4WD/AWD Operations

4WD/AWD OPERATIONS This page is about: Introduction Car/Crossover AWD System Summary SUV 4WD System Summary Truck 4WD/AWD System Summary

Introduction

4WD/AWD Operations

2008 Hiller Ford Inc. www.hillerford.com 414-425-1000

Ford 4WD/AWD Systems • Early Four-Wheel-Drive systems gave vehicles the extra traction and ground clearance needed for unpaved or poorly maintained roads • Today’s drivers still enjoy the assurance Four-Wheel Drive or All-Wheel Drive offers

• Ford has several 4WD/AWD systems on many different vehicles to suit a variety of needs, including: – Improved on-road traction in inclement weather – Access to off-road trails and terrain for recreation or business – Mobility at job locales such as construction sites

Car AWD System Summary Ford provides All-Wheel Drive on the following cars: Drive System

2008 Fusion

All-Wheel Drive (AWD)

2008 Taurus

A

A

A = Available

Crossover AWD System Summary Ford provides All-Wheel Drive on the following crossover vehicles: Drive System

2008 Edge

2008 Taurus X

A

A

All-Wheel Drive (AWD) A = Available

SUV 4WD System Summary Ford provides Four-Wheel Drive on the following SUVs:

Drive System Control Trac® Intelligent 4WD System S = Standard

2008 Escape 4WD

2008 Escape Hybrid 4WD

2008 Expedition 4WD

2008 Explorer 4WD

2008 Sport Trac 4WD

— S

— S

S —

S —

S —

— = Not available

Truck 4WD/AWD System Summary Ford provides Four-Wheel Drive on the following trucks:

DriveSystem System Drive

2001 4WD 2008 Ranger Ranger 4WD

2008 F-150 2001 F-150 4WD

2001 Super Duty 2008 F-Series F-250–550 Super Duty® 4WD 4WD

Manual Shift with Manual-locking Hubs

—

4WD/AWD —

Manual Shift-on-the-fly

—

SA

—

Electronic Shift-on-the-fly

SA

SA

)

All-Wheel Drive (AWD)

—

O

—

S = Standard

O = Optional

SA = Select availability

1)

(1)

S O

— = Not available

(1) With Ford Harley-DavidsonTM F-150 Package or Limited Package. NOTE: Feature availability: Latest Dealer Ordering Guide.

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2008 4WD/AWD Operations

4WD/AWD Operations

4WD/AWD OPERATIONS This page is about: Car Front Drive Axles Crossover Front Drive Axle

Car Front Drive Axles Independent MacPherson Strut Front Suspension (Taurus) • Coil spring is positioned over a shock absorber or strut • Uses a MacPherson strut design with a rearward-facing L-arm • Provides the maximum amount of room in front of the suspension to help improve crash performance

Independent Short- and Long-Arm (SLA) Front Suspension (Fusion) • Shock absorbers to maintain ride control • Upper and lower control arms to absorb acceleration and braking forces • Coil springs • Allows either wheel to react to road imperfections with minimal effect on the opposite wheel

Crossover Front Drive Axle Independent MacPherson Strut Front Suspension (Edge and Taurus X) • Coil spring is positioned over a shock absorber or strut • Uses a MacPherson strut design with a rearward-facing L-arm • Provides the maximum amount of room in front of the suspension to help improve crash performance

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4WD/AWD OPERATIONS This page is about: Car and Crossover AWD Systems

4WD/AWD Operations

2008 4WD/AWD Operations Car and Crossover AWD Systems All-Wheel Drive (AWD)

How AWD Works

The AWD system continuously monitors wheel speed, throttle position, and steering wheel angle sensors to determine the vehicle’s conditions and the driver’s intent. The system then determines the optimal amount of front and rear torque for the given conditions to not only reduce wheel slip but to prevent the slip from occurring in the first place.

