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SORENTO PART TIME 4WD SYSTEM (EST)

PART TIME 4WD (EST) SYSTEM

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EST (Electronic Shift Transfer)

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SORENTO PART TIME 4WD SYSTEM (EST)

CONTENTS

1. BASIC THEORY OF 4WD

1.1 2WD AND 4WD -----------------------------------------------------------------------------------

1.2 FULL TIME 4 WHEEL DRIVE VS. ALL WHEEL DRIVE (AWD) ---------------------
1.3 ADVANTAGES AND DISADVANTAGES OF 4WD --------------------------------------
1.4 BASIC LAYOUT OF 4WD ----------------------------------------------------------------------
1.5 LSD OF 4WD --------------------------------------------------------------------------------------
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2. SORENTO 4WD SYSTEM

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2.1 4WD SPECIFICATION --------------------------------------------------------------------------

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2.2 SYSTEM CONSTRUCTION(EST,TOD) & OPERATIING CONDITION ------------

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3. EST (ELECTRONIC SHIFT TRANSFER)

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3.1 INTRODUCTION --------------------------------------------------------------------------------

3.2 KINDS OF SOFT SYSTEM IN PART TIME 4WD ---------------------------------------
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3.3 FRRD(FREE RUNNING DIFFERENTIAL) ------------------------------------------------

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3.4 COMPONENTS ----------------------------------------------------------------------------------

3.5 POWER FLOW -----------------------------------------------------------------------------------
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3.6 COMPONENTS -----------------------------------------------------------------------------------

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3.7 INPUT & OUTPUT -------------------------------------------------------------------------------

3.8 DIAGNOSIS ---------------------------------------------------------------------------------------

4. TRANSFER OVERHAUL
4.1 DISASSEMBLY ----------------------------------------------------------------------------------
4.2 ASSEMBLY ---------------------------------------------------------------------------------------

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SORENTO PART TIME 4WD SYSTEM (EST)

1. BASIC THEORY OF 4WD

1.1 2WD AND 4WD

Engine power enables a vehicle to get moving and to continue moving. To transfer the engine
power into moving force an equal amount of traction is needed.

Traction is the resistance or friction happening between each tire and the ground surface. In
2WD the traction of only two wheels is used. The other two tires have traction as well, but they
are just rolling along, in rear wheel drive vehicles they are used to steer the vehicle.

If more torque is applied than there is traction available, the 2 tires will lose its grip and start
spinning. So, if in need of more power/torque to move more weight or to go faster more traction
is needed. That can be achieved by mounting larger tires with a larger footprint or sending some
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of the torque to the other two wheels (4WD) and using their traction as well.
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So, in 2WD power is divided towards 2 tires and the traction of those two tires has the burden of
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supporting the engine's power - each powered tire has deal with 50% of the available torque. In
4WD power is divided towards 4 tires. In 4WD the traction at each powered tire has to deal only
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with 25% of the torque created by engine, transmission, transfer case, and axle. Since each tire
in 4WD has to carry a much smaller torque load (25% instead of 50%), it is much less likely for
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the tires to lose its grip. That is why a 4WD can climb much steeper grades than a 2WD.
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Because much more torque is needed to move the vehicle up a steep grade, and only when the
torque load is spread out over 4 tires instead of 2 tires it is supported by sufficient traction.
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All this is true with all 4 tires on the same surface and each wheel loaded down with 25% of the
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vehicle's weight. The very moment one tire gets onto a surface with less friction (resulting in less
traction) than the other wheels - at least one differential will start acting up. The very moment one
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tire, due to rolling into a small rut for example, gets to carry less than 25% of the vehicle's weight
(also resulting in less traction).
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The wheel with less traction will receive more than 25% of the torque (power is always following
the path of least resistance) the wheel with more traction will get less torque. The opposite wheel
will get little or no torque and cannot keep the vehicle moving. 4WD was invented to use the
traction of all 4 tires to either move more weight or drive on surfaces with marginal traction, or
both.

Differential locks and traction control are invented to counteract the "stupid" differential's intention
of wasting torque on wheels with little or no traction. All driven axles have to have a differential to
make it possible in turns to send more rpm and more torque to the outside wheel and less rpm
and less torque to the inside wheel of a turn.

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SORENTO PART TIME 4WD SYSTEM (EST)

In general:

- 4WD is helpful to get moving and supports directional stability.

- 4WD is not helpful to go faster.
- 4WD is not helpful to stop the vehicle.

1.2 FULL TIME 4 WHEEL DRIVE VS. ALL WHEEL DRIVE (AWD)

Full time four wheel drive (not part time 4WD) is a system that powers all four wheels at all times.
Each tire gets about 25% of the available torque. Driver has a choice of a "4-high" and "4-low".

