Chassis

 Clutch
 Manual Transmission
 Automatic Transmission
 Transfer
 Suspension System
 Brake
 Steering
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Chassis
 Clutch
• Overall
– A dry single plate clutch which is operated by
hydraulic pressure is used
[Major Difference (from previous model)]

Engine (Previous) Major Difference

1GR-FE (5VZ-FE) Change of clutch disc size
3RZ-FE (Same) Basic construction as same as previous model
1KD-FTV (Same) Change of clutch disc size and clutch cover
1KZ-TE (Same) installed load
5L-E (3L) Change of the clutch disc size
•Change of the master cylinder location
All Models •Turnover mechanism is used
•Clutch accumulator is used
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Chassis
 Clutch
• Specification (for 1GR-FE engine)

Engine Type 1GR-FE 5VZ-FE

Clutch Type DST*1 
Cover Size [mm (in.)] 275 (10.83) 250 (9.85)
275 x 175 x 3.5 250 x 160 x 3.5
Facing Size*2 [mm (in.)]
Clutch Disc (10.83 x 6.89 x 0.14) (9.29 x 6.30 x 0.14)
Facing Area [cm2 (in2.)] 353 (54.72) 290 (44.95)
Type Conventional 
Master
Cylinder Cylinder Diameter
19.05 (0.75) 15.87 (0.62)
[mm (in.)]
Type Non-adjustable 
Release
Cylinder Cylinder Diameter
19.05 (0.75) 20.64 (0.82)
[mm (in.)]
Clutch Pedal Turnover 

*1: DST (Diaphragm Spring Turnover)

*2: Outer Diameter x Inner Diameter x Thickness
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Chassis
 Clutch
• Specification (for 3RZ-FE engine)

Engine Type 3RZ-FE Previous 3RZ-FE

Clutch Type DST*1 
Cover Size [mm (in.)] 250 (9.85) 
250 x 160 x 3.5
Facing Size*2 [mm (in.)] 
Clutch Disc (9.29 x 6.30 x 0.14)
Facing Area [cm2 (in2.)] 290 (44.95) 
Type Conventional 
Master
Cylinder Cylinder Diameter
19.05 (0.75) 15.87 (0.62)
[mm (in.)]
Type Non-adjustable 
Release
Cylinder Cylinder Diameter
23.81 (0.94) 20.64 (0.82)
[mm (in.)]
Clutch Pedal Turnover —

*1: DST (Diaphragm Spring Turnover)

*2: Outer Diameter x Inner Diameter x Thickness
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Chassis
 Clutch
• Specification (for 1KD-FTV engine)

Engine Type 1KD-FTV Previous 1KD-FTV

Clutch Type DST*1 
Cover Size [mm (in.)] 275 (10.83) 260 (10.24)
275 x 175 x 3.5 260 x 170 x 3.5
Facing Size*2 [mm (in.)]
Clutch Disc (10.83 x 6.89 x 0.14) (10.24 x 6.69 x 0.14)
Facing Area [cm2 (in2.)] 353 (54.72) 304 (47.12)
Type Conventional 
Master
Cylinder Cylinder Diameter
19.05 (0.75) 15.87 (0.62)
[mm (in.)]
Type Non-adjustable 
Release
Cylinder Cylinder Diameter
23.81 (0.94) 19.05 (0.75)
[mm (in.)]
Clutch Pedal Turnover 

*1: DST (Diaphragm Spring Turnover)

*2: Outer Diameter x Inner Diameter x Thickness
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Chassis
 Clutch
• Specification (for 1KZ-TE engine)

Engine Type 1KZ-TE Previous 1KZ-TE

Clutch Type DST*1 
Cover Size [mm (in.)] 275 (10.83) 260 (10.24)
275 x 175 x 3.5 260 x 170 x 3.5
Facing Size*2 [mm (in.)]
Clutch Disc (10.83 x 6.89 x 0.14) (10.24 x 6.69 x 0.14)
Facing Area [cm2 (in2.)] 353 (54.72) 304 (47.12)
Type Conventional 
Master
Cylinder Cylinder Diameter
19.05 (0.75) 15.87 (0.62)
[mm (in.)]
Type Non-adjustable 
Release
Cylinder Cylinder Diameter
23.81 (0.94) 19.05 (0.75)
[mm (in.)]
Clutch Pedal Turnover 

*1: DST (Diaphragm Spring Turnover)

*2: Outer Diameter x Inner Diameter x Thickness
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Chassis
 Clutch
• Specification (for 5L-E engine)

