TUCSON(JM) > 2008 > G 2.

7 DOHC > Transfer System

Transfer System > Transfer Case Assembly > Flow Diagram (M5GF1)

System Schematics

Control Algorithm Flow Chart

The base control algorithm of the ITM ECM is defined by the following flowchart:
Lock Mode Description
• Based on a driver request for lock mode, the system will supply a fixed torque to the ITM-I clutch.
• When the vehicle exceeds 30KPH the system will begin to disable lock mode by ramping down the
ITM clutch torque. When the vehicle exceeds 40 KPH the ITM clutch is reduced to its minimum
torque value. Lock mode is re-enabled following the same speed-to-torque map.
• Lock mode is activated based on part number.
 • Lock mode will override all other system requests except for during an ABS event. During an ABS
event the ITM clutch is turned off.
• If there is a speed sensor signal fault, the speeds are no longer considered reliable and lock mode
will be disabled.

Transfer System > Transfer Case Assembly > Description and Operation
(M5GF1)

Power Flow Mechanism

• Normal driving situation: 2WD base driving
• 4WD driving in driving situations (rapid activation, cornering etc.)
1. Input the information from each sensor in vehicle
A. Input torque (Throttle position sensor)
B. Cornering situation (Steering angle sensor)
C. Vehicle speed and different wheel speed front & rear (Wheel speed sensor)
D. Braking situation (Brake signal and ABS signal)
2. Distributed the required driving force after 4WD ECU operates.
3 EMC (Electric Magnetic Clutch) operates the primary clutch.
.
4 Control the cam's opening gap by operation of primary clutch.
.
5 Control the slip of inner & outer plate.
. Control variably the driving force distribution to optimize front & rear driving force.
Transfer System > Transfer Case Assembly > Troubleshooting (M5GF1)

DTC Troubleshooting

4WD ECM DTC Index

DTC
Description 4WD MIL See Page
No.

STEERING WHEEL ANGLE SENSOR SIGNAL(CAN

P1716
ERROR)
Whenever the DTCs
STEERING WHEEL ANGLE SENSOR 1-INPUT relevant to 4WD ECM
P1717
SIGNAL are set, 4WD MIL(*) will
blink.
STEERING WHEEL ANGLE SENSOR 2-INPUT
P1718
SIGNAL
 STEERING WHEEL ANGLE SENSOR C-INPUT
P1719
SIGNAL

P1726 ACCELERATION PEDAL POSITION SIGNAL

P1728 EMC OPEN/SHORTED to BATTERY

P1729 EMC SHORTED to GROUND

P1738 4WD ECU INVALID PART NUMBER

P1750 WHEEL SPEED SENSOR SIGNAL(FL)

P1751 WHEEL SPEED SENSOR SIGNAL(FR)

P1752 WHEEL SPEED SENSOR SIGNAL(RL)

P1753 WHEEL SPEED SENSOR SIGNAL(RR)

P1764 ECU-ITM CAN ERROR

P1765 TCS-ITM CAN ERROR

P1766 CAN COMMUNICATIOM BUS OFF

P1767 ABS ACTIVE SIGNAL (CAN ERROR)

4WD ECM Pin Descripition

Terminal Number Wire Color Description

 1 R BATTERY INPUT

2 - BRAKE INPUT

3 B ECU GROUND

4 G CAN L

5 O CAN H

6 L GND RTN 4

7 Br GND RTN 3

8 L GND RTN 2

9 Br GND RTN1

10 R LOCK SWITCH INPUT

11 L/B STEERING REF C

12 B/O STEERING REF RTN

C58 13 B EMC RTN

C158 14 W ISO9141 K LINE

15 R/B IGNITION INPUT

16 Gr/O 4WHEEL DRIVE INDICATOR

17 O FRONT RIGHT SPEED SENSOR

18 R FRONT LEFT SPEED SENSOR

19 R REAR LEFT SPEED SENSOR

20 O REAR RIGHT SPEED SENSOR

21 Y DIAGNOSTIC OUT

22 - TPS INPUT

23 Gr/O STEERING 1 INPUT

24 L STEERING 2 INPUT

25 Gr/B STEERING REF 5V

26 R EMC OUTPUT

Transfer System > Transfer Case Assembly > Transfer Case > Components
and Components Location (M5GF1)

Components
Transfer System > Transfer Case Assembly > Transfer Case > Repair
procedures (M5GF1)

Removal
[2.0L]
1. Remove the battery (-) terminal.
2. Lift up the vehicle.
3. Remove the propellar shaft (See 'DS' group - 'PROPELLAR SHAFT')
4. Remove the front muffler(A).

