Electronically Controlled On-Demand 4WD

4WD SYSTEM (ITM: Interactive Torque Management)
Electronically Controlled
On-Demand 4WD System
1 Chonan Technical Service Training Center

CONTENTS
1. INTRODUCTION ----------------------------------------------------------------------
2. T/M & TRANSFER CASE ---------------------------------------------------
3. COUPLING & REAR AXLE ASSEMBLY ---------------------------------------
4. INPUTS AND OUTPUTS -------------------------------------------------------------
5. DIAGNOSIS ------------------------------------------------------------------------------
6. WIRING DIAGRAM ---------------------------------------------------------------------
7. 4WD COUPLING ASSEMBLY -------------------------------------------------------

1. INTRODUCTION
Controllability of the vehicle in all driving situations is becoming an important promotional factor for
All-Wheel-Drive. An AWD vehicle has better road handling and is safer in all driving situations.
Answering these requirements, the new Electronically Controlled On-Demand 4WD of JM offers
fully controllable torque transfer characteristics and extremely rapid activation and deactivation
automatically. SANTA FE equipped Diesel VGT (Variable Geometric Turbocharger) engine has
been already using this system since November 2002. However most parts of the system such
as T/M case, transfer case, front differential and rear differential cannot be interchangeable
between JM and SANTA FE.
The characteristics of this system is that it is in the 2WD state at constant vehicle speed but it
changes the torque distribution to rear wheels in the 4WD state according to the driving state.
ENGINE
[Transfer Case]
[Coupling & Rear Axle Assembly]
[Layout of JM 4WD System]

1.1 APPLICATION
REGION GENERAL MIDDLE NORTH

KOREA EC AUS
LINE-UP AREA EAST AMERICA
DDC 2.0 M/T O O O O - -
DSL A/T O O O O - -
в-2.0 M/T - O O O O S
CVVT A/T - O O O O O
д-2.7
A/T - O O O O O
V6
* O: Optional Item, S; Standard Item
1.2 ADVANTAGES
Maximum performance and safety are achieved in all driving situations, as shown here:
Enhanced Vehicle Traction

- Torque transfer up to 1,200 Nm
- Full function in reverse
- Instant activation on differential speed
Enhanced Vehicle Dynamics

- Improved dynamics during acceleration and deceleration
- Rapid activation and deactivation
- Fully controllable torque transfer characteristics
Enhanced Vehicle System Compatibility

- On-line communication with the CAN system
Enhanced Vehicle Driving Comfort and Transparency

- No wind-up during tight cornering and parking
- Optimal traction during acceleration
Enhanced Optimization of Weight and Fuel Consumption

- The fully controllable torque transfer characteristic decreases the design requirements of the
complete AWD drive line, resulting in reduced weight and reduced fuel consumption

Variable Torque Control

- At Parking: Low or zero torque transfer needed for easy and comfortable maneuverability
- Acceleration: High torque transfer for maximum traction on all four wheels
- High speed driving: Reduced torque transfer, to minimum, still adding dynamic stability
- Driving on slippery/wet roads:
Swift activation of the coupling for maximum traction and safety depending on the slip of the
wheels. The coupling is in on-line communication with other safety systems in the vehicle
- Braking/ABS: Immediate deactivation on ABS signal to ensure full function of ABS system
- ESP/TCS
Immediate deactivation on ESP/TCS signal to ensure full function of ESP/TCS system.
Alternative is to communicate with the ESP/TCS system for adding the control possibility of the
new ON-Demand 4WD System to the ESP/TCS System
- Off-road: Rapid activation with high torque transfer for maximum traction

2. T/M & TRANSFER CASE

- 4WD Transfer Case: Santa Fe base modification
- T/M Case: Modification of 4WD transfer matching part
- T/M Differential for 4WD: Modification of transfer matching part

3. COUPLING & REAR AXLE ASSEMBLY

- Coupling: Same as Santa Fe
- Rear Axle: Santa Fe base modification
- Control Unit: Santa Fe base modification (Location: under the driver seat)
3.1 SPECIFICATION (ITM: Interactive Torque Management)
Self-contained, compact, light-weight, torque

Feature
transfer device for on-demand 4WD
Torque 2000 Nm
Weight 8 kg
Size 150mm Long, 140mm OD, 120mm ID
ITM Housing Aluminum

Operating Voltage 12 volts
Operating Temperature -40 Ў Й~ 150 Ў Й
4WD Coupling Oil Mobil Fluid – LT (0.15L)
Primary Clutch Disc (3 EA), Plate (3 EA)
Secondary Clutch Disc (10 EA), Plate (10 EA)