When "4-low" is selected the wheels receive substantially more (on Terracan of HMC and
Sorento of KMC, its 2.48 times more) power than in "4-high", at the same time the vehicle moves
at substantially slower speeds (2.48 times slower).
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The low setting is an advantage for drivers who need to tow and maneuver a heavy trailer etc
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and for drivers who at one point or another may want to negotiate difficult off-road terrain.
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All wheel drive is a system that powers all four wheels of a vehicle at all times as well. Difference
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to full time 4WD is that "4-low" is not available. Due to the lack of "low range" AWD vehicle are
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much less capable than 4WD vehicles.

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1) All Wheel Drive (AWD)

- Only mode is 4WD full time, - No 2WD available, - No 4WD "low" available,
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- Center differential locks automatically (Torsen diff, viscous coupling),

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- Almost useless beyond pavement, - No transfer case

2) Full Time 4WD

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- Main mode is 4WD. 4WD is used full time.

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- No 2WD mode available.

- All four wheels are powered at all times. Operates well on dry pavement due to a center
differential or equivalent device (viscous coupling, planetary gears).
- Part Time 4WD does not have a center differential. A center differential is essential for on-road
use but can be detrimental for off-pavement use. When leaving pavement the center differential
needs to be disabled (locked). It either locks automatically or it has to be locked (disabled)
manually.
- Normal setting for on-road use and light duty off-road use is 4WD "high"
- For more torque 4WD "low", also called low range, is available. Low range substantially
provides more torque to the wheels and allows slower speeds than in high range. 4 low does
not provide more traction. It only provides more torque.

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SORENTO PART TIME 4WD SYSTEM (EST)

3) Part Time 4 Wheel Drive

- Main mode is 2 wheel drive for everyday pavement use. Only rear wheels are powered. (In
some cases front wheels are powered instead)
- When needed (usually beyond pavement) 4WD can be engaged. (4WD is used part time)
- When 4WD is engaged front wheels are powered as well.
- There are two different settings for 4WD "high" and "low"
- 4WD "high", called high range, cannot be used on dry pavement with a "part time " system.
- For extreme situations 4WD "low" is available, it cannot be used on dry pavement either. 4WD
"low", also called low range does not provide more traction. However, it provides two to three
times more torque at about half or a third of the speeds in high range.

1.3 ADVANTAGES AND DISADVANTAGES OF 4WD

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1) Traction and Grip :

Apparently, 4-wheel drive brings traction and grip to higher level because the tractive effort
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is shared by 4 wheels instead of two. This enable higher cornering limit, especially in rough
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roads and wet condition. Since it was introduced in 1980 to rally cars, 4WD proved its
superiority in this aspect.
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2) Weight penalty and power loss :

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Because the driving mechanism of the additional wheels has frictional loss, 4WD consumes
a little bit more power than 2WD cars. Anyway, this is still a fraction compare with the
increased weight. Most 4WD systems weigh 50kg-100kg more than a 2WD system, thus
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deteriorate acceleration as well as fuel consumption.

3) Steering tendency :
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As mentioned in our study of handling, in theory, permanent 4WD cars generate neutral
steering tendency, thanks to the tractive force sharing by all 4 wheels. However, in reality
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this become much more complicated. Steering tendency can also be corrected by weight
distribution, the adjustment of camber and castor, the choice of different size tires in front
and rear etc. Moreover, it is widely agreed that a slight oversteering, if could be accurately
controlled by throttle and steering, is even more satisfying than neutral steering. In contrast,
most 50:50 permanent 4WD cars can hardly enable oversteering, unless in really slippery
surface.

4) Steering feel :
Depends on tuning, some 4WD cars deliver less steering feel, since the presence of torque
in the front wheels may generate slightly torque steer. However, most modern 4WD cars
overcame this problem.

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SORENTO PART TIME 4WD SYSTEM (EST)

1.4 BASIC LAYOUT OF 4WD

A modern 4-wheel drive system must has 3 differentials - one in the front axle to distribute
torque between the left and right front wheels, one in the rear axle again responsible for torque
distribution, the third one, calls Center Differential, distributes torque between front and rear
axles.

We all know the objective of differential. During

cornering, the outside wheels have to travel
faster than the inside wheels, therefore we
need a differential to distribute different torque
to the wheels. For a 4WD car, we in addition
need the Center Differential because the front
wheels have to travel faster than the rear
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wheels. The following diagram illustrates this:

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If without the center differential, the non-conformance of front and rear wheel speed will lead to
tire slip as well as energy losses, tire roar, wear of tires etc. Therefore center differential is a
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must for modern cars.

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1.5 LSD OF 4WD

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However, just the 3-differential layout alone cannot cope with the basic requirement for 4WD -
provides superior grip in the worst roads. In real world driving, for instance, when pushing the
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car over its limit in corner, or running on slippery surface, tire slip is inevitable. When a wheel
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loses traction, a normal differential will transfer nearly all the driving torque to that wheel. As a
result, the spinning wheel will spin even wilder, but the wheel that having traction will never
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share driving torque, therefore the car will be difficult to get out of the trouble. This problem
occurs in all kinds of car, no matter 2-wheel drive or 4WD, but it is relatively more important to
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4WD because 4WD cars are designed to run in worse roads or cornering harder.

