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Old 02-28-2007, 01:31 PM   #1 (permalink)
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Here are two articles I found this summer while doing research on the 07 SantaFe AWD system. Very informative. I though it would be a nice addition to this forum.

"Hyundai's all-wheel drive system

By Jim Kerr

Hyundai has just introduced the 2007 Santa Fe and one of the features available on this mid-size SUV is all-wheel drive. It is a new system for Hyundai and is a good example of how electronics are improving all aspects of driving.

All-wheel drive systems are confusing for many people. I must admit to wondering myself to what type of system is being described in the sales literature. Let's see if we can simplify it. All-wheel drive provides power to all the wheels, as opposed to front-wheel drive or rear-wheel drive systems that only provide power to one end of the vehicle. That's clear enough, but some systems are also called four-wheel drive. Those systems also drive all the wheels, but are not designed to operate in 4wd mode all the time. The driver has to select 4wd when traction conditions are poor. But operate in 4wd mode on hard pavement and you will soon be paying for expensive driveline repairs.

Click here to find out more!
All-wheel drive however, can be operated on hard road surfaces. Some systems drive all the wheels all the time. A viscous coupling or a variable clutch inside the transfer case controls the rate of slip between the front and rear axles. Subaru and Audi are examples of great all-wheel-drive vehicles that use these controls.

Many of the compact and mid-size SUVs such as the 2007 Santa Fe use a front-wheel drive system with an auxiliary rear-wheel drive to provide all-wheel drive. This is better than it sounds. Modern control systems allow the vehicle to operate with front-drive only for most driving to optimize fuel economy, but engage the rear-wheel drive as soon as additional traction is needed.

Hyundai's new system uses a computer-controlled clutch mechanism mounted in front of the rear axle to engage the drive. It is a Borg Warner system that can provide up to 99% of the torque to the front wheels, but automatically diverts up to 50% of the torque to the rear wheels when needed. The driver can push a button on the dash as an input to the computer, commanding it to "lock" the torque transfer at 50/50 for getting out of slippery parking spots in winter or ploughing through some soft sand. While there is no low range in the Santa Fe all-wheel drive system, it is more than capable of handling many off-road excursions.

Because the torque transfer to the rear wheels is variable, a dependable, durable clutch mechanism is needed that can be instantly engaged. To do this, the computer monitors wheel speed, accelerator pedal movement and steering inputs. When 4% or more front wheel slip is detected, the rear axle starts to engage. It can also anticipate the need for additional traction and engage the AWD system when the driver accelerates the vehicle. Another feature is it can disengage the rear axle during ABS events to optimize ABS stopping.

The computer controls a large solenoid coil in the clutch housing. When energized, the solenoid pushes against a multi-plate clutch, which in turn holds a washer-like plate from turning. Ramps and balls between this plate and a second plate cause the two plates to be forced apart, placing pressure on a second larger multi-plate clutch that connects the driveshaft to the rear axle. The path of torque is complete and the rear wheels drive.

A button on the dash can lock the clutch to provide 50% torque to the rear wheels, but this only occurs below 35 kph. Above that speed, the computer pulses the solenoid to disengage the clutch mechanism, but it will automatically engage it again when vehicle speed lowers.

Finally, the system monitors steering wheel angle. Turn the steering wheel, such as when parallel parking or turning a tight corner and the computer will decrease the torque applied to the rear wheels to there is no driveline binding during the turn.

Computer controls, electric solenoids and data communication between computers are all used to provide smooth traction regardless of the driving conditions and optimize fuel economy too. That's modern all-wheel drive."
http://www.canadiandriver.com/articles/jk/060802.htm

On the BorgWarner website I found this info.

" The BorgWarner High Energy ITM3e™ AWD System is the first industrialized all-wheel drive (AWD) coupling that combines a mechanical system, active gerotor pump, thermal management and new AWD control algorithms into a fully dynamic system that provides world-class performance in a package space only passive systems could achieve previously.