5. Remove the RH driveshaft (See 'DS' group-'DRIVESHAFT').

6. Loosen the oil drain plug and drain the fluid.
7 After draining, re-tighten the oil drain plug.
.
Tightening torque :
39.2~58.8 Nm (400~600 kgf.cm, 28.9~43.4 lb-ft)

8. Support the transfer assembly with a jack.

9. Remove the transfer assembly by loosening the mounting bolts.

Remove the transfer bracket mounting bolts(2EA) together.

[2.7L 4WD]

1. The repair of the transfer assembly requires a special skill and furthermore an improper
adjustment of the spacers may cause a severe noise and durability issue.
2. Hypoid gear set is manufactured and controlled as a pair. Any replacement of the part is to be
done as a pair, hypoid gear shaft assembly 47308-39200 and pinion shaft 47311-39000.
1. Remove the battery negative (-) cable.
2. Remove the air intake hose and air cleaner cover and then disconnect the oxygen sensor
connector.(A-Engine room left side).
3. Disconnect the oxygen sensor connector(B) and remove the oxygen sensor connector wire clamp
from a bracket. (Engine room right side).

4. Remove the wheel and tire (RH).

5. Remove the engine side cover(A) (RH).

6. Lift up the vehicle.

7. Remove the lower arm ball joint mounting bolts(A).
8. Remove the lower arm ball joint from the front axle knuckle.
9. Remove the steering bar tie rod ball joint(A) from the knuckle.

10. Remove the drive shaft(A) from the transfer.

11. Remove the front exhaust pipe(A).

12. Drain the transfer oil through drain plug hole.
13. Remove the pinion case mounting bolts(A).

14. Remove the alternator drive belt(A) using the tensioner and then alternator assembly(C) by
loosening the mounting bolts(B).

15. Remove the alternator wire terminal mounting nut(A) and connector(B).
16. Remove the heat protector(A) using a hexagonal socket.

To remove the heat protector mounting bolt easily, before removing the heat protector
mounting bolts(3EA), apply the mounting bolt with "WD-40 stops squeaks".

17. Lift up the vehicle.

18. Remove the exhaust manifold mounting nuts(7EA).

To remove the exhaust manifold mounting nut easily, before removing the exhaust manifold
mounting nuts(7EA), apply the mounting nuts with "WD-40 stops squeaks".

19. Remove the transfer mounting bracket(A).

20. Remove the transfer mounting bolts(4EA).
21. Using a flat head screw driver, remove the transfer from the transaxle by moving the driver to left
and right directions.

Replacement

Transfer Oil Replacement

1. Replace the oil every 100,000km(62,137miles) in a general condition and every
40,000km(24,854miles) in severe usage conditions.

1. Severe usage (marked '*') is defined as

1) Frequent driving on rough road (Bumpy road, gravel road, snowy road, unpaved road . Etc.)
2) Frequent driving on mountain road, ascent/descent.
3) Police, taxi, commercial type operation or trailer towing. Etc.)

2. Transfer&diff carrier lubricants should be changed anytime transfer&diff carrier have been
submerged in water.

Installation
[2.0L]
1. Remove the filler plug(A).

2 Refill the specification to the specified quantity.

.
Specification : SAE 80w/90
Quantity : 0.8L

3. Fix it in proper position with mounting bolts.

[2.7L 4WD]
1. Install the transfer assembly to the transaxle.

To install the transfer easily, install it by moving the pinion left and right directions, and slightly
rotating the inner drive shaft of transfer assembly.

2 Install the transfer mounting bolts(4EA).

.
Tightening torque :
60.8~65.7 Nm(620~670 kgf.cm, 44.8~48.5 lb-ft)

3 Install the transfer mounting bracket(A).

.
Tightening torque :
46.1~50.0 Nm(470~510 kgf.cm, 34.0~36.9 lb-ft) - 2EA
23.5~27.5 Nm(240~280 kgf.cm, 17.4~20.3 lb-ft) - 3EA

4 Tighten the exhaust manifold mounting nuts(7EA).

.
Tightening torque :
29.4~34.3 Nm(300~350 kgf.cm, 21.7~25.3 lb-ft)

5 Tighten the heat protector(A) mounting nuts(3EA).

.
Tightening torque :
11.8~14.7 Nm(120~150 kgf.cm, 8.7~10.8 lb-ft)
6. Connect the alternator wire terminal(A) and connector(B).

7 Install the alternator drive belt(A) using the tensioner and then alternator assembly(C) by tightening
. the mounting bolts(B).