Therefore 4WD cars (or even many latest 2WD sports cars) need Limited Slip Differential
(LSD). A LSD lock up both drive shafts whenever tire slip occurs, thus helps the car get out of
trouble quickly. The result is enhanced stability and even higher cornering limit.

In fact, LSD is the core of 4WD technology. There are several types of LSD: Torsion LSD,
Viscous Coupling LSD, VC differential lock and Active LSD. They have different effectiveness,
characteristic and cost so that car makers choose them according to their needs.

Regarding 4WD vehicle such as Santa-Fe(for rear diff.) of Hyundai motors and Sportage,
Sorento of Kia motors, Carbon Disc LSD is adapted for the rear as an option.

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SORENTO PART TIME 4WD SYSTEM (EST)

2. SORENTO 4WD SYSTEM

2.1 4WD SPECIFICATION

EST: Electrical Shift Transfer is standard on all models and trims for part-time 4WD, allowing
drivers to “shift on the fly” between two- and four-wheel-drive modes at speeds up to 80 km/h.

ATT: Active Torque Transfer (or “Torque-on-Demand”) electronically transfers power and torque
from the rear to the front as required, enhancing off-road traction, handling agility and steering
precision.
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[Comparison between the Part Time 4WD and the Full Time 4WD]
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Item s Parts tim e Full tim e

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Engine DSL 2.5,

2.52.9 GSL 2.4,
3.5 3.5
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Type Electronic shift transfer Active torque transfer

Model BW A 44-24 ESO F BW A 44-24 TO D

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No CFRRD
ADS
FRT axle connection CADS
FRRD
(Full tim e connection)
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W eight (Kg), Length(m m ) 35, 351 37.3, 351

Gear ratio (HIGH) 1:1

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Gear ratio (LO W ) 2.48 : 1

FRT driving type Chain

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Lubricant DEXRO N III (PermDEXRON

anent use
III : No replacem ent)
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Lub. Q uantity (L) 1.42

FRRD
CADS motorvalve
solenoid ○ ×
Front speed sensor × Hall IC effect type

Rear speed sensor ×

Pulse generator Hall IC effect type

Vehicle speed sensor Pulse

Hall generator
IC effect type Hall IC effect type

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SORENTO PART TIME 4WD SYSTEM (EST)

2.2 SYSTEM CONSTRUCTION (EST, TOD) & OPERATING CONDITION

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[EST] [TOD]
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Drive type Drive item Drive mode Drive status Useful condition
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2WD, Rear
2H Use on the roadway.
wheel drive
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* Use on the off-road or snowy and rainy road having slippery road
surface.
Drive mode 4H 4WD HIGH
* When turning on the roadway at low speed, vibration and noise
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happens by tight corner braking.

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Electric Shift Use in the condition which driving force is required like escaping from
Transfer 4L 4WD LOW
rough way and towing.
(EST type) Possible to transfer 2WD into 4WD and vice versa at 80kph or below
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2H ↔ 4H 2WD ↔ 4WD
during driving.
* Necessary to stop the vehicle for transfer
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Transfer
4H ↔ 4WD(H) ↔ - M/T vehicle : Transfer after pressing the clutch pedal.
4WD(L) 4WD(L) - A/T vehicle: Transfer after positioning the A/T lever to “N”.
* All vehicles with 4L mode should stop the vehicle for transfer.
* Use on the various road surfaces including roadway, off-road, or
snowy and rainy road surface.
* Using multiple clutch, control the revolution difference between front
AUTO 2WD ↔ 4WD
Drive mode and rear wheels electronically.
So this mode can correspond to the various road surfaces by
Active Torque
controlling the ATT unit automatically.
Transfer
(ATT type) LOW 4WD LOW Refer to 4L of part time.
* Necessary to stop the vehicle for transfer
AUTO ↔ 4WD(H) ↔ M/T vehicle: Transfer after pressing the clutch pedal.
Transfer
LOW 4WD(L) A/T vehicle: Transfer after positioning the A/T lever to “N”.
* All vehicles with 4L mode should stop the vehicle for transfer.

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SORENTO PART TIME 4WD SYSTEM (EST)

3. EST (ELECTRONIC SHIFT TRANSFER)

3.1 INTRODUCTION

EST system is a kind of part time 4wheel drive system and its full name is ‘Electronic shift
transfer’. Instead of the free wheel hub type adapted by Sportage, FRRD (Free Running
Differential) type of SOTF(Shift on the fly) system is employed.
When a vehicle runs with 2WD mode, front axle will rotates idly due to the vehicle speed. Driving
chain inside transfer rotates along with the front wheel revolution making a noise and vibration
through the propeller shaft. To prevent this, a device, FRRD system is required to cut the
connection between the front wheel and the transfer.

