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DIAGNOSTICS - FRONT AXLE CLUTCH 04-663

FRONT AXLE CLUTCH

PRECAUTION
1. If vehicle goes greater than 80km/h, the front axle clutch controller will refuse to execute switch
instruction of the four wheel driving system.
2. If dynamic assembly is damaged, it is recommended that the whole assembly to be replaced, it
is unsuitable to be opened and repaired.
3. Maintenance shall be carried out according to the standardized steps. 04
4. Connection in the circuit is forbidden.
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04-664 DIAGNOSTICS - FRONT AXLE CLUTCH

COMPONENTS DRAWING

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1 Motor component of the front axle 2 The front axle clutch controller
clutch
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DIAGNOSTICS - FRONT AXLE CLUTCH 04-665

SYSTEM SPECIFICATION
1. PRINCIPLE OF OPERATION
(a) 2H →4H: The four-wheel driving system offers combined instruction to the front axle clutch controller,
after receiving it, the front axle clutch will send corresponding instruction to the front axle clutch actuator
assembly. The actuator assembly motor drives internal gears to rotate, at last, clutch shifter drives the
clutch gear to match the main shaft. Feedback signal indicating that execution is finished to the four
wheel driving system, at the same time switch the signal to the signal the instrument, the instrument
indicating lamp shall be always on at this moment. If the first execution can’t be finished, the front axle 04
clutch controller will execute for the second time automatically; If the second time still can’t be finished,
the controller will feedback the information to the instrument, at this time, the instrument indicating lamp
glimmers, and front axle clutch will stop.
(b) 4H →2H: The four-wheel driving system offers disconnection instruction to the front axle clutch controller,
after receiving it, the front axle clutch controller will send corresponding order to the front axle clutch
actuator assembly. The actuator assembly motor drives internal gears to rotate, at last, clutch shifter
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drives the clutch gear to disconnect with the main shaft. Feedback signal indicating that execution is
finished to the four wheel driving system, at the same time switch the signal to the signal the instrument,
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the instrument indicating lamp shall be always off at this moment. If the first execution can’t be finished,
the front axle clutch controller will execute for the second time automatically; If the second time still can’t
be finished, the controller will feedback the information to the instrument, at this time, the instrument
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indicating lamp glimmers, and front axle clutch will stop.
(c) If vehicle goes greater than 80km/h, the front axle clutch controller will refuse to execute switch instruction
of the four wheel driving system.
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2. The front axle clutch controller pin

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Stitch number Pin definition Description

Connect to the ON line of ignition lock of car, and a 15A fuse
1 Power supply 12V(ON)
shall be installed on the line.

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04-666 DIAGNOSTICS - FRONT AXLE CLUTCH

Stitch number Pin definition Description

Connect to the cable of the clutch motor, this cable will output
2 Motor output (positive rotation) 12V voltage when it is in 4WD →2WD and it grounds at ordinary
times.
Connect to the cable of the clutch motor, this cable will output
3 Motor output (reverse rotation) 12V voltage when it is in 2WD →4WD and it grounds at ordinary
times.
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Connect to the negative pole of LED light, and low level will be
4 LED light output
output the, the instrument indicating lamp is on.
Inspect the state of the clutch
5 Connect to the third pin of the clutch power assembly.
controller
Inspect the state of the clutch
6 Connect to the fifth pin of the clutch power assembly.
controller
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Inspect the state of the clutch

7 Connect to the sixth pin of the clutch power assembly.
controller
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When the four wheel driving system ECU sends a low level signal,
it shows that the front axle is required to combine; if it is not a
8 Gear switch signal input;
low level , it shows that the front axle is required to be disconnect-
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ed.
Feedback signal which is sent to the four wheel driving system
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ECU. When the signal is a low level, it means that the front axle
clutch has already been combined, the four wheel driving system
can work normally, the instrument indicating lamp is on; When it
9 State output signal is not a low level, it means that the front axle clutch is disconnect-
ed, indicating lamp is off; If the clutch is out of order, then the
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controller will directly send the unusual signal to the instrument

to warn by glimmering. ( The indicating lamp is controlled through
the fourth pin)
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When the speed is greater than or equal to 80km/h, BCM will offer
Vehicle speed limitation sig- a low level (0V 2V) continuously, the controller will forbid the front
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nals (80km/h) axle clutch to work at this moment. Signals are cleared at ordinary
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times.
11 Empty: -
12 Empty: -
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13 Cathode power supply. -
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DIAGNOSTICS - FRONT AXLE CLUTCH 04-667

DEFECT PHENOMENON FORM

Defect phenomenon Suspect Area Reference
1. Fuse —
The front axle clutch indicating lamp
2.Harness or connector —
doesn’t work.
3. indicating lamp is damaged —
1. Fuse — 04
2.Harness or connector —
Chapter 34 The axle and transmis-
3 The front axle clutch actuator is of
Front axle clutch can't work normally sion shaft – front axle clutch assem-
fault
bly, replacment
Chapter 34 The axle and transmis-
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4.The front axle clutch controller
sion shaft – front axle clutch control
module
module, replacement
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04-668 DIAGNOSTICS - FRONT AXLE CLUTCH

FRONT AXLE CLUTCH CAN'T WORK NORMALLY

Circuit Diagram

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DIAGNOSTICS - FRONT AXLE CLUTCH 04-669

Diagnostic step

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F35(20 A) in the indoor fuse box (C037).

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Check whether the result is normal?

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Yes> go to step 2
No> replace fuse

2. Check harness and connectors (front axle clutch controller -grounding)

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(a) Ignition Switch: ON.