Tightening torque :
19.6~29.4 Nm(200~300 kgf.cm, 14.5~21.7 lb-ft)

8 Tighten the pinion case mounting bolts(6EA).

.
Tightening torque :
36.3~39.2 Nm(370~400 kgf.cm, 14.5~21.7 lb-ft)

9. Refill the transfer oil through the filler plug.

10. Install the front exhaust pipe(A).
11. Install the drive shaft(RH) to the transfer assembly, lower arm ball joint mounting and steering bar
tie rod ball joint.
12. Lower the vehicle down.
13. Install the engine side cover (RH) and the wheel and tire(RH).
14. Connect the oxygen sensor connector(B) and insert the oxygen sensor connector wire clamp into
a bracket. (Engine room right side).

15. Install the air intake hose and air cleaner cover and then connect the oxygen sensor connector.(A-
Engine room left side).

16. Connect the battery negative (-) cable.

Disassembly
1. Drain the transfer oil through drain plug hole.
2. Remove the pinion assembly mounting bolts (6EA) and then remove the pinion assembly(A).

This assembly can be removed with a propella shaft assembly in 'REMOVAL' step.

3. Remove the transfer cover(A) with the inner drive shaft(B) assembly.

4. Remove the transfer drive gear assembly(A) from the trasfer housing.

5. Remove the hypoid gear shaft assembly(A) from the transfer housing.
6. Remove the oil seal(A)(47452-39000, transfer drive gear left hand side).

When reassembling the transfer, be sure to always replace the oil seal(47452-39000) with new
part.

7. Using a slinding hammer, remove the taper roller bearing outer races(A) from the transfer cover(B)
and housing(C).
8. Using the SST(09455-32200), remove the oil seal(A) from the transfer cover.

When reassembling the transfer, be sure to always replace the oil seal(47350-39010) with new
part.

9. Remove the snap ring(A) from the transfer cover.

10. Remove the inner drive shaft assembly(A) from the transfer cover(B) by hammering.

11. Using a sliding hammer(A), remove the other taper roller bearing outer race(B) from the transfer
cover.

Inspection

Check For Transfer Oil

1. Check and replenish the transfer oil every 40,000km(24,855 miles).

Reassembly

1. Clean all parts except the taper roller bearings. Be careful about the direction of seals.
2. Oil bearings with hypoid gear oil API GL5.
3. Smear involute splines all covering with high pressure grease "Klueber microlube GNY202".
4. Measuring temperature: 20°±5°C.
5. O-ring has to be dipped into hypoid gear oil API GL5. Allow excess oil to drain.
6. Contact surface of the transfer housing to be coated with "SEALANT 732" or equivalent (silicon
 type sealing agent) prior to mounting. Coating thickness: 0.1mm MIN. Prior to coating, mating
surfaces must be clean and free from oil and grease.
7. Transfer oil specification : Hypoid gear oil "API GL5, SAE 80W/90 SHELL SPIRAX AX
EQUIVALENT". Filled up to lower filler plug thread level( Approx. 0.8L)
8. The hypoid gear set must be managed as a pair. Whenever installing or replacing a hypoid gear
shaft assembly(47308-39200) or a pinion shaft(47311-39000). Make sure to install or replace as
a pair.
9 In reassembling, refer to the two figures below.
.

1. Install the transfer drive gear with the taper roller bearings(47366-39000 and 47465-39000) into
transfer housing.
2. Applying the preload(100 to 200N) to bearings, measure the dimension J.
3. Measure the dimension H on transfer cover(47314-39200).

4. Select the spacer thickness from the chart below. Thickness S4= H-J+K. (K: Bearing preload = 0.07
to 0.11mm. )
Corresponding preload torque(measured without seals) : 120 to 180Ncm.
Part Number Spacer Thickness (mm)

47383-39152 1.520-1.539

47383-39154 1.540-1.559

47383-39156 1.560-1.579

47383-39158 1.580-1.599

47383-39160 1.600-1.619

47383-39162 1.620-1.639

47383-39164 1.640-1.659

47383-39166 1.660-1.679

47383-39168 1.680-1.699

47383-39170 1.700-1.719

47383-39172 1.720-1.739

47383-39174 1.740-1.759

47383-39176 1.760-1.779
 47383-39178 1.780-1.779

47383-39180 1.800-1.819

47383-39182 1.820-1.839

47383-39185 1.85-1.88

47383-39189 1.89-1.92

47383-39193 1.93-1.96

47383-39197 1.97-2.00

47383-39201 2.01-2.04

47383-39205 2.05-2.08

47383-39209 2.09-2.12

47383-39213 2.13-2.16

47383-39217 2.17-2.20

47383-39221 2.21-2.24

47383-39225 2.25-2.28

47383-39229 2.29-2.32

47383-39233 2.33-2.36

5. Reassemble the selected spacer above.

6. Measure the dimension U and V.
U…. Finished dimension of transfer housing.
V…. Distance from back of the hypoid gear to bearing measured under 100 to 200N preload.
7. Select the spacer thickness from the chart below. Thickness S2=U-(V + mounting distance 52.0
mm).
Part Number Spacer Thickness(mm)