When 4WD mode is selected by driver, FRRD air pump motor operates and a dog clutch in
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FRRD is engaged to pinion shaft making a front wheels drive. Therefore the front propeller shaft
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and the front drive shaft is coupled rotating together. Oppositely, if 2WD is selected by a driver,
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the dog clutch in a FRRD is disengaged resulting in disconnection between the front propeller
shaft and the front drive shaft.
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[EST Transfer Case]

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SORENTO PART TIME 4WD SYSTEM (EST)

3.2 KINDS OF SOTF SYSTEM IN PART TIME 4WD

1) CAM type auto free wheel hub

- Application vehicle : HMC Galloper

- For 2WD from 4WD, vehicle should be moved backward 1 or 2 meters approximately.
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2) Vacuum type free wheel hub

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- Application vehicles : HMC H-1, KMC Sportage

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- SOTF is activated in condition of 40km/h or less.

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- In respect of durability, it is difficult to prevent the air

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leakage on the wheel end side.

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SORENTO PART TIME 4WD SYSTEM (EST)

3) CADS (Center axle disconnect system) type

- Application vehicles : HMC Terracan, MMC Pajero,

Challenger, Big horn, Surf

- SOTF is activated at 80km/h or less.

4WD 2WD
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Drive shaft (RH)

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Actuator
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Free wheel clutch

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assembly
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Atmosphere
Solenoid valve ‘B’ Solenoid valve ‘A’
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Check valve
GSL: Surge tank
DSL: Vacuum pump
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Vacuum tank

When 2WD is selected by driver, the shift fork of the CADS moves by the pressure difference of
each side of the diaphragm inside actuator. It results disconnection between axle shaft and
differential shaft. Oppositely, if 4WD is selected by driver, the axle shaft and differential shaft is
connected so as to be driven by 4WD.

4) FRRD (FRee Running Differential) : refer to the following chapter.

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SORENTO PART TIME 4WD SYSTEM (EST)

3.3 FRRD(FREE RUNNING DIFFERENTIAL)

SOTF(Shift On The Fly) system for Sorento is a FRRD type. Sportage, previous KIA 4WD model,
has incorporated two types of SOTF system one is a CAM type auto free wheel hub system used
till 1999 model, the other type is a Vacuum type free wheel hub system.
A vacuum type has made better performance than a CAM type. But it still has a problem like an
air leaking in a hub which is exposed all the time.

FRRD is installed in the front axle. A driver selects 4WD mode, air pump motor is energized and
a dog clutch is engaged connecting a front propeller shaft and a front drive shaft. If a drive
selects 2WD mode on driving, the dog clutch is disengaged disconnecting the drive force to a
drive shaft.
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[FRRD case] [FRRD outer case]

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SORENTO PART TIME 4WD SYSTEM (EST)

[ADVANTAGES OF FRRD]

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PINION GEAR
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SIDE GEAR

PINION SHAFT

[FRRD section]

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SORENTO PART TIME 4WD SYSTEM (EST)

[FRRD VACUUM PUMP MOTOR]

[FRRD air pump motor] [FRRD air pump motor circuit]

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[FRRD OPERATION]
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BOLT DRIVE SHAFT

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① When driver selects 4H mode, power

supplies to an air pump motor.
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② At the moment, front propeller shaft

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begins to rotate and the speed difference

between the inner case and the outer Air pump FRRD
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case is almost same.

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DRIVE
③ Air pressure is charged inside the air PINION RING GEAR
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pump.
PROP.
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④ The pressure pushes a cam ring and a SHAFT

dog clutch and the inner case are
coupled together making a 4WD mode.

⑤ If the driver selects a 2H mode, drive

force is cut off inside a transfer and the
power of the air pump is off.

⑥ Cam ring returns by a return spring,

connection with the inner case is off to a
2WD mode.

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SORENTO PART TIME 4WD SYSTEM (EST)

[FRRD OPERATION - 4WD]

Air pressure from the

FRRD air pump motor
FRRD actuator pushes
ENGINE down the dog clutch
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[FRRD operation at 4H or 4L mode]

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Air pressure from the FRRD air pump motor pushes

down the dog clutch inside FRRD making the differential
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pinion shaft be coupled with the differential housing.

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[FRRD OPERATION - 2WD]

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ENGINE
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[FRRD operation at 2H]

The FRRD air pump motor does not operate and the
differential pinion shaft rotates freely. Therefore the
mechanical connection between the front wheels and
the transfer case is cut off.