(b) Disconnect the connector C038 of the front axle clutch controller.
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(c) Use a multimeter to measure resistance value.
Standard voltage
Multimeter connection Standard value
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C038 (13) - grounding Battery voltage

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Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check harness and connectors (front axle clutch controller -grounding)

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04-670 DIAGNOSTICS - FRONT AXLE CLUTCH

(a) Ignition Switch: OFF.

(b) Disconnect the connector C038 of the front axle clutch controller.

(c) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)

04 Multimeter connection Standard value

C038 (13) - grounding ＜2Ω
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Check whether the result is normal?

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Yes> go to step 4
No > Maintenance or replace harness.
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4. Check harness and connectors (front axle clutch controller - front axle clutch actuator)
(a) Ignition Switch: OFF.
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(b) Disconnect the connector C038 of the front axle clutch controller.
(c) Disconnect theconnector K007 of the front axle clutch actuator.

(d) Use a multimeter to measure resistance value.

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Standard electrical resistance (check whether there

existent an open circuit)
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Multimeter connection Standard value

C038 (2） - K007(1）
C038 (3） - K007(2）
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C038 (5） - K007(3） ＜2Ω

C038 (6） - K007(5）
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C038 (7） - K007(6）

Check whether the result is normal?

Yes> go to step 5
No > Maintenance or replace harness.

5. Check harness and connectors (front axle clutch actuator -grounding)

(a) Ignition Switch: OFF.

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DIAGNOSTICS - FRONT AXLE CLUTCH 04-671

(b) Disconnect theconnector K007 of the front axle clutch actuator.

(c) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
K 007 (4) - grounding ＜2Ω 04
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Check whether the result is normal?

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Yes> go to step 6
No > Maintenance or replace harness.
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6. Check the front axle clutch actuator.

(a) Ignition Switch: OFF.
(b) Disconnect theconnector K007 of the front axle clutch actuator.
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(c) Replace the front axle clutch actuator.
Has the fault been eliminated?
YES>replace the front axle clutch actuator.
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No> go to step 7
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7. Check harness and connectors (front axle clutch controller - electrical clutch release system,
vehicle speed control module, combination instrument)
(a) Ignition Switch: OFF.
(b) Disconnect the connector C038 of the front axle clutch controller.
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04-672 DIAGNOSTICS - FRONT AXLE CLUTCH

(c) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C038 (8, 9) – electrical separa-
tor system
04 C038 (10) – vehicle speed
＜2Ω
control module
C038 (10) - combination instru-
ment
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Check whether the result is normal?

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Yes> go to step 8
No > Maintenance or replace harness.
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8. Check the front axle clutch controller.

(a) Ignition Switch: OFF.
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(b) Disconnect the connector C038 of the front axle clutch controller.
(c) Replace new front axle clutch controller.
Has the fault been eliminated?
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YES>replace the front axle clutch controller.

No> Remove the defects by other means.
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DIAGNOSTICS - FRONT AXLE CLUTCH 04-673

THE FRONT AXLE CLUTCH INDICATING LAMP DOESN’T WORK.

Circuit Diagram

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04-674 DIAGNOSTICS - FRONT AXLE CLUTCH

Diagnostic step

1. Check fuse
(a) Ignition Switch: OFF.

(b) Check the fuse F30(7.5 A) in the indoor fuse box (C037).

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Check whether the result is normal?

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Yes> go to step 2
No> replace fuse

2. Check the harness and connectors (combination instrument - ground)

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(a) Ignition Switch: ON.

(b) Disconnect the connector of the combination instrumentC013。
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(c) Use a universal meter to measure voltage
Standard voltage
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Multimeter connection Standard value
C013 (19) ground Battery voltage
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Check whether the result is normal?

Yes> go to step 3
No > Maintenance or replace harness.

3. Check the harness and connectors (combination instrument - ground)

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DIAGNOSTICS - FRONT AXLE CLUTCH 04-675

(a) Ignition Switch: OFF.

(b) Disconnect the connector of the combination instrumentC013。

(c) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value 04
C013 (3) ground ＜2Ω
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Check whether the result is normal?

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Yes> go to step 3
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No > Maintenance or replace harness.

4. Check the harness and connectors(Control module, front axle clutch -electric sub-actuator four
wheel driving module)
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(a) Ignition Switch: OFF.
(b) Disconnect the front axle clutch controller module
(c) Disconnect the electric sub-actuator four wheel driving module C040
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(d) Use a multimeter to measure resistance value.

Standard electrical resistance (check whether there
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existent an open circuit)
Multimeter connection Standard value
C038（9） - C040（3）
＜2Ω
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C038（8） - C040（6）
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Check whether the result is normal?

Yes> go to step 4
No > Maintenance or replace harness.

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04-676 DIAGNOSTICS - FRONT AXLE CLUTCH

5. Check wiring bunch and socket connector(combined instrument-Electric sub-actuator four wheel
driving module)
(a) Ignition Switch: OFF.
(b) Disconnect assembly instrument C013
(c) Disconnect the electric sub-actuator four wheel driving module C040

(d) Use a multimeter to measure resistance value.

04 Standard electrical resistance (check whether there
existent an open circuit)
Multimeter connection Standard value
C013（1） - C040（9）
＜2Ω
C013（17） - C040（8）
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Check whether the result is normal?
Yes> go to step 4
No > Maintenance or replace harness.
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6. Check indicator lamp

(a) Remove the indicator lamp
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(b) Replace the indicator lamp
Check whether the result is normal?
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Yes >Replace the indicator lamp
No> Remove the defects by other means.
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