Transfer Case-Electronic Shift On The Fly (ESOF) Operation: Notes

WARNING: This page is about a different car, the 2001 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

The electronic shift on the fly (ESOF) system is an electronic shift 4x4 system that allows the operator to choose between two different 4x4 modes as well as 2- wheel drive. The operator can switch between 2WD and 4H mode at speeds up to 88 km/h (55 mph). To engage or disengage 4L range, the vehicle speed must be less than 5 km/h (3 mph), the brake pedal depressed, and the transmission must be in NEUTRAL.

The transfer case is equipped with an electromagnetic clutch which is located inside the case. This clutch is used to spin up the front driveline when shifting from 2WD to 4H mode at speed. When the control switch on the instrument panel is turned, the generic electronic module (GEM) recognizes that a shift has been requested and activates the electromagnetic clutch and the relays which power the transfer case shift motor. When the shift motor reaches the desired position, as determined by the contact plate position inputs to the GEM, power to the shift relays and motors will be removed. When the transfer case front and rear output shafts are synchronized, the spring loaded lockup collar mechanically engages the mainshaft hub to the drive sprocket. Finally, the front axle collar is engaged and the electromagnetic clutch is deactivated.

Shifts between 2WD and 4H can be made at any speed up to 88 km/h (55 mph). Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes.

Feature Inputs:

4WD mode switch (various resistances); go to Figure.
Contact plate position inputs A, B, C, D (grounded when closed, open circuit when open); go to Figure.

Feature Outputs:

4x4 shift motor relay outputs, go to Figure.
Transfer case clutch relay (grounded when relay is activated, open circuit when relay is deactivated).
4x2/4x4 vacuum solenoid (grounded when activated, open circuit when deactivated).
Cluster indicators (ground when activated, open circuit when deactivated).

When shifting into or out of 4L, the GEM requires that the vehicle speed be less than 5 km/h (3 mph), the brake is applied, and the transmission is in NEUTRAL.

Feature Inputs:

4WD Mode Switch (various resistances); go to Figure.
Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open); go to Figure.
Output Speed Shaft (OSS) Sensor (Sinusoid Signal: 0.7V-20V, 2.2 Hz/mph).
Brake Input (battery voltage when brake is depressed, open circuit when not activated).
Transmission Range Sensor (grounded when transmission is in NEUTRAL, open circuit otherwise).
Start/Clutch Depressed Input, go to Figure.

Feature Outputs:

4x4 Shift Motor Relay Outputs, go to Figure.
4x2/4x4 Vacuum Solenoid (grounded when activated, open circuit when deactivated).
Cluster Indicators (grounded when activated, open circuit when deactivated).