SECTION 4C2 - DRIVELINE CONTROL SYSTEM

Service Precaution

Shift On The Fly System

Outline of Shift on The Fly System

System Diagrams

Shift On The Fly Electrical Equipment

Axle Shaft Connection and Disconnection

Actuator Assembly

Shift On The Fly System and Association Parts

Disassembly

Inspection and Repair

Reassembly

Torque Specifications

Special Service Tool

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING

SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING

SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE

INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT,

PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the

exact part number for that application. HOLDEN will call out those fasteners that require a replacement after

removal. HOLDEN will also call out the fasteners that require thread lockers or thread sealant. UNLESS

OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on

threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque

and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct

tightening sequence and specifications. Following these instructions can help you avoid damage to parts and

systems.

Shift On The Fly System (SOF)

Outline of Shift on The Fly System

The Shift On The Fly system electronically switches between 2 wheel drive (2WD) and 4 wheel drive (4WD) in

response to the driver operating the 4WD switch on instrument panel.

This system controls the following operations.

1. Shifting the transfer case front output gear (Connecting to, and disconnecting from, front propeller shaft by motor

actuator).

2. Retrial of shifting the transfer case front output gear.

3. Connecting front wheels to, and disconnecting them from, the front axles (by axle motor actuator).

4. Illumination of the Indicator on instrument panel.

5. “4WD out” signal to the Electronic Hydraulic Control Unit.(ABS Controller)

System Diagrams

RUW34BLF000201

Shift On The Fly Electrical Equipment

Axle Shaft Connection and Disconnection

RUW34BMF000101

Actuator Assembly

412RY00004

Shift On The Fly System and Association Parts

RTW440LF000701

Disassembly steps

1. Filler plug

2. Bolt

3. Front axle drive shaft (LH side)

4. Bolt

5. Actuator assembly

6. Bolt

7. Housing

8. Sleeve

9. Clutch gear

10. Snap ring

11. Inner shaft

12. Snap ring

13. Inner shaft bearing

14. Needing bearing

15. Oil seal

Reassembly steps

To reassemble, follow the disassembly steps in

the reverse order.

Disassembly

1. Filler Plug

Remove filler plug and packing and drain oil.

2. Bolt

Loosen mounting bracket fitting bolts and remove front axle

drive shaft from front axle case.

3. Front Axle Drive Shaft (LH side)

4. Bolt

Loosen actuator ASM fitting bolts.

5. Actuator Assembly

Draw out actuator ASM.

6. Bolt

Remove hosing fitting bolts.

7. Housing

8. Sleeve

9. Clutch Gear

412RW017

10. Snap Ring

Remove snap ring from the front axle case with the use o

snap ring pliers.

11.Inner Shaft

Take out inner shaft from front axle case.

412RW016

12.Snap Ring

Remove snap ring from inner shaft with the use of snap

ring pliers.

412RW015

13.Inner Shaft Bearing

Remove inner shaft bearing by using a special tool and

press.

Remover : 5-8840-2197-0 (J-37452)

NOTE:

Be careful not to damage the shaft.

412RS045

14.Needle Bearing

Remove needle bearing from inner shaft by using a special

tool.

Remover : 5-8840-0027-0 (J-26941)

Sliding hammer : 5-8840-0084-0 (J-2619-01)

NOTE:

Be careful not to damage the shaft.

15.Oil Seal

Remove oil seal from front axle case.

NOTE:

Be careful not to damage the front axle case.

Inspection and Repair

Inspect the removed parts. If there are abnormalities such as

wear and damage, take corrective action or replace.

Visual Check

• Check and see if the inner shaft has such

abnormalities as wear and damage.

412RW014

412RS008

• When inspecting the inner shaft, be sure to check

and see if its splined part is twisted, worn, or cracked.

If so, replace with a new shaft. In case such an

abnormality in its gear part (a slide with sleeve),

replace the shaft.

412RS026

Inner Shaft Run-Out

With both end centers supported, rotate the shaft slowly

and measure deflection with a dial gauge.

Inner Shaft Run-Out (Limit) mm (in)

0.5 (0.02)

NOTE:

Do not heat the shaft to correct its bend.

RTW440SH000101

Inner Shaft Bearing

Inspect the state of inner shaft bearing. If any abnormality

such as roughness is found, replace with a new inner shaft

bearing.

Insert the clutch gear and check the state of needle

bearing.

If there is an abnormality such as roughness, replace the

needle bearing.

Sleeve

Visual Check

Check and see that there is no wear, damage, or cracking

in the sleeve.

NOTE:

Close inspection of the groove and inner gear are

required as any abnormalities to these parts will have

adverse effect to their operation.