Engine Type 5L-E 3L

Clutch Type DST*1 
Cover Size [mm (in.)] 236 (9.29) 224 (8.82)
236 x 150 x 3.5 224 x 150 x 3.5
Facing Size*2 [mm (in.)]
Clutch Disc (9.29 x 5.91 x 0.14) (8.82 x 5.91 x 0.14)
Facing Area [cm2 (in2.)] 260 (40.30) 217 (33.64)
Type Conventional 
Master
Cylinder Cylinder Diameter
19.05 (0.75) 15.87 (0.62)
[mm (in.)]
Type Non-adjustable 
Release
Cylinder Cylinder Diameter
23.81 (0.94) 20.64 (0.82)
[mm (in.)]
Clutch Pedal Turnover —

*1: DST (Diaphragm Spring Turnover)

*2: Outer Diameter x Inner Diameter x Thickness
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Chassis
 Clutch
• Clutch Pedal
– Clutch pedal has been made of plastic to reduce
the weight

Made of Plastic
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Chassis
 Clutch
• Clutch Master Cylinder
– Clutch master cylinder location has been
changed to cabin for LHD model

Clutch Master
Cylinder
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Chassis
 Clutch
• Reservoir Tank (LHD model)
– with VSC model: Have a clutch fluid reservoir
tank
– without VSC model: Brake fluid reservoir tank
common use

Brake Fluid Clutch Fluid

Reservoir Tank Reservoir Tank
(for Hydraulic brake)
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Chassis
 Manual Transmission
• Manual Transmission Line-up
– Basic construction as same as previous models

Difference from
Engine Transmission
previous model
1GR-FE R150F Synchromesh Mechanism
3RZ-FE W56 Carry Over
1KD-FTV R150F Synchromesh Mechanism
1KZ-TE  
5L-E G52 Carry Over
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Chassis
 Automatic Transmission
• Overall (A340F/A343F)
– ATF fluid type is changed to T-IV type for
smooth run and smooth shift feeling
– Line pressure optimal control has been used
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Chassis
 Automatic Transmission
• Specification
Engine Type 1GR-FE 3RZ-FE/1KZ-TE/1KD-FTV
Transmission Type A340F A343F
1st 2.804 

Gear Ratio 2nd 1.531 

(Counter Gear 3rd 1.000 
Ratio Included) 4th 0.705 0.753
Reverse 2.393 
Fluid Capacity (include differential) 10.1

[Litter (US qts, lmp. qts)] (10.67, 8.89)
Fluid Type ATF Type T-IV 
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Chassis
 Automatic Transmission
• Shift Lever
– Gate type shift lever is used

[Shift Indicator Light]

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Chassis
 Automatic Transmission
• Line Pressure Optimal Control (Except 3RZ-FE)
Primary Solenoid Valve SLT*
Regulator
Line Pressure
Shift Position
ECT Shift Range

Throttle Valve
Opening Angle
Engine Engine Speed
Pressure
Fluid

Pump Engine & ECT ECU

Current

Throttle Pressure

*: Linear Solenoid Valve

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Chassis
 Transfer
• Overall
– VF4B/VF4BM type transfer with TORSEN* LSD
have been newly developed

TORSEN
LSD

Transfer Shift Actuator

(for Center Diff. Lock)

*: TORSEN is ZEXEL’s registered trade mark

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Chassis
 Transfer
• Specification
VF4B
Transfer Type VF4BM (1 Motor) VF2A (Full manual)
(Full manual)
with VSC for without VSC 5L-E and 3RZ-FE
Engine Type 1GR-FE, 1KD-FTV model (without ABS
1KZ-TE (Except -_) (Except 5L-E) for -_ as OPT)
Drive Type Full-time  Part-time
H2   1.000
Ratio
H4 1.000  
Gear
L4 2.566  
Reduction Gear Type Single pinion Planetary Gear  
Center Differential
TORSEN LSD  
Gear Type
Oil Capacity [Litter
1.4 (1.48, 1.23)  1.0 (1.1, 0.9)
(US qts, lmp. qts)]
Oil Viscosity SAE 75W-90  
Oil Grade API GL-4 or GL-5  
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Chassis
 Transfer
• Shift Pattern
– L4F (Low gear center differential Free) position
is added in VF4BM transfer

[VF4BM]