3.2 LOCATION
[Location of ITM Coupling]
3.3 STRUCTURE
Coupling Case Clutch Housing
Secondary
Clutch
From Front To Rear
Wheel Wheel
Back Plate
Primary Clutch Armature Apply Cam

EMC Coil

3.4 COMPONENTS
Wave spring
Steel balls (6EA)
Snap ring
Base cam
Oil seal
Snap ring Thrust washer
Thrust race
Back plate
Snap ring
Primary clutch
Disc
(3EA) Plate
(3EA)
Secondary
clutch Clutch
housing
Plate
Disc
(10EA)
(10EA) Electric magnetic
clutch
Coupling case
Snap ring
Oil seal
Armature Flange
Oil seal
Spacer
Input shaft Nut
214-218 (2140-2180, 158-161)

TORQUE : N⋅⋅m (kg⋅⋅cm, lb⋅⋅ft)

[Housing] Primary Clutch [Primary Clutch]
[Armature]
Armature Base Cam [Base Cam]
4WD ECU Back Plate To rear differential

EMC connector
Apply Cam Balls

3.5 OPERATION OF COUPLING

- Constant speed drive: almost 2WD state
- Torque distribution (4WD state) changes according to the driving state (ex: sudden start,
turning, at low-mu surface) by the ECU logic
- Basic information: Input torque (Throttle Position Sensor), Steering Angle Sensor, Wheel
Speed Sensor, Brake Signal as well as ABS signal
- EMC Coil energizes to operate the Primary Clutch
- The amount of electromagnetic force in the Primary Clutch decides displacement of a Base
Cam
- Displacement of the Base Cam increases frictional force between Inner Plates and Outer
Plates of the Secondary Clutch
- While braking: performs a different control logic to get efficient braking
·Throttle Position Sensor

Judge the driving
·Wheel Speed Sensor
state
·Steering Angle Sensor
·ABS Signal
Decide an optimal
4WD ECU
torque distribution
Torque distributed at the

4WD operation 4WD coupling
[Operating Chart]

Modulating Primary Clutch
Secondary Wet Friction Clutch
Apply Force Multiplier
1) MODULATING PRIMARY CLUTCH
CLUTCH HOUSING
Ошибка!
PRIMARY CLUTCH
EMC COIL
Compress
Primary Clutch
Magnetic Field ARMATURE
Primary torque in base cam
Input torque from propeller shaft
When an EMC Coil energizes, electromagnetic field is generated attracting an Armature as well as
Primary Clutch and it increase the frictional force between inner metal plates and outer metal
plates of Primary Clutch.
Higher frictional force applies bigger torque to rotate the Base Cam because the outer plates
splined to a clutch housing and the inner plates splined to a Base Cam..

2) APPLY FORCE AMPLIFIER
Apply Cam Primary torque

in base cam
Apply Force
Base Cam
Ball cam
Ball at rest
Primary torque
in base cam
When the primary torque in the Base Cam increases, the Base Cam begins to rotates over the Ball
on the Apply Cam and it pushes the Apply Cam increasing the apply force to the Secondary Clutch.
3) SECONDARY WET FRICTION CLUTCH
Clutch Housing Clutch Plates
Compress
Secondary Clutch Back Plate
Apply Cam
Output torque
to Rear Axle
The apply force from the Apply Cam compresses the Secondary Clutch and it increases the
frictional force between inner plates which is splined with a Input Shaft and outer plates which is
splined to a Clutch Housing. The more frictional force generates the higher output torque.

4. INPUTS AND OUTPUTS
INPUTS OUTPUTS
BATTERY & IGNITION1

EMC
STEERING ANGLE SENSOR

(ESP by CAN)
4WD WARNING LAMP

WHEEL SPEED SENSOR
(ABS/TCS, ESP by CAN) 4WD
CONTROL
ABS ACTIVE (by CAN) MODULE

(ITMCM) 4WD LOCK LAMP
TPS (by CAN)
4WD LOCK SWITCH DIAGNOSIS
* CAN (Controller Area Network)

1) STEERING ANGLE SENSOR (Refer to ESP section for detailed information)

Steering angle signals of the vehicle with ESP (Electronic Stability
Program) come to the ITMCM through the CAN BUS line. However
without ESP, steering angle signals directly come to the ITMCM from the
sensor side. With the steering angle information, the ITMCM detects the
amount of steering and it controls the EMC coil current to prevent torque
conflict between the front wheels and the rear wheels.
2) WHEEL SPEED SENSOR (Refer to ESP section for detailed information)