412RW011

Functional Check

Operate the sleeve with the inner shaft combined with the

clutch gear.

If any roughness is felt, replace the sleeve.

NOTE:

Gear oil should be applied to the contact surface of gear.

412RW022

Dimensional Check

Check the width of sleeve center groove.

Sleeve Center Groove (Limit) mm (in)

7.1 (0.28)

RTW440SH000201

Clutch Gear

Visual Check

Check and see that there is no wear, damage, crack, or

any other abnormality in the clutch gear.

Functional Check

If there is an abnormality such as roughness when

operated in combination with sleeve, replace the clutch

gear.

NOTE:

When inspection, gear oil should be applied to the contact

surface of gear.

RTW440SH000301

Dimensional Check

Confirm dimensions shown in the illustration.

Clutch Gear Out Side Diameter (Limit) mm (in)

36.98 (1.46)

RTW440SH000501

RTW440SH000401

Actuator

Visual Check

Check and see that there is no damage, cracking, or other

abnormality.

Functional Check

Confirm correct operation of actuator with voltage (12V)

applied to terminal 3, 4 and set the tester to terminal 1,

2 in accordance with the table below.

State Port

3Port 4Port 1, 2

Conducting Function

A + − C

B − + × D

If there is an abnormality, replace the actuator as an

assembly.

NOTE:

Be careful not to permit the entry of water or dust into the ports

of the actuator.

Do not open the actuator cover, if the actuator is to be reused.

RTW440SH000601

RTW440SH000801

Dimension Check

Confirm correct measurements for dimensions A, B, and C

as shown in illustration.

Limit mm (in)

A 64.3 (2.53)

B 6.7 (0.26)

C 6.7 (0.26)

RTW440SH000701

Reassembly

15. Oil seal

Install the new oil sea, which has been immersed in

differential gear oil, by using an oil seal installer.

Installer 5-8840-2407-0 (J-41693)

Grip 5-8840-0007-0 (J-8092)

412RS051

14. Needle Bearing

Force a new needle bearing into inner shaft by using the

special tools.

Installer : 5-8840-2408-0 (J-41694)

Grip : 5-8840-0007-0 (J-8092)

412RS044

13. Inner Shaft Bearing

• Place a new snap ring in inner shaft.

• Force a new inner shaft bearing into the inner shaft.

Installer : 5-8840-2197-0 (J-37452)

12. Snap Ring

NOTE;

Be careful not to damage the inner shaft.

11.inner Shaft

• Clean the housing contact surface of the front axle

case.

• Insert inner shaft assembly into the front axle case.

NOTE:

Be careful not to damage oil seal.

412RW017

10. Snap Ring

Install snap ring in the groove of front axle case.

NOTE:

Be sure to install the snap ring properly.

9. Clutch Gear

Apply differential gear oil to clutch gear.

8. Sleeve

Apply differential gear oil to sleeve.

412RW023

7. Housing

• Clean contact surface with the front axle and actuator

mounting surface.

• Apply liquid gasket to the contact surface on the front

axle case and install in the housing.

6. Bolt

Tighten bolts to specified tightening torque.

Housing Bolt Torque N m (kg m/lb ft)

75 (7.6/55)

5. Actuator

• Clean the actuator contact surface of the housing.

• Apply liquid gasket to the contact surface on the

actuator side.

• Align shift arm with the groove of sleeve and install

the actuator.

4. Bolt

Tighten bolts to specified torque.

Actuator Bolt Torque N m (kg m/lb ft)

9 (0.95/78)

3. Front Axle Drive Shaft (LH side)

2. Bolt

• Install front axle drive shaft and mounting bracket.

• Tighten fitting bolts to specified tightening torque.

Bolt Torque N m (kg m/lb ft)

116 (11.8/85)

1. Filler Plug

• Pour specified amount of differential gear oil.

Front Differential Oil Capacity liter (US/UK gal)

1.4 (0.37/0.31)

Actuator Housing Oil Capacity liter (US/UK gal)

0.12 (0.03/0.03)

• Install filler plug through packing and tighten to

specified torque.

Filler Plug Torque N⋅m (kg⋅m/lb⋅ft)

78 (8.0/58)

Torque Specifications

N⋅m (kgf⋅m / lb ft)

RTW440LF000801

Special Service Tool

ILLUSTRATION PART NO. PART NAME

5-8840-0007-0

(J-8092)

Grip

5-8840-2407-0

(J-41693)

Installer: Oil seal

5-8840-2408-0

(J-41694)

Installer: Bearing needle

5-8840-0027-0

(J-26941)

Remover: Bearing needle

5-8840-0084-0

(J-2619-01)

Hammer: Sliding

5-8840-2197-0

(J-37452)

Remover: Bearing inner shaft