CHASSIS – TRANSFER CH-59
TRANSFER
DESCRIPTION
The new Hilux uses manual operation type 4WD system.
This model uses part-time 2-speed type VF2A transfer. In this transfer, planetary gear unit is used in the
reduction mechanism and a silent chain is used to reduce noise for the front drive. A synchromesh
mechanism is used for smooth engagement from L4 gear to H4 gear, and from H2 gear to H4 gear.
Front Drive Gear Piece Shift Pattern
Planetary Gear Unit
Front Drive Clutch Sleeve
Front Drive Hub
Rear Output Shaft
Silent Chain
Transfer Input
Shaft
Oil Pump Front Driven Sprocket
233CH19
233CH18
Specifications
Transfer Type VF2A
Drive Type Part-Time
H2 1.000
Gear Ratio H4 1.000
L4 2.566
Reduction Gear Type Single Pinion Planetary
Center Differential Gear Type
Oil Capacity Liters (US qts, Imp.qts) 1.0 (1.1, 0.9)
CH-60 CHASSIS – TRANSFER
Oil Viscosity SAE 75W-90
Oil Grade API GL-3
Weight (Reference)* kg (lb) 31.5 (69.4)
* : Weight shows the figure with the oil fully filled.
CHASSIS – TRANSFER CH-61
PLANETARY GEAR
1. General
The planetary sun gear integrates with the transfer input shaft.
4 planetary pinion gears are fitted to the planetary carrier. Each pinion gear shaft is fixed to the planetary
carrier. A planetary spline piece is fitted to the rear of the planetary carrier and internal gear teeth of the
planetary spline piece can be engaged with the external teeth of the low and high clutch sleeve. At the
rear of the transfer input shaft, a high and low clutch sleeve is installed via the synchromesh mechanism
on the output shaft.
The planetary ring gear is fixed to the transfer case and internal teeth are meshed with the planetary
pinion gear.
Planetary Ring Gear
Planetary Carrier
Pinion Shaft
Planetary Spline Piece
Transfer Input Shaft
High and Low Clutch Sleeve
High and Low Clutch Hub
Planetary Sun Gear
Planetary Pinion Gear
232CH53
CH-62 CHASSIS – TRANSFER
2. H2/ H4 Position
In the H2/ H4 position, the splines at the rear of the transfer input shaft mesh with the internal gear teeth of
the high and low clutch sleeve.
Also, the high and low clutch sleeve is meshed to the rear output shaft via the high and low clutch hub.
Thus, the rotation of the input shaft is transmitted to the high and low clutch sleeve, high and low clutch
hub, and to the rear output shaft.
Planetary Pinion Gear Planetary Ring Gear
Planetary Ring Gear Planetary Carrier Planetary Pinion Gear
Planetary Spline
Transfer Input Piece
Shaft
High and Low
Clutch Sleeve
Planetary Carrier
Rear Output Shaft (Pinion Shaft) Planetary Sun Gear
(Input Shaft)
233CH21
3. L4 Position
In the L4 position, the external teeth of the high and low clutch sleeve are meshed with the planetary spline
piece.
Thus, the rotation of the input shaft is transmitted in a reduced form to the planetary sun gear, planetary
pinion gear, planetary pinion gear shaft, planetary carrier, planetary spline piece, high and low clutch
sleeve, high and low clutch hub, and rear output shaft.
Planetary Pinion Gear
Planetary Pinion Gear
Planetary Ring Gear Planetary Carrier
Planetary Ring Gear
Planetary Spline Piece
Transfer Input
Shaft
High and Low
Clutch Sleeve
Planetary Carrier
(Pinion Shaft)
Rear Output Shaft
Planetary Sun Gear
(Input Shaft)
233CH22
CHASSIS – TRANSFER CH-63
CH-64 CHASSIS – TRANSFER
4WD SYSTEM
1. General
In the 4WD system of the new Hilux, the VF2A transfer switches to H2, H4, or L4 when the driver
manually operates the 4WD shift lever.
