Professional Documents
Culture Documents
Mercedes 4wd
Mercedes 4wd
&
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
44
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
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
11
Passenger Car
Passenger Car
13
Passenger Car
3.
4.
5.
Spur gears
Output shaft front
axle
Input shaft
14
Passenger Car
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
MY2004
components
shown
1.
2.
3.
4.
16
Passenger Car
1. Transfer case
2. Propeller shaft to front axle gearbox
3. Front axle gearbox
4. Right front axle shaft
5. Left front axle shaft
17
Passenger Car
18
Passenger Car
19
Passenger Car
20
Passenger Car
Power
Circuit 31
Hydraulic control
unit A7/
Terminal 61
Stop lamp switch
Parking Brake
FRT VSS
REAR VSS
ETS MIL
ABS MIL
Data Link (X11/4) 21
Passenger Car
7a
7b
7c
16
45
45a
Fill port
Control port
Drain port
Transfer case
Rear case mount
Right case mount
22
Passenger Car
Fill port
23
Passenger Car
1 extension or punch
2 front axle shaft
24
W163
Model W163
Starting MY1998
4ETS plus Hi/Low range
25
W163
W163
vs.
Passenger Cars
52%
60%
48%
40%
Chain drive
Lubrication pump
Gear drive
Splash lube
26
W163
W163
Conditions:
Vehicle stopped
Selector in N
Idle (400-1500rpm)
W163
29
W163
High/Low Range
HIGH
LOW
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
32
W163
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
33
W163
34
W163
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
03
Snap ring
07
Int.shaft compl
12
Retaining ring
04
Carrier compl.
07a
Int shaft
13
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
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
Companion
flange
37
Oil seal
38
Washer
39
Stake nut
40
Drain plug
41
Motor bracket
42
21
21a
Case assy
Transfer case
1
1
31a
31b
2
1
21b
31c
Cam follower
21c
Retaining ring
31d
22
Oil seal
32
23
Shift shaft
assy
32a
Shift shaft
24
Oil seal
43
Shift motor
32b
Spacer
25
44
Oil seal
32c
Torsion spring
26
Magnet
45
32d
Hex head
screw
27
Ball brg.
33
Shift rail
46
ECU
28
Lower drive
sprocket
34
Hex bolt
18
47
RTV
AR
37