Transfer Type Shift Pattern

VF4BM L
H4F-H4L-L4F-L4L
(Motor and Manual shift)
VF4B (Manual shift) H4F-H4L-N-L4L
N
VF3B (Previous model)  H
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Chassis
 Transfer
• System Diagram (Only for VF4BM model)
Center Differential
Skid
Control
Engine Buzzer Lock Switch
ECU
ECU
4WD
Control
ECU
L Position
Neutral Position Switch*
Park/ Switch
Neutral
Position
Switch*
Transfer Shift Actuator
•Center Diff. Lock Shift Motor
•Center Diff. Lock Shift
•Vehicle Speed
Motor Limit Switch
•VSC OFF Indicator Light
•Center Diff.
•Center Differential
Lock Position Switch
Lock Indicator Light
•A/T P Indicator Light*
Combination Meter

*: Only for Automatic Transmission model

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Chassis
 Transfer
• System Diagram (Only for VF4B model)
Combination Meter
Engine
ECU
•Vehicle Speed
•Center Differential
Skid Lock Indicator Light
Control
ECU
•A/T P Indicator Light*1

Neutral Position Switch*1

L Position Switch *2
Park/Neutral
Center Diff. Lock
Position
Position Switch
Switch*1

*1: Only for Automatic Transmission model

*2: Except with ABS and Rear Diff. Lock
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Chassis
 Transfer
• Center Diff. Lock Position Switch
– Center differential lock position switch is built in
actuator
Center Diff. Lock Shift
Motor Limit Switch

Center Diff. Lock

Shift Fork Shaft

Center Diff.
Lock Position
Motor
Switch
NOTE: Non-disassemble Part
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Chassis
 Transfer
• Center Diff. Lock Shift Motor Limit Switch
– Contact point contacted by protuberance and
the combination of contact point has detected
shift motor position
[Center Diff. Lock Shift
Motor Limit Switch]

Contact Point

Protuberance
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Chassis
 Transfer
• TORSEN LSD Components (Except VF2A)

Ring Gear Pinion Gear

Coupling

Differential
Case
Sun Gear
Coupling

Planetary
Carrier
Clutch Plate No.4
Sun Gear
Clutch Plate No.2
Clutch Ring Gear
Plate No.1
Clutch Plate No.3

NOTE: Non-disassemble Part

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Chassis
 Transfer
• TORSEN LSD Components

Clutch Ring Gear Clutch Plate No.2

Plate No.1 Sun Gear
Ring Gear Coupling
Differential Coupling
Case

Carrier Nut
Planetary Carrier
Thrust Plate
Clutch Plate No.4
Sun Gear
Clutch Plate No.3 Pinion Gear
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Chassis
 Transfer
• TORSEN LSD
– Normal driving

Front
Sun Gear Coupling Output
Differential Planetary Pinion
INPUT Rear
Case Carrier Gear
Ring Gear Coupling Output
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Chassis
 Transfer
• TORSEN LSD
– Normal driving

Front
Sun Gear Coupling Output
Differential Planetary Pinion
INPUT Rear
Case Carrier Gear
Ring Gear Coupling Output
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Chassis
 Transfer
• TORSEN LSD
– Normal driving

Front
Sun Gear Coupling Output
Differential Planetary Pinion
INPUT Rear
Case Carrier Gear
Ring Gear Coupling Output
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Chassis
 Transfer
• TORSEN LSD
– Normal driving

Front
Sun Gear Coupling Output
Differential Planetary Pinion
INPUT Rear
Case Carrier Gear
Ring Gear Coupling Output
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Chassis
 Transfer
• TORSEN LSD
– Normal driving

Fr
Output

Rr Output

Front
Sun Gear Coupling Output
Differential Planetary Pinion
INPUT Rear
Case Carrier Gear
Ring Gear Coupling Output
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Chassis Confidential
 Transfer
• TORSEN LSD (Torque Sensing)
– TORSEN LSD automatically adjust the torque
distribution ratio for the three modes according
to the wheel speed condition to ensure the
driving stability
Torque Distribution Ratio
Wheel Speed Condition Under
Acceleration Front Rear

Front Wheel = Rear Wheel 40 60

Front Wheel > Rear Wheel 29 71
Front Wheel < Rear Wheel 53 47
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Chassis
 Transfer
• TORSEN LSD
– Front wheel speed = Rear wheel speed

[Torque Distribution]
Front : Rear= 2 : 3
Front: 2/5 x 100=40
Rear: 3/5 x 100=60

ar
n
Fro

Re
Front : Rear= 40 : 60
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Chassis
 Transfer
• TORSEN LSD
– Front wheel speed > Rear wheel speed

Fr
Output

Rr Output

Front
Sun Gear Coupling
Output
Differential Planetary Pinion
INPUT Rear
Case Carrier Gear
Ring Gear Coupling
Output
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Chassis
 Transfer
• TORSEN LSD
– Front wheel speed > Rear wheel speed
Friction
Fr
Output

