4ETS for Passenger Cars
&
4ETS for W163
Starting MY1998
1
327 HO 06 4ETS (WJB,RP,GC) 02-27-04
Objectives
At the end of this session, you should be able to:
Identify which 2004 models have the 4ETS option
List the advantages of 4ETS
List 4ETS mechanical components and describe their function
Explain basic operation of 4ETS
Describe transfer case maintenance procedures
Describe the unique features of the W163 transfer case
Explain the operation and function of the W163 system
These technical training materials are current as of the date noted on the materials, and may be revised or updated without notice. Always check for revised or updated information.
To help avoid personal injury to you or others, and to avoid damage to the vehicle on which you are working, you must always ref er to the latest Mercedes -Benz Technical Publication and follow all
pertinent instructions when testing, diagnosing or making repair.
Illustrations and descriptions in this training reference are based on preliminary information and may not correspond to the final US version vehicles. Refer to the official introduction manual and WIS
when available.
Copyright Mercedes-Benz USA, LLC, 2004
WIS document numbers shown apply to WIS Version USA/CDN at date of writing.
Reproduction by any means or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Mercedes -Benz USA, LLC or it's
successors.
Published by Mercedes -Benz USA, LLC
Printed in U. S.A.
Contents
MY2004 4ETS vehicles
Purpose and advantages of 4ETS
Driving with 4ETS
Additional 4ETS components
4ETS Brake torque control range
4ETS block diagram
MY2004 ETS Maintenance and service
Model W163
Off-roading with the W163
W163 Transfer case and controls
Transfer case control unit
W163 block diagram
W163 service notes
4
6
9
10
19
21
22
25
27
29
32
33
34
3
MY2004 4ETS Vehicles
All ML-class vehicles
All G-class vehicles
C-class sedans & wagons with V6 engine-NEW for 2004
E-class sedans and wagons with V6 and V8 engines-NEW for 2004
S-class sedans with V8 engine-NEW for 2004
44
AWD, 4WD, 4ETS and 4ETS+
AWD and 4WD are used interchangeably by some manufacturers
Permanent and full-time are sometimes interchanged, too
Heres the way MB retail training literature puts it:
C-, E-, S-class
System availability: Optional
Type of drive system: 4MATIC AWD with 4ETS
Torque Split Front/Rear: Permanent 40/60 via center differential
4ETS
M-class, G-class
System availability: Standard
Type of drive system: "Permanent full-time 4WD
Torque Split Front/Rear: G-class: 50/50 via center differential
Torque Split Front/Rear: M-class: 48/52 via center differential
G-class: 3 locking differentials. 4ETS with unlocked differentials
M-class: Low range 2-foot mode; downhill traction function. 4ETS+
What is 4ETS?
It is a system that:
is always in 4-wheel drive, without driver having to switch the
system on
works with ABS and ASR in the Electronic Stability Program
(ESP) to provide optimal handling stability and traction
distributes drive torque to the front and rear axle through a
transfer case, which acts like a center differential.
uses brake pressure to control wheel spin, transferring torque
to the wheel with traction
warns driver of wheel slip by flashing warning lamp in
instrument cluster
Torque Application at the Wheels Having
Traction
Wheels without traction are braked to transfer
torque to the wheels with traction
In Comparison to 1990-1993 4MATIC:
Ride height lower
Simpler front suspension
No additional hydraulics
Less intrusive to interior space (floorpan)
More cost-effective
Reduced weight
Better fuel mileage
Improved turning radius
Tire life extended
Driving With 4ETS
Nothing to switch on
Driver is informed via a flashing warning lamp in instrument
cluster that one or several wheels are starting to spin. (The
owners manual says to ease off on the accelerator when this
happens)
Throttle reduction control (ESP) can be switched off using ESPOFF button, but 4ETS continues to operate. Warning lamp
stays illuminated in this mode.
Additional 4ETS Components
Transfer case
Propeller shaft, front
Front differential mounted to engine oil pan on right side
Engine oil pan Front axle shafts different length axles, but both ends identical
10
Passenger Car
Transfer Case
MY2004 components shown
8 Hexagon nut with collar
9 Hexagon nut with collar
10 Output flange to front axle
12 Output flange to rear axle
13 Output shaft to rear axle
15 Transfer case rear cover
16a Transfer case housing front
16b Transfer case housing rear
17 Output shaft to front axle
18 Intermediate gear
19 Hollow gear
20 Input shaft
20a Securing washer
20b Washer
20c Securing washer
25 Planetary gear set
11
Passenger Car
Transfer Case Lubrication
Gears serve as an oil
pump-oil ducts and
splasher pipe supply lube oil
to bearings and planetary
gear system
Automatic Transmission
Fluid
(2004=001 989 2303)
Lifetime fill
For 2004: Check oil level
at room temperature and
not at transfer case
operating temperature.