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SORENTO PART TIME 4WD SYSTEM (EST)

3.4 COMPONENTS

Planetary gear
(4 LOW)
Rear output

TM input
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Front input
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EST case and TOD case looks almost

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4LOW operation
same. But inside it, EST and TOD has
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some different part for a part time or a

Shift fork
full time mechanism.
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In case of EST, a lock-up fork and a

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Driving chain
lock-up collar is added for a part time
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mechanism. And EST only has a rear

Shift cam
output speed sensor differently from a
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TOD transfer case which has a front

output speed sensor as well.
Clutch housing
A 4 low mode transfer part which has a
planetary gear set to make an output
Lock up collar
gear ratio of 2.48:1 is the same as that
of TOD. Magnetic clutch

Speed sensor

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SORENTO PART TIME 4WD SYSTEM (EST)

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SORENTO PART TIME 4WD SYSTEM (EST)

3.5 POWER FLOW

4H
4L operation
operation

Reduction
fork
Lock up fork
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MPS
Shift cam
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Shift motor
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Driving chain
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LOCK-UP SHIFT FORK Shift CAM Shift shaft

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Comparing with the TOD transfer, EST has

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one more shift fork for engaging 2WD and

4WD. That is a ‘Lock up shift fork’.

EST TOD
Reduction shift fork Yes Yes Shift Motor

Lock up shift fork Yes No

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SORENTO PART TIME 4WD SYSTEM (EST)

1) POWER FLOW: 2H Mode (Rear Wheel Drive)

At 2H mode, driving force coming from a transmission output shaft directly delivered to the
rear output shaft. A shift motor does not operate making a lock-up shift fork remain still.
However, driving chain that transfers the rear output speed to the front output shaft can
rotate because of the front wheel rotation while driving. The front wheel rotation is transferred
into the transfer case rotating a drive chain. To prevent this, front drive shaft and front
propeller shaft connected with a transfer case should be disconnected at 2H mode.
FRRD(FRee Running Differential) is a kind of center axle disconnect system for that
purpose.
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SORENTO PART TIME 4WD SYSTEM (EST)

2) POWER FLOW: 4H Mode

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At 4H mode, TCCM(Transfer Case

Control Module) sends a signal to the
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shift motor to rotate. Shift motor rotation

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slides up a lock-up shift fork which is

connected a lock-up shift collar.

The Shift collar is engaged an upper

sprocket that drives a drive chain
delivering a drive force to the front shaft
as soon as a magnetic clutch is on.

At the moment, TCCM also send a signal

to the FRRD air pump motor in order to
connect a center axle.

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SORENTO PART TIME 4WD SYSTEM (EST)

* 2WD engagement

4L engagement Sleeve
EMC

Input RR P/S

Lock-up fork
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Shift CAM
MPS
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Driving
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chain
FRT P/S
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Shift motor
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* 4WD engagement
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Sleeve
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4L engagement
EMC
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Input RR P/S

Lock-up fork

Shift CAM
MPS
Driving
chain

FRT P/S Shift motor

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SORENTO PART TIME 4WD SYSTEM (EST)

3) POWER FLOW: 4L Mode

At 4L mode, TCCM (Transfer Case

Control Module) sends a signal to the
shift motor to rotate. Shift fork as well
as a lock-up shift fork which is
connected a lock-up shift collar slides
up by shift motor rotation.

A reduction hub slide outward along

the shift fork and a planetary gear is
engaged making a lower speed. The
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output gear ratio is 2.48:1 and the

vehicle can get more driving torque
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than it is in a 4H mode.
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A lock-up shift collar slide outward

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along the lock-up shift fork and it is

engaged with an upper sprocket that
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drives a drive chain delivering a drive

force to the front shaft as soon as a
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magnetic clutch is on.

At the moment, TCCM also send a

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signal to the FRRD air pump motor in

order to connect a center axle
connection. If a 4L mode is selected
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from a 4H mode, then the FRRD air

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pump motor keeps ON and center

axle connection remains engaged.

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SORENTO PART TIME 4WD SYSTEM (EST)

* Planetary gear engagement (1:1 connection – 2H, 4H)

Planetary gear
Reduction hub

[1:1 connection (2H, 4H)]

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Reduction hub
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Input
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Sun gear
Pinion gear Reduction fork
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Ring gear (Fix)

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Shift CAM

Planetary gear carrier

TM output comes into the input shaft of the transfer. At 2H or 4H mode, the planetary gear is not
involved because the reduction hub, when it moves inward the planetary gear, is not connected
with a planetary pinion gear carrier. Therefore input shaft is directly coupled with the rear output
shaft allowing the same revolution speed of the both shafts.

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SORENTO PART TIME 4WD SYSTEM (EST)

* Planetary gear engagement (4L mode)

Movement of a reduction hub at 4L mode

Planetary gear

Reduction hub
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[4-Low mode Æ gear ratio 2.48:1]

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Reduction hub
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Input
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Sun gear
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Pinion gear Reduction fork

Ring gear (Fix)
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Shift CAM

Planetary gear carrier

TM output comes into the input shaft of the transfer. At 4L mode, the planetary gear is involved
because the reduction hub, when it moves outward the planetary gear, is connected with a
planetary pinion gear carrier. Therefore input shaft is coupled with the planetary gear and then
is delivered to the rear output shaft allowing 2:48:1 revolution speed difference between the
input shaft speed and the rear output shaft speed.