Wheel speed sensor signals of the vehicle with ABS/TCS, ESP come to
the ITMCM through the CAN BUS line. However vehicle with a
conventional brake system, wheel speed signals directly come to the
ITMCM from the sensor side. 4WD system always comes with ABS/TCS,
ESP or conventional brake system not with ABS only.
ITMCM varies the EMC current by the Information of the speed
difference between the front wheels and the rear wheels.
For example, if the speed difference is high, more EMC current is applied by the ITMCM to
reduce the speed gap.
Front wheel speed = (FL Wheel Speed + FR Wheel Speed) / 2
Rear wheel speed = (RL Wheel Speed + RR Wheel Speed) / 2
3) ABS ACTIVE SIGNAL

Vehicle is in ABS control, ITMCM does not control the EMC current. Vehicle condition is in 2WD
state.
IGN - Type : ABSCM side --- OPEN COLLECTOR TYPE

ITMCM - ITMCM side --- 12V PULL UP
10㏀ (NO ABS CONTROL 9.0V, ABS IN CONTROL 0.5V)

ABSCM
- PULL UP resistance = 10§
17
4) TPS

TPS information comes from the ECM through the CAN BUS line. TPS is an input torque data.
TPS angle suddenly increases, then the applied current to an EMC goes up. Therefore the
torque distribution to rear wheels goes up.
5) 4WD LOCK SWITCH

This switch is selected 4WD LOCK lamp comes on. The ITMCM applies maximum current to
the EMC resulting in 50 to 50 torque distribution.
[4WD LOCK Switch] [4WD LOCK Lamp]
6) EMC (Electro Magnetic Clutch)

The ITMCM varies the applied current to the EMC to make a torque distribution to the rear
wheels. The EMC current increases then the magnetic force increases. Stronger magnetic
force results in higher pressing force to secondary clutch.
[In Engine Idling] [When ‘4WD LOCK’ is selected]

7) 4WD WARNING LAMP

4WD warning lamp blinks (2Hz) when a system failure is detected.
5. DIAGNOSIS

While the ITMCM is actived it periodically monitors its inputs

and outputs. If a fault is detected the Diagnostic Bulb is
illuminated and flash at a rate of 0.25 seconds “ON”, and 0.25
seconds “OFF”. A fault code will also be stored in the ECU
memory.
The first time a fault is detected a DTC is stored in the ECU’s
Non-Volatile memory. This DTC will remain in memory until
the ITMCM is instructed to erase DTC's by the diagnostic tester.
DTC's will not be erased by disconnecting power to the ITMCM.
[ITM Control Module]
DTCs ITMES DESCRIPTION
P1717 Steer 1 Loss of signal out of range

P1718 Steer 2 Loss of signal out of range
P1719 Steer C Loss of signal out of range
P1726 TPS input-loss of signal Loss of signal out of range
P1728 EMC-open/short to battery Short/Open to battery
P1729 EMC-short to ground Short to ground
P1750 FLSS loss of signal Malfunction of front & left speed sensor
P1751 FRSS loss of signal Malfunction of front & right speed sensor
P1752 RLSS loss of signal Malfunction of rear & left speed sensor
P1753 RRSS loss of signal Malfunction of rear & right speed sensor
ECM-ITM CAN line, or ECM side
P1764 Malfunction of ECM-ITMCM CAN line
malfunction
TCS-ITM CAN line, or ECM side
P1765 Malfunction of TCSCM-ITMCM CAN line
malfunction
Error Diagnostic
Input Diagnostic Clearing Strategy
Description Lamp

Loss of signal Active P-code cleared error is

TPS P1726 Blinking
Out of range removed after 1 second
Error
Strategy A fault code from the CAN Bus, Signal lost for 1 sec. Fault code stored in memory
ECU
Action TPS=0, The ITMCM will not send current to the clutch coil.
Loss of signal Blinking Active P-code cleared if error is

Steer_1 P1717
Loss of signal Blinking Active P-code cleared if error is

Steer_2 P1718
Loss of signal Active P-code cleared if error is

Steer-C P1719 Blinking
Error
Strategy Out of Range Signal : Voltage >= 4.5 vdc for greater than 1 second
ECU
Action Steering Wheel Sensor input=0. The ITMCM will not send current to the clutch coil.
P1750
FLSS
(C1201)
P1751
FRSS Fault cleared at ignition cycle
(C1201)
Loss of signal Blinking reset. P-code stored, and erased
P1752
RLSS by K-Line tool
(C1201)
P1753
RRSS
(C1201)
Error Measure individual wheel, if speed difference is 30kph for 30 seconds fault code
Strategy will be set. Ignition cycle reset
ECU
Action Speed sensor error will turn ITM off. ITM will not have output
Error Diagnostic
Input DTC Clearing Strategy
Description Lamp