• AWD uses electromagnetic activation of an internal clutch pack

(Edge, Fusion, Taurus and Taurus X) • Seamless operation with no switch — totally transparent to the driver • Tuned with an emphasis on performance while offering allweather driving confidence • Constantly predicts traction conditions and delivers torque to the appropriate wheel by monitoring:

• It engages when sensors detect wheel slip in the front wheels, and often acts preemptively to prevent slip from happening in the first place • When activated, the system uses force from an electromagnet to push clutch plates together • Driveshaft torque is transmitted through the unit to the rear wheels, taking power from the front wheels and sending it to the rear • The system can react within as little as 50 milliseconds to distribute up to 100 percent of the available torque to the rear wheels

– Vehicle speed – Throttle input – Steering angle (on vehicles with AdvanceTrac®) • Helps eliminate torque steer and helps balance the vehicle when cornering • The active AWD is always monitoring the driver and vehicle, and based on the demands of the driver, is commanding torque transfer to prevent wheel slip and offer the best possible performance in all weather driving conditions • Delivers torque to all four wheels even before the wheels slip • An active on-demand coupler can deliver the precise amount of torque to the rear wheels • When AWD is combined with All-Speed Traction Control or the AdvanceTrac system, a high degree of torque can be sent to the wheel with the best traction, even if the other three wheels have no traction at all

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4WD/AWD Operations

4WD/AWD OPERATIONS This page is about: SUV 4WD Systems

2008 4WD/AWD Operations SUV 4WD Systems

Intelligent 4WD System (Escape and Escape Hybrid) • Automatically distributes power to the wheels with the most traction • Always drives the front wheels and monitors vehicle and driving surface conditions using signals such as individual wheel speeds and throttle position • Seamlessly sends power to the rear wheels as needed to control wheel slip or to prevent it from occurring in the first place • Eliminates the need for a driver-operated switch • Automatically monitors wheel speeds up to 200 times per second to help avoid slippage • Improves vehicle stability by reacting quickly to changes in road conditions

Control Trac® (Explorer, Sport Trac and Expedition) • This system includes electronic logic and a full-featured, 2-speed transfer case • For Explorer and Sport Trac, the system is activated using push buttons on the instrument panel: 4x4 AUTO, 4x4 HIGH and 4x4 LOW • For Expedition, the system is activated using a rotary switch on the instrument panel with four positions: 4A (four-wheeldrive AUTO), 4H (four-wheel-drive HIGH), 4L (four-wheeldrive LOW) and 2H (two-wheel-drive HIGH)

• The 4x4 HIGH (4H) mode provides four-wheel drive with full power to both axles. It is only intended for severe winter or off-road conditions, such as deep snow and ice (where no pavement remains uncovered) and shallow sand. 4x4 HIGH should never be used on dry pavement, as the vehicle will bind when going around corners. In 4H, the system provides electronically locked four-wheel-drive power to the front and rear wheels • The 4x4 LOW (4L) mode supplies four-wheel drive with full power to both axles and includes a lower gear ratio for low speeds. It is only intended for off-road applications that require extra power, including deep sand, steep grades and when pulling a boat and trailer out of water. 4x4 LOW should never be used on dry pavement, as the vehicle will bind when going around corners • 2HIGH (2H) (Expedition only) uses the Integrated Wheel End (IWE) System to disengage the front driveline at the wheel ends and send all available engine torque to the rear wheels. With 2HIGH engaged, a 4x4 Expedition operates as a rear-wheel-drive vehicle. Explorer and Sport Trac do not offer a 2HIGH (2H) setting and do not incorporate the IWE system • Only the Explorer and Sport Trac Control Trac automatic models can be retrofitted with a Neutral Tow Kit through a Ford dealer to allow the transfer case to be shifted to Neutral. This permits the vehicle to be flat or “neutral” towed for extended distances (such as behind a motorhome) without risking damage to the automatic transmission

• The 4x4 AUTO (or 4A) mode provides four-wheel drive with full power to the rear axle, and to the front axle as required for increased traction. This mode is appropriate for any driving, whether on dry pavement or in adverse conditions. However, for extreme winter weather or off-road driving, a customer may choose to switch to 4x4 HIGH (4H) or 4x4 LOW (4L)

4X4 AUTO

4X4 HIGH

4X4 LOW

Explorer 4x4 Control Buttons

Expedition Integrated Wheel End (IWE) System

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4WD/AWD OPERATIONS This page is about: SUV 4WD System Operation/Demonstration Control Trac® Intelligent 4WD System

4WD/AWD Operations

2008 4WD/AWD Operations

SUV 4WD System Operation/Demonstration As a professional Sales Consultant, it’s important that you be able to explain 4x4 operation to your customers: • Many new 4x4 owners are first-time buyers who may not know how to operate their systems • Give a complete delivery demonstration and include some off-road time if possible • A proper demonstration will go a long way toward heading off problems that could tarnish customer satisfaction

Transfer Case Basics Ford 4x4 systems, with the exception of Escape and Escape Hybrid, feature a transfer case positioned behind the transmission. This transfer case has the ability to split engine torque, sending it back to the rear wheels and forward to the front wheels.