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SORENTO PART TIME 4WD SYSTEM (EST)

3.6 COMPONENTS

1) Mode selection switch

- 2H mode: Rear wheel drive mode

- 4H mode: Transferring from 2WD to 4WD

can be achieved even while vehicle driving.
(SOTF: Shift On The Fly). At this time, the
vehicle speed should not be over than 80km/h.
If the shift is successfully finished, the 4WD
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High lamp will be turned on.

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- 4L mode: The vehicle should be stopped

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(3km/h or less). At the moment a shift lever

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should be positioned “N” position(A/T) or a

“Clutch” pedal should be ON before selecting
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a 4L mode.
2H-4H-4L
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After a mode change is successfully finished, switch

the 4L lamp will be turned on.
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SORENTO PART TIME 4WD SYSTEM (EST)

2) Shift motor & Motor position sensor

When a driver selects a driving mode, a mode signal comes to a TCCM. Then the TCCM
operates a shift motor.

There is a MPS(Motor Position Sensor) inside the motor contacting a position plate which
sends a motor position signal to the TCCM. TCCM can get a feedback of a driving mode
position.

If the MPS sends to the TCCM different position signals from a mode switch position, a
relevant failure code is memorized.

Magnetic
Worm gear
w
w
w
.C

Rotor
ar
Ga

MPS contacting plate

r ag

[Shift motor operation while shifting]

2H 4L
e.

4H 4L 4H 2H
12 V 12 V
ir

1 1
+ -
2 2

T + T -
C C
12 V M 12 V M
C C
- +
U U
17 17
- +
16 16

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SORENTO PART TIME 4WD SYSTEM (EST)

* Motor position sensor

5V
0V

0V

5V

[Sensor output voltage at 2H/4H/4L mode] [Sensor output voltage while being shifted]
The common return terminal is off-grounded. The common return terminal is grounded for 7
w

The output voltage of position sensor 1,2,3,4 seconds. The output voltage of sensor which
keeps 5 volts. contacts the steel plate drops 0 volts.
w

MPS output signal (2HÆ 4H) MPS output signal (4HÆ 4L)
w
.C

Position 1 Position 1
ar
Ga

Position 2 Position 2
r ag
e.
ir

MPS output signal (2HÆ 4H) MPS output signal (4HÆ 4L)

Position 4 Position 4

Position 3 Position 3

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SORENTO PART TIME 4WD SYSTEM (EST)

3) EMC(Electronic Magnetic Clutch) signal

EMC is energized to pull the lock-up shift fork to make

4H mode.

2H 4H

EMC
w
w
w
.C
ar
Ga

3.7 INPUT AND OUTPUT

Input Output
r

Motor position sensor TCCM

ag

Position 1 Shift motor

Micro processor

Position 2
e.

Position 3 Electro magnetic clutch

Position 4
ir

Cluster ‘4L’ lamp

EST switch

A/T ‘N’ signal Cluster ‘4H’ lamp

ROM

Clutch interlock switch

K-Line
Speed sensor
FRRD solenoid valve
RAM

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SORENTO PART TIME 4WD SYSTEM (EST)

3.8 DIAGNOSIS

1) TCCM & DLC location

w

Under the crash pad(Passenger side)

w
w
.C
ar
Ga

2) DTC
r

There is no P-code for EST system. DTC is supported with binary code. The binary fault code
ag

shall be displayed if a corresponding input or output part is failed.

e.

Decimal Binary Fault

ir

1 001 TCCM (Transfer case control module)

2 010 Shift motor
3 011 EMC (Electro magnetic clutch)
4 100 Speed sensor
5 101 FRRD air pump motor
6 110 2H-4H-4L switch
7 111 MPS (Motor position sensor)

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SORENTO PART TIME 4WD SYSTEM (EST)

3) EST standard input and output value in TCCM

Signal
No Items Condition Remarks
Type Level
1 A1 MOTOR OUTPUT IDLE("N") DC Vbatt * Current :
(2H-4H-4L) ↑ 0V INRUSH(+) : 4.64A
2 A2 MOTOR OUTPUT IDLE("N") DC Vbatt INRUSH(-) : 4.4A

(2H-4H-4L) ↑ 0V Operation : 0.6A

3 A3 GND
4 A4 CLUTCH COIL IDLE DC Vbatt * Current :
(2H →4H →4L) ↑ 0V 4.28A
5 A5 POSITION 1 MTR IDLE 2H CODE : 1010 * MTR POS. CODE :
w

(P/R/N/D/2/L) 2H →4H CODE : 0011 1/2/3/4 = XXXX

w

4H →4L CODE : 1100 (1 = 5V dc)

w

LOGIC HI(1) : 5V (0 ≤0.5V dc)

.C

LOGIC LO(0) : 0.5V or less

6 A6 SPEED SNSR IDLE PULSE * VSS of 60KPH :
ar

HI : 16.4V
Ga

135Hz at 60KPH LO : -6.4V

7 A7 2H SW SW OFF DC 4.5 ～5.5V

r ag

SW ON ↑ 0.5V or less
8 A8 4H DISPLAY SW OFF DC Vbatt
e.

