Transfer Box (Exploded View): General

The DD295 transfer box is a full time, permanent four-wheel-drive unit, with 50/50 torque distribution to the front and rear driveshafts. The unit is manufactured by Magna Steyr Powertrain in Graz, Austria and supports the following features:

• Permanent four-wheel-drive with a bevel gear center differential, providing a 50:50 torque split
• Selectable high and low range for optimum on-road and off-road performance
• Two-speed, fully synchronized 'shift-on-the-move' system allows the driver to change the range without having to stop the vehicle
• Electronically controlled multi-plate clutch providing a center differential lock and torque biasing function to give improved traction performance and vehicle dynamic stability.

A strategy, to electronically control the center differential multi plate clutch assembly, has been developed to provide:

• a pre-loading function, increasing locking torque with increased driving torque
• a slip controller to increase locking torque under off-road conditions and decrease locking torque for optimum comfort, e.g. parking.

The unit is located under the vehicle and is mounted on the crossmember, behind the transmission. The unit is identical for all engine derivatives.

The transfer box receives a torque input from the transmission output shaft, which is passed through the unit to two outputs for the front and rear drive shafts.

The input torque is equally distributed via a bevel gear type differential. In order to provide an optimal torque distribution to each wheel in all driving conditions, the unit is equipped with an electronically controlled locking and torque-biasing device. This device detects wheel slip via various vehicle system inputs to the transfer box control module and locks the differential accordingly. The locking torque is applied through a multi-plate clutch assembly.

A planetary gear set, located in the differential assembly, allows the driver to select high or low range while driving, this is known as 'shift on the move'. When in low range, the planetary gear set provides a ratio of 2.93:1, which gives the vehicle an extremely low crawl speed for off road driving and trailer towing. High range is a direct drive from the transmission output shaft and provides a 1:1 ratio.

Both the center differential locking and biasing and the 'shift on the move' features are actuated via a DC transfer box motor, which is controlled by the transfer box control module, via a Pulse Width Modulation (PWM) signal.