Control Trac® (Explorer and Sport Trac) How to shift from 4x4 AUTO to 4x4 HIGH • Move between 4x4 AUTO and 4x4 HIGH at any speed by using the appropriate control buttons • If 4x4 HIGH is selected, the icon in the instrument cluster will illuminate • 4x4 HIGH should not be used on dry pavement How to shift from 4x4 HIGH to 4x4 LOW • To engage 4x4 LOW, the vehicle must be fully stopped • Depress the brake pedal • The transmission must be shifted into the Neutral position • Push the 4x4 LOW button; the icon in the instrument cluster will illuminate (4x4 LOW range provides a 2.48:1 gear reduction ratio for added pulling power) • To disengage 4x4 LOW, the vehicle must be fully stopped • Depress the brake pedal • The transmission must be shifted into the Neutral position • Select the desired drive by pushing the appropriate control button • 4x4 LOW should not be used on dry pavement or at speeds exceeding 35 miles per hour (Expedition) How to shift from 2H to 4A • With the vehicle stopped or moving at less than 55 miles per hour, rotate the control to 4A. (At temperatures below 32° F, shifts to 4A should not be performed above 45 miles per hour and should not be performed if the rear wheels are slipping) • 4x4 AUTO will illuminate in the Message Center May 2007

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Several Ford 4WD systems include a 2-speed transfer case. This feature gives the transfer case added capabilities that significantly increase the amount of torque delivered to all four driving wheels — a must for off-road driving. The functions of a typical 2-speed transfer case are as follows: • In the 4x2 position, the transfer case is disengaged, sending engine torque only to the rear wheels. This mode delivers normal traction and maximum fuel economy • In the 4x4 HIGH (or 4H) position, the input transfer gear is locked to the input shaft, and power flows to both front and rear axles. This mode provides extra traction at all speeds • In the 4x4 LOW (or 4L) position, the planetary gearset is locked, resulting in approximately a 2.5:1 gear ratio

How to shift from 4A to 4H • Rotate the control to 4H • 4x4 will illuminate in the Message Center • 4H should not be used on dry pavement How to shift from 4H to 4L • To engage 4L, the vehicle must be fully stopped • Depress the brake pedal • The transmission must be shifted into the Neutral position • Rotate the control to the 4L position. 4x4 will illuminate in the Message Center (4L range provides a 2.64:1 gear reduction ratio for added pulling power) • To disengage 4L, the vehicle must be fully stopped • Depress the brake pedal • The transmission must be shifted into the Neutral position • Select the desired drive by rotating the control to the appropriate position • 4L should not be used on dry pavement or at speeds exceeding 35 miles per hour How to shift from 4A to 2H • Rotate the control from 4A to 2H at any forward speed • 4x4 AUTO in the Message Center will turn off

Intelligent 4WD System (Escape and Escape Hybrid) • System is automatically engaged with no driver-operated switch • Does not require the driver to actively engage the system

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4WD/AWD Operations

4WD/AWD OPERATIONS This page is about: Truck Front Drive Axles Truck 4WD Systems

Truck Front Drive Axles Today’s wide range of 4WD systems offers numerous front drive axle configurations. Ford trucks use two types:

Short- and Long-Arm (SLA) Independent

Twin-coil Monobeam

• Equal-length halfshafts transmit power to the front wheels

• Used on all F-Series Super Duty® 4WD models • A traditional design that uses a conventional tube axle with steering knuckles mounted at each end

Twin-coil Monobeam Front Suspension

• Differential assembly is mounted to the front frame

• Used on all Ranger 4WD models • F-150 uses SLA suspension with coil-over-shock design on both 2WD and 4WD models

F-150 Short- and Long-Arm (SLA) Independent Front Suspension

Truck 4WD Systems Manual Shift with Manual-locking Hubs

Manual Shift-on-the-fly

Standard on F-250 – F-550 Super Duty 4WD models

Standard on F-150 XL, STX Styleside box and XLT Styleside box (Regular Cab and SuperCab) 4WD models

• Used in 4WD applications since the 1950s and is highly regarded by serious off-roaders

• The transfer case is engaged manually using a floor-mounted transfer case shift lever

– This system is activated using a floormounted transfer case shift lever – To engage the front axle, the operator must stop, exit the vehicle and rotate both hublock selector knobs to the LOCK position