SW ON ↑ 0.5V or less
9 A9 BATT IGN OFF DC Vbatt
ir

IGN ON ↑ Vbatt
10 A10 BATT IGN OFF DC Vbatt
IGN ON ↑ Vbatt
11 A11 GND
12 A12 POSITION 2 MTR IDLE 2H CODE : 1010 * MTR POS. CODE :
(P/R/N/D/2/L) 2H →4H CODE : 0011 1/2/3/4 = XXXX

4H →4L CODE : 1100 (1 = 5V dc)

LOGIC HI(1) : 5V (0 ≤0.5V dc)

LOGIC LO(0) : 0.5V or less

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SORENTO PART TIME 4WD SYSTEM (EST)

Signal
No Items Condition Remarks
Type Level
13 A13 4L SW SW OFF DC 4.5 ～5.5V
SW ON ↑ 0.5V or less

14 A14 INHIBITOR SW(AT N DC 0V

CLUTCH INTERLOP/R/D/2/L ↑ 5V
SW(MT)

15 A15 4L DISPLAY IDLE("N") DC Vbatt

↑ 0V

16 A16 MOTOR OUTPUT IDLE("N") DC Vbatt

(4L-4H-2H) ↑ 0V
w

17 A17 MOTOR OUTPUT IDLE("N") DC Vbatt

w

(4L-4H-2H) ↑ 0V
w

18 A18 COMMON RETUR IGN OFF DC 0.9V or less

.C

IGN ON ↑ 4.75 ～5.25V

19 A19 IGN 1 IGN OFF DC 0V
ar

IGN ON ↑ Vbatt
Ga

20 A20 POSITION 4 MTR IDLE 2H CODE : 1010 * MTR POS. CODE :

(P/R/N/D/2/L) 2H →4H CODE : 0011 1/2/3/4 = XXXX
r

4H →4L CODE : 1100 (1 = 5V dc)

ag

LOGIC HI(1) : 5V (0 ≤0.5V dc)

LOGIC LO(0) : 0.5V or less
e.

21 A21 POSITION 3 MTR IDLE 2H CODE : 1010 * MTR POS. CODE :

ir

(P/R/N/D/2/L) 2H →4H CODE : 0011 1/2/3/4 = XXXX

4H →4L CODE : 1100 (1 = 5V dc)

LOGIC HI(1) : 5V (0 ≤0.5V dc)
LOGIC LO(0) : 0.5V or less

22 A22 DIA. DISPLAY In comm. PULSE 4V or more

0～0.9V

23 A23 C.A.D.S IDLE OFF Vbatt

(2H →4H) ON 0.5V or less

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SORENTO PART TIME 4WD SYSTEM (EST)

4) Wiring diagram

w
w
w
.C
ar
Ga
r ag
e.
ir

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SORENTO PART TIME 4WD SYSTEM (EST)

4. TRANSFER OVERHAUL
4.1 DISASSEMBLY

* Prepare an EST unit on a table with proper

tools.
w

1. Before overhaul, remove an EMC coil wire

w

carefully from the connector.

w
.C
ar
Ga
r ag
e.
ir

* After removing the pin, correct the stopper of

the pin using a driver.

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SORENTO PART TIME 4WD SYSTEM (EST)

2. Remove the shift motor assembly.

* After removing the shift motor assembly.

w
w
w
.C
ar
Ga

3. Remove the vehicle speed sensor.

r ag
e.
ir

4. Remove the lock nut.

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SORENTO PART TIME 4WD SYSTEM (EST)

5. Remove the companion flange and the

oil seal.

6. Remove the rear speed sensor.

w
w
w
.C
ar
Ga

7. Remove the cover bolts.

r ag
e.
ir

8. Remove the EMC coil nuts.

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SORENTO PART TIME 4WD SYSTEM (EST)

* Check the rubber bush and extension housing.

9. Remove the oil seal.

w
w
w
.C
ar
Ga

* After removing the oil seal.

r ag
e.
ir

10. Remove the speedo gear.

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SORENTO PART TIME 4WD SYSTEM (EST)

11. Remove the tone wheel.

12. Remove the case upper cover.

w
w
w
.C
ar
Ga

13. Remove the EMC coil and the coil housing.

r ag
e.
ir

* EMC coil and housing

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SORENTO PART TIME 4WD SYSTEM (EST)

* EMC housing (bottom)

* EMC coil
w
w
w
.C
ar
Ga

14. Remove the 4H mode return spring.

r ag
e.
ir

15. Check the proper function of the lock-up

assembly by pressing the lock-up hub.

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SORENTO PART TIME 4WD SYSTEM (EST)

* Examine the wear on the face.