On a model equipped with a front differential with A.D.D. (Automatic Disconnecting Differential) shift
actuator, when the driver operates the shift lever to 4WD or 2WD, the 4WD control ECU operates the
A.D.D. shift actuator in order to lock or free the engagement of the front drive shaft and the front
differential.
System Diagram
4WD Control Engine & ECT Transmission
ECU ECU Control ECU*
Combination Meter
4WD Indicator Light
AT P Warning Light
A.D.D.
Detection
Switch
Limit
Switch
4WD
Detection Transfer Neutral
Switch Switch
271CH32
L4 Position
Switch
* : Only for A340F Automatic Transmission Model
CHASSIS – TRANSFER CH-65
CH-66 CHASSIS – TRANSFER
Layout of Main Components
4WD Indicator
Light
Transmission
Control ECU*
Engine ECU
AT P Warning
Light
4WD Control
ECU
A.D.D. Shift Actuator
A.D.D. Shift Motor LHD Model
A.D.D. Shift Motor
Limit Switch
A.D.D. Detection L4 Position
Switch Switch Transfer Neutral
Switch
4WD Detection
Switch
* : Only for A340F Automatic Transmission Model 271CH33
CHASSIS – TRANSFER CH-67
CH-68 CHASSIS – TRANSFER
2. A. D. D. Shift Actuator Operation
General
On a model equipped with a front differential with A.D.D. shift actuator, the 4WD detection switch
provided in the transfer detects that the driver has operated the 4WD shift lever to the 4WD (H2 H4)
or 2WD (H4 H2) position. Then, the 4WD control ECU operates the A.D.D. shift actuator in order to
lock or free the engagement of the front drive shaft and the front differential.
Wiring Diagram
A.D.D. Shift Actuator
IG DM1 A.D.D. Shift Motor
DM2
4WD Indicator
Limit Switch
IND1 DL1
4WD Control ECU
DL2
4WD Detection Switch
4WD ADD
A.D.D. Detection Switch
GND
Skid Control ECU
271CH34
CHASSIS – TRANSFER CH-69
A. D. D. Shift Actuator
A.D.D. shift actuator, which contains A.D.D. shift motor, A.D.D. shift motor limit switch, and A.D.D.
detection switch, cannot be disassembled.
A.D.D. shift motor limit switch has 2 contact point switches (DL1 and DL2). The combinations of 2
contact point switches have been detected shift motor position (A.D.D. OFF or A.D.D. ON).
Limit Switch
(DL1, DL2)
A.D.D. Detection Switch
A.D.D. Shift Motor
237CH21
Combinations of 2 Contact Point Switches
A.D.D. ON A.D.D. OFF
ON
DL1
OFF
ON
DL2
OFF
237CH22
CH-70 CHASSIS – TRANSFER
CHASSIS – TRANSFER CH-71
H2 H4 (4WD)
When the 4WD shift lever turns to H4 position, this signal is input into the 4WD control ECU, and the
4WD control ECU actuates the A. D. D. shift motor.
The operation of the A.D.D. shift motor causes the A.D.D. shift fork and sleeve to move towards the front
differential, thus engaging the front drive shaft and the front differential. As a result, the drive force
from the transfer is transmitted to the front wheels.
A.D.D. Detection
Sleeve A.D.D. Switch Signal
Shift Fork
Limit Switch
Signal 4WD
Control
Motor Actuate
Signal
ECU
Transfer
A.D.D.
Shift Motor 271CH35
Sleeve
H4 H2 (2WD)
When the 4WD shift lever turns to H2 position, this signal is input into the 4WD control ECU, and the
4WD control ECU actuates the A. D. D. shift motor.
The operation of the A.D.D. shift motor causes the A.D.D. shift fork and sleeve to move towards the front
wheels, thus freeing the engagement of the front drive shaft and the front differential. This prevents the
front differential and the front propeller shaft from being rotated by the front wheels while the vehicle
A.D.D. Detection
is being driven. Sleeve A.D.D. Switch Signal
Shift Fork
Limit Switch
Signal 4WD
Control
Motor Actuate
Signal
ECU
Transfer
A.D.D.
Shift Motor 271CH36
Sleeve
CH-72 CHASSIS – TRANSFER