47384-39130 1.300-1.319

47384-39132 1.320-1.339

47384-39134 1.340-1.359

47384-39136 1.360-1.379

47384-39138 1.380-1.399

47384-39140 1.400-1.419

47384-39142 1.420-1.439

47384-39144 1.440-1.459

47384-39146 1.460-1.479
47384-39148 1.480-1.499

47384-39150 1.500-1.519

47384-39152 1.520-1.539

47384-39154 1.540-1.559

47384-39156 1.560-1.579

47384-39158 1.580-1.599

47384-39160 1.600-1.619

47384-39162 1.620-1.639

47384-39164 1.640-1.659

47384-39166 1.660-1.679

47384-39168 1.680-1.699

47384-39170 1.700-1.719

47384-39172 1.720-1.739

47384-39174 1.740-1.759

47384-39176 1.760-1.779

47384-39178 1.780-1.799

47384-39180 1.800-1.819

47384-39182 1.820-1.839

47384-39184 1.840-1.859

47384-39186 1.860-1.879

47384-39188 1.880-1.899

47384-39190 1.900-1.919

47384-39192 1.920-1.939

47384-39194 1.940-1.959

47384-39196 1.960-1.979

47384-39198 1.980-1.999

47384-39200 2.000-2.019

47384-39202 2.020-2.039

47384-39204 2.040-2.059

47384-39206 2.060-2.079
 47384-39208 2.080-2.099

47384-39210 2.100-2.119

47384-39212 2.120-2.139

47384-39214 2.140-2.159

47384-39216 2.160-2.179

47384-39218 2.180-2.199

47384-39220 2.200-2.219

47384-39222 2.220-2.239

47384-39224 2.240-2.259

47384-39226 2.260-2.279

47384-39228 2.280-2.299

47384-39230 2.300-2.319

47384-39232 2.320-2.339

47384-39234 2.34-2.37

47384-39238 2.38-2.41

47384-39242 2.42-2.45

47384-39246 2.46-2.49

47384-39250 2.50-2.53

8. Install the spacer selected above, the taper roller bearings and the hypoid gear shaft assembly
(47308-39200). And preload the assembly without the spacer(Hypoid gear shaft assembly-Transfer
cover side) with 100 to 200N.
9. Measure the dimension L after 10 rotations.
10. Measure the dimension M on transfer cover (47314-39200).
11. Select the spacer thickness from the chart above in the step 7. Thickness S3=M-L+(0.09 to
0.12mm) preload.
12. Install the spacer selected above.
13. Install the taper roller bearing outer races to the transfer housing and cover.
14. Insert the inner drive shaft assembly into the transfer cover.
15. Fixing the inner drive shaft assembly with a snap ring(A), insert a new oil seal into the transfer
cover.
16. Install a new oil seal(A) in the transfer housing.

17. Install the hypoid gear shaft assembly(A) in the transfer housing.

18. Install the transfer drive gear assembly(A) in the trasfer housing.
19 Assemble the transfer cover(A) and inner drive shaft assembly(B) with the transfer housing
. assembly. Tighten the mounting bolts.

Tightening torque :
36.3~39.2 Nm(370~400 kgf.cm, 14.5~21.7 lb-ft)

20. Measure the dimension F.

F…. Assembled dimension of pinion assembly.
G…. Finished dimension of transfer housing.(=88.0mm)
E…. Mounting distance(=69.500 ± deviation).
21. Select the spacer thickness from the chart below. Thickness S1=E+F-G

If it is not possible to reach the exact mounting distance, select the next thinner spacer S1.