Super Duty 4WD Manual Shift Lever

• There is no need to manually engage the front hubs; a sliding collar in the front axle called a center disconnect will automatically engage after the transfer case shift lever is shifted

F-150 Manual Shift Transfer Case Lever

– This engages a cam-and-spring mechanism that connects the hub to the axle shaft

• At temperatures below 32°F, shifts from 2H (4x2) to 4H (4WD HIGH) should not be performed above 45 mph

– When returned to the FREE position, the front drive axle components do not turn while driving

• Manual transfer case includes a Neutral position that overrides the transmission and puts the vehicle in Neutral regardless of transmission gearshift lever location

– This reduces frictional drag and wear on the front drive axle components

• 4WD HIGH can be engaged at any speed up to 55 mph

• Many 4WD owners consider manuallocking hubs to be the most reliable design because of their simplicity

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Super Duty Manual-locking Front Hub

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4WD/AWD OPERATIONS This page is about: Truck 4WD Systems cont’d

4WD/AWD Operations

2008 4WD/AWD Operations Truck 4WD Systems cont’d Electronic Shift-on-the-fly

F-Series Super Duty

Standard on F-150 XL SuperCrew, STX with Styleside box, XLT SuperCrew and all with Flareside box and all FX4 and Lariat 4x4

• F-Series Super Duty models equipped with the available Electronic Shift-on-the-fly 4WD system feature Pulse Vacuum Hublocks (PVH)

Standard on Ranger 4x4 Optional on F-150 XL Regular and SuperCab, STX with Styleside box, XLT Regular and SuperCab with Styleside box 4x4 All F-Series Super Duty® 4x4 Ranger and F-150

• The Electronic Shift-on-the-fly system can be disengaged from the cab of the vehicle by shifting from 4WD HIGH (four-wheel-drive HIGH) to 4x2 (two-wheel drive) at any forward speed

• Electronic shift 4WD systems are activated using a 3-position rotary switch on the instrument panel • Essentially, the electronic shift 4WD system is the same as the manual shift system, except an electric motor shifts the transfer case instead of a lever-operated mechanism

• The PVH system allows for synchronous hublock engagement when the customer shifts on the fly. This provides for virtually silent 4WD engagements and disengagements

F-Series Super Duty Rotary Switch

• There are no shift delays in cold weather Ranger

• On F-150 4WDs, an electromagnetic Rotary Switch clutch is used to spin up the front drive system from 0 mph to vehicle 2H speed. When the transfer case 4H front and rear output shafts 4L are synchronized, a springloaded lockup collar mechanically engages the mainshaft hub to the drive sprocket, and Integrated Wheel Ends (IWE) activate to connect the front halfshaft to the F-150 4WD Electronic wheels. The electromagnetic clutch Shift-on-the-fly Switch is then deactivated

• This system optimizes fuel economy because all front driveline components are disconnected at the wheels in 4x2 mode • 4x2 mode noise, vibration and harshness (NVH) are minimized because the front driveline is static • F-Series Super Duty models feature manual override capability. This permits the driver to lock the front hubs at the front wheels if preferred

F-Series Super Duty Automatic-locking Front Hub with Manual Override

• 4WD HIGH can be engaged at any speed up to 55 mph

AWD (All-Wheel Drive) Available on F-150 with the Ford Harley-DavidsonTM F-150 Package or Limited Package • This system includes electronic logic and single-speed transfer case. It has two modes, selected using a rotary switch: All-Wheel Drive (AWD) and four-wheel-drive HIGH (4H) • The AWD system sends full power to the rear axle, and to the front axle as required for increased traction. It monitors wheel speeds and throttle position to control wheel slip and often prevents slip from occurring in the first place. This mode is appropriate for any driving, whether on dry pavement or in adverse conditions

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• 4H provides full power to both axles. It is only intended for severe winter weather or off-road conditions, such as deep snow and ice (where no pavement remains uncovered) or mud and sand. This mode should never be used on dry pavement, as the vehicle will bind when going around corners • Shifts between AWD and 4H can be made at any speed

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4WD/AWD Operations

4WD/AWD OPERATIONS This page is about: Truck 4WD System Operation/Demonstration

2008 4WD/AWD Operations

Truck 4WD System Operation/Demonstration Transfer Case Basics

Manual Transfer Case/Shift-on-the-fly

All Ford truck 4WD systems feature a transfer case positioned behind the transmission. This transfer case has the ability to split engine torque, sending it back to the rear wheels and forward to the front wheels. Ford truck systems are part-time, meaning that their normal mode of operation is two-wheel drive (with power flowing to the rear wheels). All four wheels receive power only when the driver engages the four-wheeldrive mode.

