must
be the same size, load range, and construction as the original tires. Mixing tire sizes will cause
serious damage to the transfer case when in 4WD AUTO, 4HI, or 4LOW positions.
Installing a different size tire on the vehicle will cause the following:
• If the tire size difference is minimal and does not cause the difference between front
propeller shaft and rear propeller shaft speeds to exceed the maximum rpm difference, the
system will perform normally in 2HI and AUTO; a binding on the driveline and possible tire
hop will occur on good traction surfaces when in 4HI and 4LOW modes
• If the tire size difference is great enough to cause a difference between front propeller shaft
and rear propeller shaft speeds that exceeds maximum rpm difference, the system will
perform as follows:
– 2 HI—No effect on the system
– AUTO mode—Binding occurs as the control module tries to correct for what it
interprets as wheel slippage; on a good traction surface, the control module will not be
able to stop the slippage by applying the transfer case clutch pack. The transfer case
clutch pack, usually the weakest link, slips to make up the rpm difference
– The control module tries to stop the wheel slip by applying the clutch to full duty
cycle for a maximum of 10 seconds; if the control module cannot stop the slip after 10
seconds, it sets a code and disables the system for the rest of that ignition cycle; this
DTC is stored as a history code when the ignition is cycled; because the DTC becomes
saved in the vehicle’s history, this process repeats each time the driver restarts the
vehicle
– 4HI or 4LOW—Binding occurs if the vehicle is moving on a good traction surface; the
transfer case clutch pack, usually the weakest link, slips to make up the rpm difference;
the control module cannot protect the clutch pack from slipping in 4HI and 4LOW, so
the clutch will be damaged in a short time

120 4WD/AWD Diagnosis and Repair

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

4WD/AWD Diagnosis and Repair 121

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

122 4WD/AWD Diagnosis and Repair

GLOSSARY

all wheel drive Refers to a system or mode that automatically transfers torque to both the
(AWD) front and rear axles when needed; under normal conditions, engine torque is
transferred to one axle: front or rear; if the wheels on the drive axle begin to
slip, torque is automatically transferred to the opposite axle.
A transfer case that will automatically connect the front and rear axles when
case wheel slip is detected; a clutch is typically used to connect the axles; there are
typically no driver inputs to the system.
active on- A transfer case that is a hybrid design between a part-time transfer case and
demand an active transfer case; it has capability of obtaining the modes and ranges of a
typical part-time transfer case, and also adds an AUTO mode.
actuator A type of motor for moving or controlling a mechanism or system
The name given to the system controlling the operation of the anti-lock brakes
and traction control.
center A device within the transfer case that distributes power to the front and rear
axles and allows the driveshafts to turn at different speeds.
A device typically found inside an axle containing a set of gears that allows the
driving wheels to turn at different speeds when necessary.
detent A device that holds a component in a position.
The percent of time that a device spends in an active state as a fraction of
the total time under consideration; typically used to describe the electronic
control of a particular device.
eccentric cam A disc with an irregular shape so that it gives motion to another object when
rotated.
A system of electronic control using a control module, sensors, and a shift
motor to change the position of the transfer case.
The term used to describe a clutch assembly typically found in the rear axle of
controlled a vehicle equipped with a transverse mounted powertrain; the clutch connects
coupling/ the driveshaft to the rear axles.
clutch
ϐǦǦ ϐϐ
ϐǤ
Ǧ A transfer case in which both front and rear driveshafts are connected at all
times through a device, such as a center differential, eliminating driveline
windup.
Ǧ Refers to an operating mode in which both front and rear axles are
drive (4WD) mechanically locked to the output of the transmission.
Ǧ Refers to an operating range in which engine torque is sent to both front and
drive HIGH rear axles with no torque multiplication.
(4HI)

4WD/AWD Diagnosis and Repair 123

Ǧ Refers to an operating range in which engine torque is sent through a
drive LOW planetary gear set prior to being sent to the axles; this will multiply the output
(4LO) torque.
gear ratio The ratio of two meshed gears, which is calculated by dividing the number of
teeth on the driven gear by the number of teeth on the drive gear.
Ǧ A term used to describe an axle shaft on a vehicle equipped with independent
suspension; they typically contain constant velocity joints or universal joints.
Ǧ A transducer that varies its output voltage in response to a magnetic field.
device
helical gear A gear with curved or spiral cut teeth.
hill descent A function on some AWD systems that allows the driver to select a maximum
control speed for descending a hill; the vehicle will utilize the BTCS and manipulate
engine torque to control speed.
mode Refers to the number of wheels receiving power from the engine by way of the
4WD system.
multi-disc A type of clutch that has several driving members stacked with several driven
members, consisting of alternating steel and friction discs.
neutral A transfer case mode that disengages the input shaft and both output shafts so
that they may all rotate independently.
part–time A transfer case containing multiple selectable modes and ranges such as 2HI,
4HI, 4LOW, and NEUTRAL.
A gear system consisting of multiple gears in constant mesh to produce a
set mechanical advantage; a sun gear is an external gear that sits in the center; the
planet (pinion) gears, in mesh with the sun, are external gears attached to a
planet carrier in such a way that they are allowed to spin in place as the carrier
rotates around the sun gear; the annulus (ring) gear is an internal gear that is
in constant mesh with the outer surface of the planet gears.
A gearbox found in a vehicle equipped with a transverse mounted powertrain
unit that transmits engine torque longitudinally to the rear driveshaft.
pulse-width A method of controlling electrical output devices by manipulating duty cycle.
modulation
range Refers to the number of speeds at which a transfer case can operate.
rear drive A gearbox that accepts engine torque from the driveshaft, providing torque to
module/rear the rear half-shafts through the use of an electronically controlled clutch on
drive unit vehicles equipped with a transverse mounted powertrain.
recreational ϐ
towing in neutral and still obtain proper lubrication.
selec-speed A function on some AWD systems that allows the driver to set a vehicle speed
control for off-road use.
Typically describes a component of manual transmissions used to bring two
components to the same speed for engagement purposes.
torque Rotational force

