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Re: wondered how Monty II and III Front axle disconnect Active Track system works. [Re: icysyrup] #769981
12/07/06 05:26 PM
12/07/06 05:26 PM
Alex Kogan  Offline OP
Body Damage is Cool
Joined: Apr 2000
Posts: 1,664
Portland, OR
[Linked Image]
Lets talk about how Active Track (Super Select) works inside transfer case.
There are several key parts which allow to achieve that one-lever operation.

Input Drive Shaft 30311 goes inside front side gear 30426 and connects to pinion shaft 30423 of the center differential.
Spider gears drive Front Side Gear 30426 and Rear Output Shaft 30413.
Chain Drive Sprocket 30370 seats atop Front Side Gear on needle bearings 30306 which allows them to rotate freely relative to each other.
Differential Lock Hub 30426 seats on front most splines of Input Drive Shaft.
2-4WD Synchronizer ring 30367Q seats on the end of Front Side Gear 30426 held in place with snap ring.

Operation of Active Track is achieved by moving the t-case lever, of course, which corresponds to movement/positioning of 4WD Sliding Collar 30411.

2WD:
Sliding Collar seats in front-most position. In this position it links Differential Lock hub (as well as Input Drive Shaft) to 2-4WD Synchronizer ring . Since in this position input drive shaft is effectively locked to one of the side gears of center differential. Differential at this stage is effectively locked. Drive Sprocket is allowed to rotate freely relative to Front Side Gear in this position thus all output goes to Rear Output Shaft.

4WD with differential unlocked:
Move that lever forward and Collar slides backwards a little. Notice, there are two matching groves, one on the inside of the collar and one on the surface of the Differential Lock Hub. Also, Drive Sprocket has gear ring on the front which matches diameter of 2-4WD Synchronizer ring. Moving Collar back meshes groves and teeth on Differential Lock Hub which is now allowed to rotate freely relative to Collar. What it means is that Front Side Gear is no longer locked to Input Drive shaft and is free to rotate with different speed relative to it - center differential now is unlocked. But, moving that Collar backwards also locked gear teeth on Drive Sprocket to 4WD Synchronizer Ring and Front Side Gear as well. Thus now power is distributed between to rear and front at the mercy of differential. 4WD is engaged. Differential unlocked. 4WD detection switch at this point sends signal to ECU to disengage front solenoids and lock the free wheeling clutch.

Only in this position Viscous Coupling 30421 can show its usefulness. Since it's connected to center differential and rear output shaft, if either of axles starts to slip relative speed between Differential Case and Rear Output shaft will be different. Thus the VC will start to warm up and provide limited slip effect.
Word of caution here. If you are stuck in 4WD and start spin your tires a lot, lock the center diff. Allowing VC to spin uncontrollably for long time will ruin it. VC will possibly lock up effectively converting your truck into part-time machine. Also it will make a horrible noise by some accounts I've heard.


4WD with differential locked:
Move that lever sideways. Collar slides backwards even more. Drive Sprocket and 4WD Synchronizer ring still locked together but now teeth on the front of the Sliding Collar mesh with rear teeth on Differential lock hub again. Front Side gear is locked to Input Drive Shaft again via 4WD Synchronizer - Center Differential is locked.

Moving lever forward in 4WD Low doesn't effect this part of the t-case any more only engages Low range.


92 SR, 285/75R16 Yoko MT ARB locker GAST compressor AirLift 1000 MM10500 Snorkel custom rear bumper
02 Montero LS died protecting the master
08 PowerWagon (stock!)
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Re: wondered how Monty II and III Front axle disconnect Active Track system works. [Re: bretwalda] #769982
12/07/06 05:34 PM
12/07/06 05:34 PM
Alex Kogan  Offline OP
Body Damage is Cool
Joined: Apr 2000
Posts: 1,664
Portland, OR
Quote
Yes good stuff - I think I'm getting it

...So practically speaking - a case problem...

I have not yet put in a new lower butterfly plenum on my DOHC. I have it disconnected.

When I am on a flat stretch of freeway doing about 70-75 on a windless day, (slower speed in headwind) my 4wd lights will start flashing. If I let off the gas and then step on it again to maintain my original speed - the lights will go off. Only to come on again over a short period of time or if I put a slight bit more load on the engine.

My theory is I have a vaccuum leak from the bad plenum, and this is somehow affecting the system. But isn't there less vaccuum at higher RPM's? So would it be a bad check valve?