16. Remove the lock-up assembly and the

shift-fork together.
w
w
w
.C
ar
Ga

* Lock-up assembly and the shift-fork

r ag
e.
ir

17. Inspect the 4H shift-fork and wear of fork

pads.

Fork pads

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SORENTO PART TIME 4WD SYSTEM (EST)

* After removing the lock-up assembly and

the shift-fork

18. Remove the chain and sprocket together

w
w
w
.C
ar
Ga

19. Remove the magnet before removing the

pump from the output shaft.
r ag
e.
ir

20. Rotate the output shaft to rotate inner

pump gear and remove the pump assembly
and the shaft together.

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SORENTO PART TIME 4WD SYSTEM (EST)

21. Remove the spacer.

22. Lift pump of the shaft.

w
w
w
.C
ar
Ga

* Pump assembly is not a serviceable item and

should be replaced as an assembly.
r ag
e.
ir

23. Inspection of the upper output shaft.

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SORENTO PART TIME 4WD SYSTEM (EST)

* Check the spline teeth for brakes, chipping,

crack.

* Check journals for excessive wear or

discoloration.
w
w
w
.C
ar
Ga

* After removing the output shaft

r ag
e.
ir

24. Remove the shift rail.

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SORENTO PART TIME 4WD SYSTEM (EST)

25. Remove a shift cam.

26. Remove a reduction fork.

w
w
w
.C
ar
Ga

* Inspect the reduction fork. Check the fork

pad for wear or discoloration from heat.
r ag
e.
ir

27. Remove a reduction hub.

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SORENTO PART TIME 4WD SYSTEM (EST)

* Check the reduction hub teeth for wear,

brakes, chipping, crack.

* Snap ring
w
w
w
.C
ar
Ga

28. Ply open the snap ring and pull out the
planetary carrier assembly from the cover.
r ag
e.
ir

* After removal

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SORENTO PART TIME 4WD SYSTEM (EST)

* Planetary carrier assembly

w

29. Remove a snap ring.

w
w
.C
ar
Ga
r ag

30. Remove a snap ring.

e.
ir

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SORENTO PART TIME 4WD SYSTEM (EST)

31. Remove the input gear assembly from the

carrier assembly.

32. Disassemble the input gear assembly using

a press.
w
w
w
.C
ar
Ga

* Input shaft assembly

r ag
e.
ir

* Shift cam assembly

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SORENTO PART TIME 4WD SYSTEM (EST)

33. Disassemble shift cam assembly

* 4H lock-up assembly
w
w
.C
ar
Ga

34. Disassemble the 4H lock-up assembly by

removing a snap ring between the cowl and
r ag

lock-up hub
e.
ir

* 4H lock-up assembly

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SORENTO PART TIME 4WD SYSTEM (EST)

4.2 DISASSEMBLY

1. Reassemble the sun gear to the input gear.

And install new input bearing snap ring.

w
w
w
.C
ar

After installation
Ga
r ag
e.
ir

2. Install the input assembly into the carrier

assembly and then install the snap ring.

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SORENTO PART TIME 4WD SYSTEM (EST)

3. Insert the shift cam assembly.

w

4. Place the reduction hub and the shift fork

w

together into the carrier.

w
.C
ar
Ga
r ag

* After installation
e.
ir

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SORENTO PART TIME 4WD SYSTEM (EST)

5. Slide the pump onto the shaft and align the

drive pin on the slot in the pump.

6. Insert the output shaft into the input and

reduction hub.
w
w
w
.C
ar
Ga

7. Insert the magnet into the case.

r ag
e.
ir

8. Install a spacer over the shaft onto the pump.

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SORENTO PART TIME 4WD SYSTEM (EST)

* Location of the spacer.

Spacer

9. Place the chain and sprocket on the shaft.

w
w
w
.C
ar
Ga

* After installation
r ag
e.
ir

10. Locate blue chain link which is always on the

top side of chain facing up.

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SORENTO PART TIME 4WD SYSTEM (EST)

11. Place the lock-up assembly and 4H shift fork

on the sprocket aligning the lock-up collar teeth
with the sprocket teeth.

* After installation
w
w
w
.C
ar
Ga

12. Place the coil housing on the shaft.

r ag
e.
ir

13. Install the shift fork return spring.

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SORENTO PART TIME 4WD SYSTEM (EST)

14. Insert the coil in the case.

15. Install the EMC coil nuts.

w
w
w
.C
ar
Ga

16. Install cover bolts.

r ag
e.
ir

17. Install the speed sensor.

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SORENTO PART TIME 4WD SYSTEM (EST)

18. Insert the coil pin to the connector.

w

19. Apply sealant to the shift motor seat on the

case.
w
w
.C
ar
Ga

20. Install the shift motor on the case.

r ag
e.
ir

21. Attach wire retainer to the connector.

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SORENTO PART TIME 4WD SYSTEM (EST)

* After installation
w
w
w
.C
ar
Ga
r ag
e.
ir

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