F-150 XL, STX and XLT Regular Cab and SuperCab models; F-Series Super Duty® 4WD models(1)

Ford truck 4WD systems include a 2-speed transfer case. This feature gives the transfer case added capabilities that significantly increase the amount of torque delivered to all four driving wheels — a must for off-road driving. The functions of a typical 2-speed transfer case are as follows: • In the 2WD position, the input transfer gear is disengaged, sending engine torque only to the rear wheels. This mode delivers normal traction and optimum fuel economy • In the 4WD HIGH position, the input transfer gear is locked to the input shaft, and power flows to both front and rear axles. This mode provides extra traction at all speeds • In the 4WD LOW position, the planetary gearset is locked, resulting in approximately a 2.5:1 gear reduction ratio. When engaged, the engine is often running at over twice its normal speed for a given mph, and this provides a tremendous amount of power for negotiating off-highway trails, slick boat ramps or whenever huge amounts of torque are called for • The lever-operated transfer case available on F-Series also has a Neutral position, used when towing the vehicle, such as behind a motorhome or tow truck. Consult the Owner’s Guide for specific instructions and restrictions when towing any vehicle

How to shift from 4x2 HIGH to 4WD HIGH • On F-150, move the transfer case lever to 4WD HIGH at a stop or at any forward speed up to 55 mph. At temperatures below 32°F, shifts from two-wheel-drive HIGH to 4WD HIGH should not be performed above 45 mph • On Super Duty® models, engage the locking hubs by rotating the hublock control from FREE to LOCK, then move the transfer case lever to 4H (4WD HIGH). Super Duty manual shift systems are not intended to be shifted on the fly NOTE: Do not shift into 4H (4WD HIGH) with the wheels slipping.

How to shift from 4WD HIGH to 4x2 HIGH • With F-150, move the transfer case lever to 4x2 at a stop or at any forward speed up to 55 mph. With F-Series Super Duty, move the transfer case lever to 2H (4x2), at a stop or at any forward speed up to 55 mph. With the vehicle at a complete stop, disengage the locking hubs by rotating the hublock control from LOCK to FREE How to shift from 4x2 HIGH to 4WD LOW • Bring the vehicle to a speed below 2 mph • Depress the brake • Place the gearshift lever in N (Neutral) (automatic transmission) or depress the clutch (manual transmission) • Pull the transfer case shift lever through N (Neutral) directly to 4WD LOW • On Super Duty models, engage the locking hubs by rotating the hublock control from FREE to LOCK, then move the transfer case lever to 4L (4WD LOW)

(1) F-250 – F-550 Super Duty shift pattern shown. F-150 and Ranger pattern is slightly different.

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4WD/AWD OPERATIONS This page is about: Truck 4WD System Operation/Demonstration cont’d

4WD/AWD Operations

2008 4WD/AWD Operations

Truck 4WD System Operation/Demonstration cont’d Electronic Shift-on-the-fly

On Dry Pavement

Ranger, F-150 and F-Series Super Duty® 4WD Models(1)

All Ranger, F-150 and F-Series Super Duty 4WD models feature part-time 4WD systems. Operating these part-time systems in four-wheel drive on dry pavement could result in difficult disengagement of the transfer case, increased tire wear and decreased fuel economy. These part-time 4WD systems are designed to provide enhanced traction on lowerfriction surfaces such as gravel, snow, ice, dirt, wet pavement and off-highway road or trail surfaces.

How to shift from 2WD to 4WD High • Move the rotary control to 4WD HIGH from 4x2 at a stop or at speeds up to 55 mph. With F-150, at temperatures below 32°F, shifts from 2H (two-wheeldrive HIGH) to 4H (4WD HIGH) should not be performed above 45 mph NOTE: Do not shift into 4WD with the rear wheels slipping.

How to shift from 4WD HIGH to 2WD • Move the rotary control to 4x2 at any forward speed. There is no need to drive in Reverse to unlock How to shift between 4WD HIGH and 4WD LOW • Bring the vehicle to a complete stop • Depress the brake • Place the gearshift lever in N (Neutral) (automatic transmission) or depress the clutch (manual transmission) • Move the rotary control to the 4WD HIGH or 4WD LOW position

(1) Ranger rotary dial shown. F-150 and F-Series Super Duty dials are slightly different.

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