I dont understand what the resevoir is doing either <img src="/forums/images/graemlins/confused.gif" alt="" />

Yes, go buy a plenum...somebody spare me $400. <img src="/forums/images/graemlins/barf.gif" alt="" />

I'm not willing to spend money, I'd just like some free answers <img src="/forums/images/graemlins/smile.gif" alt="" />
Sounds like you might have a problem with your check valve or maybe solenoids. They are located relatively high on right fender but still might get submerged, which very well could have happened when you got stuck <img src="/forums/images/graemlins/shiner.gif" alt="" /> a year or two ago. Sucking in dirt/water wont make solenoids happy. Intake manifold vacuum depends on throttle position. More throttle - less vacuum. That's why manual says to coast when trying to engage 4WD. Coasting with heavy foot off accelerator will create most vacuum in the system. Later on vacuum reservoir will hold some extra vacuum to engage/keep 4WD engaged even then car is driven hard. Malfunctioning check valve will most certainly defy that. Plenum leak won't have that much effect unless it's really bad but then you couldn't really drive your truck either.


92 SR, 285/75R16 Yoko MT ARB locker GAST compressor AirLift 1000 MM10500 Snorkel custom rear bumper
02 Montero LS died protecting the master
08 PowerWagon (stock!)
Re: wondered how Monty II and III Front axle disconnect Active Track system works. [Re: Alex Kogan] #769983
12/08/06 04:31 PM
12/08/06 04:31 PM
Brewmaster  Offline
Wheeler
Joined: Sep 2006
Posts: 100
Quote
Quote
TDoes the front drive shaft spin when in 'Free Wheeling' Two wheel drive? Looking at the transfer case diagram I would guess yes?

No.
As to 4WD they actually recommend to engage it every now and then just so it's kept in working order. Say every month or so.


So are you saying that when in 2WD the front hubs are NOT locked? I was under the impression that with the Super Select 4WD (Active Track) the front end was locked up at all times. If what you're saying is true, then when you shift it into 4WD (AWD) the VC engages, spinning up the front end and then locking the front hubs?

Last edited by Brewmaster; 12/08/06 04:32 PM.
Re: wondered how Monty II and III Front axle disconnect Active Track system works. [Re: Brewmaster] #769984
12/08/06 07:10 PM
12/08/06 07:10 PM
Alex Kogan  Offline OP
Body Damage is Cool
Joined: Apr 2000
Posts: 1,664
Portland, OR
Are you referring to propeller shaft or axle shafts? Axle shafts are rotating all the time. There are no hubs on Gen 2 Montero. Right side axle disconnects inside/beside diff using air actuated free-wheeling clutch that prevents propeller shaft and R&P from rotating.


92 SR, 285/75R16 Yoko MT ARB locker GAST compressor AirLift 1000 MM10500 Snorkel custom rear bumper
02 Montero LS died protecting the master
08 PowerWagon (stock!)
Re: wondered how Monty II and III Front axle disconnect Active Track system works. [Re: Alex Kogan] #769985
12/08/06 08:09 PM
12/08/06 08:09 PM
Brewmaster  Offline
Wheeler
Joined: Sep 2006
Posts: 100
Quote
Are you referring to propeller shaft or axle shafts? Axle shafts are rotating all the time. There are no hubs on Gen 2 Montero. Right side axle disconnects inside/beside diff using air actuated free-wheeling clutch that prevents propeller shaft and R&P from rotating.


Fogive my backyard mechanic questions but you're talking a little over my head. Propeller shaft!? I thought this was a truck, not a plane! (Sorry, I couldn't resist that one.)

So, if I gather what you're saying, the axles are permenantly connected to the wheels as I suspected. But the drive shaft to the front diff, and the diff itself, do not rotate unless engaged? So when you engage 4WD the VC engages, bringing the shaft and diff up to speed, then the axles engage to the diff by some vacuum or pressure clutch system?

R&P?


Kelvin
91 Pajero Exceed - Controls mounted curb-side for convenience
82 Mercedes 300SD
Re: wondered how Monty II and III Front axle disconnect Active Track system works. [Re: Brewmaster] #769986
12/08/06 08:27 PM
12/08/06 08:27 PM
Brewmaster  Offline
Wheeler
Joined: Sep 2006
Posts: 100
Quote
[quote]Are you referring to propeller shaft or axle shafts? Axle shafts are rotating all the time. There are no hubs on Gen 2 Montero. Right side axle disconnects inside/beside diff using air actuated free-wheeling clutch that prevents propeller shaft and R&P from rotating.


AHA!

Is it like this!?

http://www.4x4wire.com/dodge/tech/solid_axle_cad/


Kelvin
91 Pajero Exceed - Controls mounted curb-side for convenience
82 Mercedes 300SD
Re: wondered how Monty II and III Front axle disconnect Active Track system works. [Re: Brewmaster] #769987
12/08/06 08:42 PM
12/08/06 08:42 PM
Alex Kogan  Offline OP
Body Damage is Cool
Joined: Apr 2000
Posts: 1,664
Portland, OR
Pretty much


92 SR, 285/75R16 Yoko MT ARB locker GAST compressor AirLift 1000 MM10500 Snorkel custom rear bumper
02 Montero LS died protecting the master
08 PowerWagon (stock!)
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