124 4WD/AWD Diagnosis and Repair

A transmission typically found on front wheel drive vehicles that integrates the
axle differential.
A gearbox that is typically mounted to the rear of the transmission with the
capability of splitting engine torque between the front and rear axles.
transverse Typically used to describe a powertrain layout in which the engine and
transmission are mounted cross-ways in the chassis, such as most front wheel
drive vehicles.
two-wheel Refers to an operating mode in which engine torque is provided to only one
drive (2WD) axle; depending on application, either the rear axle (RWD) or the front axle
(FWD) may receive engine torque.
worm gear ϐǡ
drive worm shaft, which turns a more traditionally shaped gear, called a worm gear.

4WD/AWD Diagnosis and Repair 125

Notes:_________________________________________________________________________________________________________

________________________________________________________________________________________________________________

126 4WD/AWD Diagnosis and Repair

UNITED STATES AND CANADA
The special service tools referred to herein are required for certain service operations. These special service
tools or their equivalent, if not obtainable through a local source, are available through the following outlet.

28635 Mound Road, Warren, MI 48092, U.S.A.

MILLER SPECIAL TOOLS

ŽƐĐŚƵƚŽŵŽƟǀĞ^ĞƌǀŝĐĞ^ŽůƵƟŽŶƐ

Telephone 1-800-801-5420 FAX 1-800-578-7375

The special tools referred to herein are required for certain service operations. These special service tools
or their equivalent, if not obtainable through a local source, are available through the following outlets.

MILLER SPECIAL TOOLS BOSCH AUTOMOTIVE SERVICE BOSCH AUTOMOTIVE SERVICE

INTERNATIONAL ^K>hd/KE^WƚǇ>ŝŵŝƚĞĚ ^K>hd/KE^;h<Ϳ
;ƵƐƚƌĂůŝĂͿ
ŽƐĐŚƵƚŽŵŽƟǀĞ^ĞƌǀŝĐĞ^ŽůƵƟŽŶƐ Ironstone Way
655 Eisenhower Drive 300 Wellington Road Brixworth, Northants, NN6 9UD
Owatonna, MN 55060, U.S.A. Mulgrave Victoria 3170 Tel: + 44-1327-303-400
Tel: 1-507-455-7320 Tel: 61-3-9544-6222 Fax: + 44-1327-871-625
Fax: 1-507-455-7063 Fax: 61-3-9544-5222
BOSCH AUTOMOTIVE SERVICE BOSCH AUTOMOTIVE SERVICE SPX CHINA
^K>hd/KE^ŽƌƉŽƌĂƟŽŶ;:ĂƉĂŶͿ SOLUTIONS MEXICO
Miyako Gotanda Building 333 Fuquan Road North IBP
West Tower 8th Floor Mitla No. 442
Col. VĞƌƟz Narvarte Changning District
5-6-2 Osaki Shanghai 200335 P.R. China
Shinagawa-ku, Tokyo, 141-0032 03600 Mexico D.F.
Tel: (52)55-25-95-16-30 Tel: +86 21 2218 2758
Tel: +81-3-5436-3610 Fax: +86 21 2218 2667
Fax: +81-3-5436-3621 Fax: (52)55-25-95-16-39