12
Passenger Car
Transfer Case Torque Distribution:
MY1998-2002
3 = Double planetary gear set: acts as center differential
13
Passenger Car
Transfer Case Torque Distribution:
Starting MY2004
60 % of the drive torque is
transmitted to the rear
axle and 40 % to the front
axle.
1. Output shaft rear axle.
2. Double planetary gear
set
3.
4.
5.
Spur gears
Output shaft front
axle
Input shaft
14
Passenger Car
Friction Disc in 2004 Planetary Gear Set
To help quickly transfer torque to the front wheels when the rear starts to spin.
It is critical that 4ETS receives accurate wheel speed signals in order to properly
control torque distribution. All 4 wheels / tires must have the exact same
diameter and proper inflation pressures or the clutches will be damaged.
A worn disc would be noticed when driving in very slick conditions and
comparing response with that of a known good vehicle.
15
Passenger Car
Transfer Case & Propeller Shafts
MY2004
components
shown
1.
2.
3.
4.
Propeller shaft to rear axle
Double planetary gear set
Spur gears
Propeller shaft to front axle
The transfer case is
directly flange-mounted to
the automatic
transmission.
16
Passenger Car
Front Wheel Drive Components
MY2004 components
shown
1. Transfer case
2. Propeller shaft to front axle gearbox
3. Front axle gearbox
4. Right front axle shaft
5. Left front axle shaft
The driveshaft has been carried over from model 210
4MATIC and has been modified in length
17
Passenger Car
Front Axle Open Differential Cutaway
MY2004
components
shown
Front axle gear box on model 220 with engine 113
1. Front axle gearbox mounted to oil pan
2. Pinion gear
3. Ring gear
4. Engine Oil Pan with cast-in through pipe
18
Passenger Car
4ETS Brake Torque Control Range
A. Control of rear axle
Engages upon slippage in range of 0 to 50mph
Once engaged, control may remain active up to 80mph
B. Control of front axle
Engages upon slippage in range of 0 to 25mph
Once engaged, control may remain active up to 50mph
19
Passenger Car
4ETS Control Logic
Traction control according to wheel speed
Low speeds: Individual brake application at any of the 4
wheels for maximum traction
Medium speeds: Limited brake pressure increase at the
2nd rear wheel if one rear wheel spins. Simultaneous
pressure increase if both rear wheels spin. Stability and
road adhesion take precedence.
High speeds: Simultaneous braking pressure to both rear
wheels if one spins. At the same time the system refrains
from any braking intervention at the front axle to achieve the
best possible handling stability.
20
Passenger Car
4-ETS Block Diagram
Return pump Relay
K40/
Power
Circuit 31
Hydraulic control
unit A7/
Terminal 61
Stop lamp switch
ETS warning lamp
N47/
Parking Brake
FRT VSS
REAR VSS
ETS MIL
ABS MIL
Data Link (X11/4) 21
Passenger Car
Maintenance MY2004 Transfer Case
Check oil level port 7b
Filling with oil port 7a
The rear transverse mount (45)
and the drive shaft must be
removed.
Draining oil port 7c
The rear mount (45) and the
right case mount (45a) must be
removed.
7a
7b
7c
16
45
45a
Fill port
Control port
Drain port
Transfer case
Rear case mount
Right case mount
22
Passenger Car
Maintenance MY2004 Front Differential
Check oil level port 7
Oil level should be at lower level
of fill port.
Check oil level at room
temperature - not at differential
operating temperature.
Right wheel well
7
Fill port
23
Passenger Car
Removing MY04 Front Axle Shaft:
Wrap chain tool around
constant velocity joint
and tighten. Tap against
chain to remove axle.
1 extension or punch
2 front axle shaft
24
Reference: WIS job AR33.30-P-0620P
W163
Model W163
Starting MY1998
4ETS plus Hi/Low range
25
W163
W163
vs.
Passenger Cars
52%
60%
48%
40%
High/Low range motor
Shift fork
Single speed range
------------
Chain drive
Lubrication pump
Gear drive
Splash lube
26
W163
Off-Roading with the W163
Possible to switch to Low range before driving off road, crossing
water, or towing on steep grades.
