1. SPECIFICATIONS Part-time transfer case. Mating surface of front flange kg (including oil)

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Posy Mills
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1 SPECIFICATIONS Type Total length Description Mating surface of front flange Weight Oil capacity Oil type Location Specifications Part-time transfer case 343 mm 40 mm 32.4 kg (including oil) 1.4 L ATF DEXRON III Transfer case Major element Housing Part-time & TOD Bolt 11 ea, M8 x 1.25 Input shaft A/T: outer spline M/T: inner spline

4WD "HIGH" and 2.48 of reduction gear ratio when selecting 4WD "LOW".

2 OVERVIEW By using the planetary gear sets, two-gears shift type part time transfer case achieves direct connection when selecting 4WD "HIGH" and 2.48 of reduction gear ratio when selecting 4WD "LOW". The silent chain in transfer case transfers the output power to front wheels. The simple operation of switches on instrument panel allows to shift between "2H" and "4H" easily while driving (for 4L: stop vehicle first). The warning lamp warns the driver when the system is defective. Side View Rear View Front Rear

3 Operation Description Mode Conditions 2H 2 Wheel drive (rear wheel) Rear-wheel drive mode. This is used under normal or high-speed driving conditions on public roads or highways. Driving mode 4H 4L 4 Wheel drive (high speed) 4 Wheel drive (low speed) This is used under sandy, muddy or snowcovered road conditions This is used for maximum traction. When cornering with low speed in 4WD condition, there could be tire dragging, some mechanical shocks and resistances in vehicle s drive train. These are normal conditions due to internal resistance in the drive train when the 4WD system is properly working 2H 4H 2 Wheel drive 4 Wheel drive Shifting is possible while driving at the speed of 70 km/h or less Mode change 2H, 4H 4L 2 Wheel drive, 4 Wheel drive (high speed) 4 Wheel drive (low speed) For Automatic Transmission: Stop the vehicle on level ground and move the gear selector lever into the N position. Turn the switch to the desired position. For Manual Transmission: Stop the vehicle on level ground and move the gear selector lever into the N position. Then turn the switch to the desired position while depressing the clutch pedal. To make the mode change easily, stop the vehicle on level ground and turn the mode switch to the desired position and move the shift lever to "N"-"R"-"N" while depressing the brake pedal.

4 LAYOUT Front axle Front locking hub system (IWE) Front propeller shaft DSI 6-speed automatic transmission Part-time transfer case Rear propeller shaft Rear axle

3240-01 07-7 1) Components Location Magnet clutch power supply connector (for 1 pin) Transfer case main connector Shift motor connector Transfer case

5 ) Components Location Magnet clutch power supply connector (for 1 pin) Transfer case main connector Shift motor connector Transfer case assembly T/C motor Oil drain plug (Tightening torque: 19 ~ 30 Nm) Damper Rear propeller shaft Front propeller shaft Oil filler plug (Tightening torque: 19 ~ 30 Nm)

6 SYSTEM LAYOUT 4WD mode switch Indicators 4H: 4 Wheel drive, high speed 4L: 4 Wheel drive, low speed 2H: 2 Wheel drive TCCU 4H: 4WD HIGH indicator ON 4L: 4WD LOW indicator ON 2H: Indicator OFF System failure: 4WD CHECK warning lamp ON Solenoid valve

3240-01 07-9 4. IWE LOCKING HUB SYSTEM 1) Overview The vacuum locking hub uses the IWE (Integrated Wheel End) system, and in this system, the vacuum is generated only within the hub actuator.

7 IWE LOCKING HUB SYSTEM 1) Overview The vacuum locking hub uses the IWE (Integrated Wheel End) system, and in this system, the vacuum is generated only within the hub actuator. It is structured to transmit power to the front section after the actuator hub is engaged following the release of vacuum from the drive shaft end gear and the hub end gear Operating Process Booster TCCU To atmosphere Locking hub actuator Vacuum solenoid valve for IWE Vacuum pump Electric signal Locking hub actuator Vacuum generation process in front hub actuator Vacuum pump 4WD mode switch Vacuum solenoid valve TCCU Hub actuator (FR) Hub actuator (FL) to atmosphere to atmosphere

07-10 2) Vacuum System Related to 4WD In 4WD mode, the TCCU blocks the

not be engaged with the front end hub gear.

pressure is released from the hub actuator.

8 ) Vacuum System Related to 4WD In 4WD mode, the TCCU blocks the transferring of vacuum pressure from vacuum pump to locking hub by supplying the power to solenoid valve. During 2WD mode, the vacuum pressure from vacuum pump is continuously transmitted to the locking hub system. This vacuum pressure pulls in the locking hub actuator so that it will not be engaged with the front end hub gear. Hub actuator (RH) Hub actuator (LH) tmosphere (in 4WD mode) The vacuum pressure is released from the hub actuator. At this time, the front hub end gear is engaged. 22WD (applying vacuum pressure to hub actuator) The vacuum pressure pulls in the locking hub actuator so that it will not be engaged with the front end hub gear.

9 POWER FLOW Switching 2H, 4H 4L TCCU Vacuum solenoid Locking hub operation (Released internal vacuum) Transfer case Front propeller shaft Rear propeller shaft Front axle Rear axle Front wheel Rear wheel

10 ) 2H Mode (2 Wheel Drive) Power Flow Output shaft of transmission Rear wheel Input shaft of transfer case Output shaft of transfer case Rear propeller shaft Rear axle Rear wheel

11 ) 4H Mode (4 Wheel Drive - High Speed) Power Flow

12 ) 4L Mode (4 Wheel Drive - Low Speed) Power Flow

SPECIFICATIONS kg (including oil) ATF DEXRON II or III. Major element Housing Part-time Bolt 11EA, M8 x 1.25

SPECIFICATIONS kg (including oil) ATF DEXRON II or III. Major element Housing Part-time Bolt 11EA, M8 x 1.25 3240-01 05-3 1. SPECIFICATIONS Description Specifications Total length 343 mm Weight 32.4 kg (including oil) Oil capacity 1.4 L Oil type ATF DEXRON II or III Location Transfer case Major element Housing