BOSCH AUTOMOTIVE SERVICE

SOLUTIONS BRAZIL
Av. Maria Coelho de Aguiar,
573 - G10 Cj. D
São Paulo, Brazil 05805-000
Tel: 55 11 5853 7477
Fax: 55 11 5853 7489
EŽƉĂƌƚŽĨƚŚŝƐƉƵďůŝĐĂƟŽŶŵĂǇďĞƌĞƉƌŽĚƵĐĞĚ͕ƐƚŽƌĞĚŝŶĂƌĞƚƌŝĞǀĂů
ƐǇƐƚĞŵŽƌƚƌĂŶƐŵŝƩĞĚ͕ŝŶĂŶǇĨŽƌŵŽƌďǇĂŶǇŵĞĂŶƐ͕ĞůĞĐƚƌŽŶŝĐ͕
ŵĞĐŚĂŶŝĐĂů͕ƉŚŽƚŽĐŽƉǇŝŶŐ͕ƌĞĐŽƌĚŝŶŐ͕ŽƌŽƚŚĞƌǁŝƐĞ͕ǁŝƚŚŽƵƚƚŚĞ
ƉƌŝŽƌǁƌŝƩĞŶƉĞƌŵŝƐƐŝŽŶŽĨŚƌǇƐůĞƌ'ƌŽƵƉ>>͘
ŽƉǇƌŝŐŚƚ 2018 ŚƌǇƐůĞƌ'ƌŽƵƉ>>

81-699-18013 Rev. 7/18/2018

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00 0322208 4wd Awd Diagnosis and Repair SWB

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00 0322208 4wd Awd Diagnosis and Repair SWB

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4WD/AWD DIAGNOSIS AND REPAIR

No part of this publication may be reproduced, stored

Copyright © 2018 FCA US LLC

4WD/AWD Diagnosis and Repair i

ii 4WD/AWD Diagnosis and Repair

• Properly diagnose and repair transverse powertrain 4WD/AWD systems

4WD/AWD Diagnosis and Repair 1

2 4WD/AWD Diagnosis and Repair

4WD/AWD Diagnosis and Repair 3

4 4WD/AWD Diagnosis and Repair

LESSON 1 4WD/AWD SYSTEMS

Figure 1 Jeep Renegade 4WD

4WD/AWD Diagnosis and Repair 5

4WD/AWD SYSTEM TYPES

6 4WD/AWD Diagnosis and Repair

Figure 2 Selec-Terrain Switch

4WD/AWD Diagnosis and Repair 7

Figure 3 Part-time Transfer Case

8 4WD/AWD Diagnosis and Repair

4WD/AWD Diagnosis and Repair 9

Figure 4 Part-time Transfer Case in 4HI or 4LOW

10 4WD/AWD Diagnosis and Repair

Figure 5 Full-time Transfer Case

4WD/AWD Diagnosis and Repair 11

12 4WD/AWD Diagnosis and Repair

Figure 6 Full-time Transfer Case in AWD

4WD/AWD Diagnosis and Repair 13

ACTIVE TRANSFER CASE

Figure 7 Active Transfer Case

14 4WD/AWD Diagnosis and Repair

Figure 8 Active Transfer Case in AWD

4WD/AWD Diagnosis and Repair 15

Figure 9 Active On-demand Transfer Case

16 4WD/AWD Diagnosis and Repair

4WD/AWD Diagnosis and Repair 17

Figure 10 Active On-demand Transfer Case in 4LOW or 4HI

18 4WD/AWD Diagnosis and Repair

Figure 11 Active On-demand Transfer Case in AUTO

4WD/AWD Diagnosis and Repair 19

TRANSVERSE POWERTRAIN 4WD/AWD SYSTEMS

1 Transaxle 3 Drive Shaft

20 4WD/AWD Diagnosis and Repair

1 Electronically Controlled Coupling 3 4WD Lock Switch

4WD/AWD Diagnosis and Repair 21

22 4WD/AWD Diagnosis and Repair

DRIVELINE COMPONENT IDENTIFICATION

1 Model Number 4 Low Range Ratio

4WD/AWD Diagnosis and Repair 23

1 ϐ  3 Drain Plug

24 4WD/AWD Diagnosis and Repair

THE IMPORTANCE OF TIRE SIZE AND WEAR

4WD/AWD Diagnosis and Repair 25

26 4WD/AWD Diagnosis and Repair

1 Mode Sleeve 4 Range Select Fork

The main components of a part-time transfer case include:

4WD/AWD Diagnosis and Repair 27

28 4WD/AWD Diagnosis and Repair

1 Sun Gear 3 Planetary Gear and Carrier Assembly

4WD/AWD Diagnosis and Repair 29

1 Transfer Case Housing 2 Lubricating Pump and Housing

30 4WD/AWD Diagnosis and Repair

1 Range Select Fork 2 Mode Fork

4WD/AWD Diagnosis and Repair 31

1 Range Select Fork 2 Mode Fork

32 4WD/AWD Diagnosis and Repair

1 Range Select Fork 2 Mode Fork

4WD/AWD Diagnosis and Repair 33

1 Range Select Fork 2 Mode Fork

34 4WD/AWD Diagnosis and Repair

1 Transfer Case Shifter 2 Shift Cable

4WD/AWD Diagnosis and Repair 35

Figure 24 Transfer Case Shift Selector Switch

36 4WD/AWD Diagnosis and Repair

1 Shift Motor/Mode Sensor

4WD/AWD Diagnosis and Repair 37

Figure 26 Part-time Transfer Case Wiring Schematic Example

1 ϐ 3 Drain Plug