C100 Service Training Manual :

All Wheel Drive (AWD)

Participants Handout

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C100 Driveline All Wheel Drive Participants Handout

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

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C100 Driveline All Wheel Drive Participants Handout

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All Wheel Drive : General description

System 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. 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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C100 Driveline All Wheel Drive Participants Handout

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

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C100 Driveline All Wheel Drive Participants Handout

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 Getrag 760 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.

Fill plug Drain plug

Oil capacity 0.8 0.1L

Oil specification

Synthetic hypoid 75W-90

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All Wheel Drive : Transfer case

Transfer case exploded view -1

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C100 Driveline All Wheel Drive Participants Handout

1. 2. 3. 4. 5. 6. 7. 8. 9.

Transfer Case Drain Plug Transfer Case Fill Plug Transfer Case Input Shaft Seal Left Transfer Case O-Ring Seal Transfer Case Left Transfer Case Vent Assembly Transfer Case Half Locating Pin (Quantity: 2) Front Wheel Drive Shaft Shield 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. 18. 19. 20. 21. Transfer Case Heat Shield Bolt (Quantity: 4) Transfer Case Heat Shield Transfer Case Half Bolt (Quantity: 11) Transfer Case Right Transfer Case Seal
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C100 Driveline All Wheel Drive Participants Handout

All Wheel Drive : Transfer case

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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All Wheel Drive : Drive axle

Driver axle(Front)

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C100 Driveline All Wheel Drive Participants Handout

RH Intermediate Shaft (AWD) Intermediate Shaft(FWD)

LH

Driver axle (Rear)

1. Inboard Seal Kit 2. Inboard Seal Kit 3. Outboard Joint Kit 4. Outboard Seal Kit

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C100 Driveline All Wheel Drive Participants Handout

All Wheel Drive : Propeller shaft

Propeller shaft The propeller shaft assembly is a 2piece design. The front shaft consists of a plunging Atype 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 takeoff 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

1. Description The 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 ondemand 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 fronttorear speed difference; there is no torque/power to the rear wheels. 3) When fronttorear 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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C100 Driveline All Wheel Drive Participants Handout

[ Rear Drive Module]

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C100 Driveline All Wheel Drive Participants Handout

All Wheel Drive : Rear Drive Module

2. Specification
Item Manufacturer Operating temperature Operating voltage Coupling Torque capacity Oil capacity Coil resistance Number of multi-disk clutch Number of ball Gear ratio Rear axle Max. torque Oil capacity Oil specification Specification Getrag -40 ~ 100 9V ~ 16V 1,000 Nm 200 (impossible of oil replacement) 1.9 0.2 Main clutch : 12 EA, Pilot clutch:1 EA 6 EA 2.53 : 1 2,530 Nm 0.6 0.1 Synthetic hypoid 75W-90

2 5 9 10 11 8

4 3

7 1

1. 4. 6. 9.
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Side bracket

2.

Differential assy

3. 5 8.

Side cover .Drive shaft seal Clutch couple assy

CCM (Coupling Control Module) Side cover seal Couple housing 7. Pinion gear seal

10. Pinion flange

11. Nut

All Wheel Drive : Rear Drive Module

3. AWD torque flow

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C100 Driveline All Wheel Drive Participants Handout

Torque through propeller shaft

Torque to rear diff

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C100 Driveline All Wheel Drive Participants Handout

All Wheel Drive : Rear Drive Module

4. Operation of Active coupling

[Ball ramp system working mechanism]

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All Wheel Drive : Rear Drive Module

5. Control system
Power Power supply(B+) supply(B+) Operation Operation signal signal BCM BCM

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C100 Driveline All Wheel Drive Participants Handout

Wheel Wheel speed speed sensor sensor Steering Steering angle angle sensor sensor ABS operation signal ABS operation signal APP APP sensor sensor Input Input Engine Engine RPM RPM Parking Parking brake brake S/W S/W System power System power mode mode PNP PNP S/W S/W

Magnetic Magnetic coil coil

CCM CCM
Temperature Temperature sensor sensor GMLAN GMLAN

Coupling Coupling status status Transfer status Transfer status Temperature Temperature status status AWD AWD warning warning lamp lamp

Output Output

Cluster Cluster

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C100 Driveline All Wheel Drive Participants Handout

All Wheel Drive : Rear Drive Module

6. Functions 1) 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 drivers 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 vehicle stability. 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 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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C100 Driveline All Wheel Drive Participants Handout

AWD warning lamp

DTC

Lamp ON

Description Rear Axle Coupling Solenoid Control Circuit (Over Current) Rear Axle Coupling Solenoid Control Circuit (Wiring) Rear Axle Coupling Solenoid Temperature Sensor Circuit Electronic Control Unit(ECU) Performance(ROM) Electronic Control Unit(ECU) Performance(Wiring) Calibration Data Not Programmed/Learned System Permanently disabled Information Stored Device{single or 1} Voltage Low Lost Communication With Engine Control Module Lost Communication With AntiLock Brake System(ABS) Control Module Lost Communication With Body Control Module

C0393 ON C0394 ON ON C0550 ON C0558 C0561 C0899 U0100 U0121 U0140 ON Blinking Blinking Blinking Blinking Blinking

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C100 Driveline All Wheel Drive Participants Handout

All Wheel Drive : Wiring diagram

Wiring diagram

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