The ITM 3e™ is unlike any other active AWD product. The design features a third friction element, which provides maximum torque transfer in a package size optimized to allow installation in smaller passenger cars and crossover vehicles (CUVs). It also combines best-in-class drag torque performance, which improves fuel economy. The ITM 3e™ was recently launched in the Hyundai Santa Fe and in the Chery Tiggo produced in China. A new North American CUV program and a European high-performance application will begin production later this year.

The BorgWarner High Energy ITM3e™ AWD System and The BorgWarner Turbo & Emissions Systems Gasoline Turbocharger with Variable Turbine Geometry have been named finalists for the 2007 PACE Awards."

Guess who developed Acura's popular SH-AWD system? Thats right, BorgWarner.

I also read that the ITM 3e™ was also used and adapted to the 2006 and up Porche 911TT's!

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Old 02-28-2007, 03:26 PM   #2 (permalink)
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good post phatboyc, it would take me three days and bandaged fingers to type that lot!
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Old 03-17-2008, 12:24 AM   #3 (permalink)
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I'm making this sticky.
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Old 10-14-2008, 09:38 PM   #4 (permalink)
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Great info, thanks.
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Old 11-06-2008, 12:13 PM   #5 (permalink)
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QUOTE (acrispy1 @ Oct 14 2008, 08:38 PM)
Quote:
Great info, thanks.


Good work....very clear and informative.
Thx
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Old 06-21-2009, 07:18 PM   #6 (permalink)
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And that is what I got from Borg-Warner as an answer to my question which was: What the AWD system in the Santa Fe really is?

Quote:
Originally posted by Borg-Warner+-->QUOTE (Borg-Warner)
Quote:
The system in your Santa Fe is an active on-demand AWD. What this means is; the Driveline is actively managed by an on board computer that monitors and adjusts the Driveline torque distribution to the front and rear wheels every 5 milliseconds. The on board computer has been programmed and calibrated to work with your vehicles motor, transmission and axles to insure traction when needed. When you are turning your vehicle the on board computer allows slip in the coupling which stops Driveline binding from occurring. When you are in need of additional traction the system senses un-wanted slip and activates the Driveline coupling to transfer torque to the rear wheels for AWD capability.

This is accomplished by a TTD (Torque Transfer Device) mounted to the rear axle. When un-wanted front to rear axle slip occurs the on board computer sends electrical energy to the coupling. This electrical energy is applied to a coil which applies a force to a clutch pack. Because of the relative motion between the front and rear wheels there is slip across the clutch system. The force from the coil, clutches in the system and a ball cam amplifier all work together to provide a smooth locking effect thru the Driveline. All these items working together give the Santa Fe its AWD capability.
About the clutch plates inside the coupler:<!--QuoteBegin-Borg-Warner

[b]The clutch plates are the first ever to utilize an organic paper based material. The coupling itself i.e. the cast housing is Aluminum.
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Old 04-08-2010, 08:48 PM   #7 (permalink)
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Here is an expanded picture of the transfer case blown up:

http://www.automaticchoice.com/Catalogue/tb_bw_4424.pdf

Borg-warner 4424
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Old 04-09-2010, 10:06 PM   #8 (permalink)
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Changed the transfer case fluid today at my neighborhood speedshop - used Amsoil 80w90 full synthetic

QUOTE (dabbdc @ Apr 8 2010, 08:48 PM)
Quote:
Here is an expanded picture of the transfer case blown up:

http://www.automaticchoice.com/Catalogue/tb_bw_4424.pdf

Borg-warner 4424
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Old 06-09-2010, 12:49 PM   #9 (permalink)
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Thanks for the thorough info. As a former Subaru owner, it's good to be aware that the AWD is not fulltime on the Santa Fe, and how it actually works.
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Old 06-09-2010, 02:28 PM   #10 (permalink)
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QUOTE (golfergurl @ Jun 9 2010, 12:49 PM)
Quote:
Thanks for the thorough info. As a former Subaru owner, it's good to be aware that the AWD is not fulltime on the Santa Fe, and how it actually works.
If you had subies with Auto tranny's like I have had.. there really isn't much difference in the way both work.. my Outback and Forester were basically a 90/10 Front/Rear drive until it detected issues and needed more juice to the rear wheels.
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