Low range of transfer case provides a 2.64:1 ratio (High range =
1:1 ratio)
Off-road software in ABS improves braking when in Low Range
under 18.5mph. Front wheel brakes only allowed to partially
lock. (Helps by packing dirt in front of tires. Steering may be
affected)
Switching into either Low or High transfer case range can be
done only if all of the conditions on next slide are met
27
W163
High/Low Range Selection
Conditions:
Vehicle stopped
Selector in N
Idle (400-1500rpm)
High to Low Lamp
2 flashes, then stays ON.
Low to High - 2 flashes, turns Off.
Conditions not met - flashes 5 times,
28
turns off.
W163
W163 Transfer Case & Controls
High/Low range motor
(A55)
Control unit (N78)
Low Range Switch
(S97/6)
29
W163
High/Low Range
HIGH
LOW
Front gear set: selects High or Low range operation
Rear double planetary gear set (center differential): distributes torque to front
and rear differentials
30
W163
High Range
Low Range
1:1
2.64:1
1 Input shaft
2 Intermediate
shaft
11 Reduction
hub
13 Shift fork
18 Planetary
gear set
19 Planetary
carrier assy
31
W163
Transfer Case Control Unit (N78)
N78 retains DTCs while the ignition is on. All Activity
Module (N10) stores the DTCs after ignition is switched off.
32
W163
W163 Block Diagram
CAN-C
Circuit 30
Circuit 15
Transmission Control
module (N15/3
Circuit 31
Low Range Switch
(S97/6)
Transfer case
actuator motor
(A55)
Traction Control
(N47/)
N78
ME-SFI
(N3/10)
AAM (N10)
X11/4
Low Range Lamp
A1e46
33
W163
W163 Service Notes
Transfer case is filled for life
ML transfer case must be in Hi range before disassembly
W163 transfer case has a total of 5 replaceable seals (items
#22, 24 at each output shaft, 37, 44 on exploded view drawing)
3 seals can be replaced without removing transfer case (#24 at
rear, 37,44 on exploded view drawing)
Transfer case halves are sealed with silicone sealer only
Transfer case oil pump operates in forward gears only
Towing: MB recommends using flat bed equipment
When towing with all wheels on ground, place gear selector
in N, ignition switch in position 2, at a speed of = 30mph
and towing distance = 30 miles.
See owners manual for more options/cautions
34
W163
Transfer Case Exploded View
Legend on next pages
35
W163
Legend
Item No.
Description
Qty
Item No.
Description
Qty
Item No.
Description
Qty
01
Snap ring
05
Thrust washer
10
Ball brg
02
Ball bearing
06
Reduction hub
11
Ball brg suppt
03
Snap ring
07
Int.shaft compl
12
Retaining ring
04
Carrier compl.
07a
Int shaft
13
Diff ring gear
04a
Pinion shaft
07b
Bushing
14
Rr output shaft 1
04b
Planet carrier
plate
08
Gerotor pump
15
Thrust washer
04c
Input shaft
08a
Cover
16
Carrier compl
04d
Needle brg
08b
Gear set
16a
Pinion shaft
04e
Thrust washer
08c
Pump body
16b
Thrust washer
12
04f
Planet carrier
08d
Bolt
16c
Pinion gear
04g
Thrust washer
08e
Hose
16d
Planet carrier
04h
Pinion gear
08f
Hose clamp
17
Spacer
04i
Needle brg
90
08g
Oil pickup &
filter
18
Upper sprcket
04j
Pinion spacer
09
Thrust washer
18a
Upper drive
36
W163
Legend
Item No.
Description
Qty
Item No.
Description
Qty
Item No.
Description
Qty
18b
Bushing
29
Ball brg
35
T-case cover
19
Spacer
30
Chain drive
36
20
Retng ring
31
Red. Shft fork
Companion
flange
37
Oil seal
38
Washer
39
Stake nut
40
Drain plug
41
Motor bracket
42
Hex head bolt
21
21a
Case assy
Transfer case
1
1
31a
31b
Shift fork facg
Shift fork red.
2
1
21b
Ring red. gear
31c
Cam follower
21c
Retaining ring
31d
Shift fork pin
22
Oil seal
32
23
Lwr output shft
Shift shaft
assy
32a
Shift shaft
24
Oil seal
43
Shift motor
32b
Spacer
25
Spring pin dwl.
44
Oil seal
32c
Torsion spring
26
Magnet
45
32d
Elect shift cam
Hex head
screw
27
Ball brg.
33
Shift rail
46
ECU
28
Lower drive
sprocket
34
Hex bolt
18
47
RTV
AR
37