ECM-ITMCM
Communication Active P-code cleared if error is
C.A.N P1764 Blinking
Line, or ECM removed
side malfunction
Error
Strategy Loss of the following signals TPS, Transmission type.
ECU
Action The ITMCM will not send current to the clutch coil.
TCSCM-ITMCM
C.A.N CAN Line, or Active P-code cleared if error is
P1765 Blinking
ECM side removed
malfunction
Error Loss of the following signals Wheel Speed No signal for greater than 1 second, and
Strategy a fault will be set.
ECU
Action Speed sensor error will turn ITM off. ITM will not have output
Short/Open to
P1728 Blinking
Battery
EMC Same as Speed sensor fault
Short to Grid P1729 Blinking
Error
Strategy 25 occurrences in a row mature
ECU
action EMC Error will turn ITM off. The ITMCM will not send current to the clutch coil
6. WIRING DIAGRAM (for CBS)

Ошибка!
[Connector-Male]

PIN DESCRIPTION
44-50-000-093-a 44-50-000-094-a 44-50-000-095-a

Pin No.
(95447-39980, CBS) (95447-39982, ABS/TCS) (99447-39984, ESP)
1 EMC GND EMC GND EMC GND
2 STEERING REF GND STEERING REF GND
3 STEERING REF C STEERING REF C
4 4WD LOCK SWITCH INPUT 4WD LOCK SWITCH INPUT 4WD LOCK SWITCH INPUT
5 RRSS GND RTN
6 RLSS GND RTN
7 FRSS GND RTN
8 FLSS GND RTN
9 CAN H CAN H CAN H
10 CAN L CAN L CAN L
11 ITMCM GROUND ITMCM GROUND ITMCM GROUND
12
13 BATTERY INPUT BATTERY INPUT BATTERY INPUT
14 EMC OUTPUT EMC OUTPUT EMC OUTPUT
15 STEERING REF 5V STEERING REF 5V
16 STEERING 2 INPUT STEERING 2 INPUT
17 STEERING 1 INPUT STEERING 1 INPUT
18
19 4WD WARNING LAMP 4WD WARNING LAMP 4WD WARNING LAMP
20 RR SPEED SENSOR
21 RL SPEED SENSOR
22 FR SPEED SENSOR
23 FL SPEED SENSOR
24 4WD LOCK LAMP 4WD LOCK LAMP 4WD LOCK LAMP
25 IGNITION INPUT IGNITION INPUT IGNITION INPUT
26 K LINE K LINE K LINE
* CBS: Conventional Brake System (without ABS)
7. 4WD COUPLING ASSEMBLY

7.1 SPECAL TOOLS
TOOLS
ILLUSTRATION USE
(PART NUMBER & NAME)
09432-33200 Removal of 4WD coupling

Bearing removing plate flange oil seal
09478-26000 Installation of 4WD coupling

Flange oil seal installer flange oil seal
09478-26100 Removal of 4WD coupling

Back plate remover back plate
7.2 TORQUE
ITEMS N⋅⋅m kg⋅⋅cm lb⋅⋅ft

Coupling flange lock nut 214-218 2140-2180 158-161
EMC (Electric Magnetic Clutch) mounting nuts
8-11 80-110 6-8
(3EA)
Rear propellar shaft to 4WD coupling mounting
100-120 1000-1200 74-88
bolts (3EA)
4WD coupling to rear differential carrier bolts 60-65 600-650 44-48

7.3 REMOVAL AND INSTALLATION
1. Remove the 4WD coupling bolts (3EA)

Connecting
mounted to the rear propellar shaft.
bolts (3EA)
Coupling
assembly
2. Using a flat tool, separate the propellar shaft

from 4WD coupling.
Flat tool
Rear propellar
shaft
Coupling assembly

3. Remove the rear axle (Differential carrier)

Socket
bolts mounted to the 4WD coupling.
Coupling
assembly Rear differential
carrier
4. Remove the electric magnetic clutch

Magnetic clutch connector
connector.
5. Using a flat tool, separate the 4WD coupling

Rear differential carrier
assembly from the rear differential carrier.
Flat tool
6. Remove the 4WD coupling assembly.
7. Installation is the reverse of the removal.

Coupling assembly

7.4 DISASSEMBLY
1. Remove the coupling flange mounting nut.

Nut
Flange
2. Remove the flange spacer. Spacer
3. Remove the coupling flange oil seal.