Part Number Spacer Thickness(mm)

47385-39125 1.25-1.28

47385-39129 1.29-1.32

47385-39133 1.33-1.36

47385-39137 1.37-1.40

47385-39141 1.41-1.44

47385-39145 1.45-1.48
47385-39149 1.49-1.52

47385-39153 1.53-1.56

47385-39157 1.57-1.60

47385-39161 1.61-1.64

47385-39165 1.65-1.68

47385-39169 1.69-1.72

47385-39172 1.720-1.739

47385-39174 1.740-1.759

47385-39176 1.760-1.779

47385-39178 1.780-1.799

47385-39180 1.800-1.819

47385-39182 1.820-1.839

47385-39184 1.840-1.859

47385-39186 1.860-1.879

47385-39188 1.880-1.899

47385-39190 1.900-1.919

47385-39192 1.920-1.939

47385-39194 1.940-1.959

47385-39196 1.960-1.979

47385-39198 1.980-1.999

47385-39200 2.000-2.019

47385-39202 2.020-2.039

47385-39204 2.040-2.059

47385-39206 2.060-2.079

47385-39208 2.080-2.099

47385-39210 2.100-2.119

47385-39213 2.13-2.16

47385-39217 2.17-2.20

47385-39221 2.21-2.24

47385-39225 2.25-2.28
 47385-39229 2.29-2.32

47385-39233 2.33-2.36

22. Install the pinion assembly with the selected spacer above and measure the circumference
backlash on pinion.
(Measuring diameter, backlash and permissible deviations for measurement on pinion, see table
below).
If the result is out of permissible range, change the spacer thickness S2, then start again with the
step 8~12).
Tips for spacer adjustment for hypoid gear backlash and contact pattern
Item Symptom Remedy

Adjust backlash by installing the spacer S1

When more than the standard value
using a thinner one and gradually install a
(0.16~0.21mm)
thicker one.
Backlash
Adjust backlash by installing the spacer S1
When less than the standard value
using a thicker one and gradually install a
(0.16~0.21mm)
thinner one.

Item Symptom Remedy

• Normal state
• Standard tooth pattern
Both drive and coast surfaces are in
center in lateral direction and slightly
inclines to TOE side in vertical
direction
• If the pattern deviates from the
standard, adjust it by following proce
Hypoid gear dure
tooth contacy
pattern • Abnormal state
• The dirve surface inclines to TOE
and TOP and the coast surface
inclines to HEEL and TOP
The tooth contact patterncan be moved
to the arrow direction by installing the
spacer S2(47384-39000) using a
thinner one and gradually install a
thickerone

23. Remove the pinion assembly. With the spacer S3 and transfer cover mounted, combined preload
torque for the hypoid gear shaft assembly and transfer gear (measured on transfer gear) should
be 2.7 to 3.8Nm. The spacer S3 has to be changed, if the preload torque is not within the
permissible range.
24 Tighten the pinion assembly mounting bolts (6EA) to install the pinion assembly(A).
.
Tightening torque :
36.3~39.2 Nm(370~400 kgf.cm, 14.5~21.7 lb-ft)
 1. Before installing the pinion assembly, check the pinion O-ring and apply the oil to the O-
ring.
2. To make the installation of the pinion to the transfer easier, tap the pinion using a plastic
hammer after aligning the bolt holes.

25 Refill the transfer oil through the drain plug hole to the specification.
.
Transfer oil: API GL-5 or SAE 80W/90
Quantity: 0.8L

Transfer System > Transfer Case Assembly > Coupling Assembly > Repair
procedures (M5GF1)

Removal
1 Remove the 4WD coupling bolts (A-3EA) mounted to the rear propellar shaft(B).
.
Tightening torque :
49.1~68.7N.m (5.0~7.0kgf.m, 36.2~50.6lb-ft)

2. Using a flat tool(A), separate the propellar shaft(C) from 4WD coupling(B).
3 Remove the rear axle (B-Differential carrier) bolts mounted to the 4WD coupling(A) by a socket(C).
.
Tightening torque :
58.9~63.8N.m (6.0~6.5kgf.m, 43.4~47.0lb-ft)
4. Remove the electric magnetic clutch connector(A).

5. Using a flat tool(A), separate the 4WD coupling assembly(B) from the rear differential carrier(C).

6. Remove the 4WD coupling assembly(A).

Installation
Installation is the reverse of the removal.

Disassembly

Don't disassemble the coupling assembly more than bleow procedure because its performance
may get bad influence after disassembling.

1. Remove the coupling(A) flange(B) mounting nut(C).

2. Remove the flange spacer(A).

3. Remove the coupling flange oil seal(A).

4. Using a general tool, 3-way puller(A), remove the flange assembly(B) from the coupling(C).

5. Remove the flange oil seal(A) using special tool (09432-33200).

6. Remove the coupling case assembly(A).