Oil seal

4. Using a general tool, 3-way puller, remove

the flange assembly. 3-way puller
Flange
5. Remove the flange oil seal using special tool Press

Suitable tool
(09432-33200).
09432-33200
Oil seal
6. Remove the coupling case assembly.

Coupling
case
Clutch housing
1) Remove the coupling case oil seal.

Oil seal
NOTE
Insert the (-) driver between the oil seal

and the clutch housing, then remove the oil
seal.

2) Remove the snap ring.
Snap ring
3) Remove the Electric Magnetic clutch

mounting nuts (3EA).
Magnetic
clutch
7. Remove the wave spring for fixing the back

Wave
plate and the secondary clutch assembly. spring
Back plate
8. Remove the snap ring.

Snap
ring

9. After removing the oil seal, remove the snap

ring.
10. Remove the back plate and the secondary

clutch assembly simultaneously using 09478-26100
special tool (09478-26100).
Back plate &

secondary
clutch
1) Separate the back plate from the input

shaft.
Back
plate
2) Remove the plates (10EA) and the discs

(10EA). Plate
Disc

3) Remove the armature.

Armature
4) Remove the input shaft.

Input shaft
11. Remove the steel balls (6EA) on the base

cam. Steel ball
12. Remove the base cam.

Base cam

13. Remove the thrust washer.

Thrust
washer
14. Remove the thrust race.

Thrust race
15. Remove the clutch of the primary clutch.

Snap ring
16. Remove the plate of the primary clutch.

Plate
NOTE
Additionally remove each 2EA discs and

plates alternately.

7.5 REASSEMBLY
1. When reassembling the back plate oil seal,

reassemble it using a suitable tool. Suitable tool
Oil seal
2. In case of the coupling case oil seal, too,

reassemble it using a suitable tool.
Suitable tool
Coupling
case oil seal
3. When reassembling the 4WD coupling

assembly and the flange, too, reassemble
them using a suitable tool.
Suitable tool
Flange
4. Install the flange oil seal using special tool.
09478-2600
Flange
Oil seal

Electronically Controlled On-Demand 4WD

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4WD SYSTEM (ITM: Interactive Torque Management)

1 Chonan Technical Service Training Center

2. T/M & TRANSFER CASE ---------------------------------------------------

3. COUPLING & REAR AXLE ASSEMBLY ---------------------------------------

4. INPUTS AND OUTPUTS -------------------------------------------------------------

6. WIRING DIAGRAM ---------------------------------------------------------------------

7. 4WD COUPLING ASSEMBLY -------------------------------------------------------

2 Chonan Technical Service Training Center

[Coupling & Rear Axle Assembly]

[Layout of JM 4WD System]

3 Chonan Technical Service Training Center

REGION GENERAL MIDDLE NORTH

* O: Optional Item, S; Standard Item

Enhanced Vehicle Traction

Enhanced Vehicle Dynamics

Enhanced Vehicle System Compatibility

Enhanced Vehicle Driving Comfort and Transparency

Enhanced Optimization of Weight and Fuel Consumption

4 Chonan Technical Service Training Center

Variable Torque Control

5 Chonan Technical Service Training Center

2. T/M & TRANSFER CASE

6 Chonan Technical Service Training Center

3. COUPLING & REAR AXLE ASSEMBLY

3.1 SPECIFICATION (ITM: Interactive Torque Management)

Self-contained, compact, light-weight, torque

ITM Housing Aluminum

7 Chonan Technical Service Training Center

[Location of ITM Coupling]

Coupling Case Clutch Housing

Primary Clutch Armature Apply Cam

8 Chonan Technical Service Training Center

Input shaft Nut

214-218 (2140-2180, 158-161)

9 Chonan Technical Service Training Center

[Housing] Primary Clutch [Primary Clutch]

Armature Base Cam [Base Cam]

4WD ECU Back Plate To rear differential

Apply Cam Balls

10 Chonan Technical Service Training Center

3.5 OPERATION OF COUPLING

·Throttle Position Sensor

Torque distributed at the

11 Chonan Technical Service Training Center

Modulating Primary Clutch

Secondary Wet Friction Clutch

Apply Force Multiplier

1) MODULATING PRIMARY CLUTCH

Magnetic Field ARMATURE

Primary torque in base cam

Input torque from propeller shaft

12 Chonan Technical Service Training Center

2) APPLY FORCE AMPLIFIER

Apply Cam Primary torque

3) SECONDARY WET FRICTION CLUTCH

Clutch Housing Clutch Plates

13 Chonan Technical Service Training Center

4. INPUTS AND OUTPUTS

BATTERY & IGNITION1

STEERING ANGLE SENSOR

4WD WARNING LAMP

ABS ACTIVE (by CAN) MODULE