Rr Output

Front
Sun Gear Coupling
Output
Differential Planetary Pinion
INPUT Rear
Case Carrier Gear
Ring Gear Coupling
Output
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Chassis
 Transfer
• TORSEN LSD
– Front wheel speed > Rear wheel speed

Fr
Output

Rr Output

Clutch Plate No. 4

Front
Sun Gear Coupling
Output
Differential Planetary Pinion
INPUT Rear
Case Carrier Gear
Ring Gear Coupling
Output
Click! Clutch Plate No.1
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Chassis
 Transfer
• TORSEN LSD
– Front wheel speed < Rear wheel speed

Fr
Output

Rr Output

Front
Sun Gear Coupling
Output
Differential Planetary Pinion
INPUT Rear
Case Carrier Gear
Ring Gear Coupling
Output
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Chassis
 Transfer
• TORSEN LSD
– Front wheel speed < Rear wheel speed
Friction
Fr
Output

Rr Output

Front
Sun Gear Coupling
Output
Differential Planetary Pinion
INPUT Rear
Case Carrier Gear
Ring Gear Coupling
Output
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Chassis
 Transfer
• TORSEN LSD
– Front wheel speed < Rear wheel speed

Fr
Output

Rr Output

Clutch Plate No. 4

Front
Sun Gear Coupling
Output
Differential Planetary Pinion
INPUT Rear
Case Carrier Gear
Ring Gear Coupling
Output
Click! Clutch Plate No.1
Clutch Plate No.2
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Chassis
 Suspension System
• Suspension
– Front: Double wishbone type independent
suspension
– Rear: 4-links coil spring with lateral rod type
suspension
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Chassis
 Suspension System
• Front Suspension
– Optimally allocate the components and the
realizes excellent riding comfort and
controllability
Coil Spring:
Shock Absorber: Optimized
Optimized location and spring constant
characteristics

Stabilizer Bar:
Location changed to front
of axle and used the
hollow type
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Chassis
 Suspension System
• Rear Suspension
– Optimally allocate the components and the
realizes excellent riding comfort and
controllability
Shock Absorber:
Optimized location and
characteristics

Stabilizer Bar:
Optimized spring constant
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Chassis
 Suspension System
• EMS (Electric Modulated Suspension)
– Driver can select 4-type of damping force of
shock absorber
Hard

Absorber
Control
Switch Damping
Force

Soft

COMFORT SPORT
Absorber Control Switch Position
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Chassis
 Suspension System
• EMS (Electric Modulated Suspension)
– System diagram (EMS control)

Skid Crankshaft
Vehicle Speed Position Sensor
Control
Sensor (FR)
ECU
Engine
Front Acceleration ECU
Sensor (FR)
Rear Acceleration
Sensor (Rear) Rear Shock
Front Shock Suspension
Absorbers
Absorbers Control ECU
and Actuators
and Actuators
Front Acceleration
Sensor (FL)
Damping
DLC3
Steering Mode
Angle Select
Stop Light
Sensor Switch
Switch
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Chassis
 Suspension System
• EMS (Electric Modulated Suspension)
– Layout of components

Engine
ECU

Skid Control Damping

ECU* Model
Select
Suspension Switch
Control ECU

Stop Light
Switch

Steering Angle *: with VSC model

Sensor
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Chassis
 Suspension System
• EMS (Electric Modulated Suspension)
– Semi-active control (Non-linear H∞ Control)

Suspension Control ECU

Acceleration
Sensors Non-linear
H∞ Control
Unsprung
Information

Steering
Angle Sensor
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Chassis
 Suspension System
• EMS (Electric Modulated Suspension)
– Semi-active control (Non-linear H∞ Control)
Frequency
Emphasis
Gain
No Control Coefficient

Frequency
Under Control

Time
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Chassis
 Suspension System
• EMS (Electric Modulated Suspension)
– Semi-active control (Non-linear H∞ Control)

New Model
(Non-linear H∞ Control)

Previous Model
(Sky-hook Control)
Click!
Movie
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Chassis
 Suspension System
• EMS (Electric Modulated Suspension)
– Imaginary roll damper control

Suspension Control ECU

Steering
Angle Sensor Imaginary
Roll Damper
Shock Absorber
Control
Stroke
Information

Acceleration
Sensors
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Chassis
 Suspension System
• EMS (Electric Modulated Suspension)
– Imaginary roll damper control

Click!
Movie
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Chassis
 Suspension System
• Rear Air Suspension
– System diagram (Air suspension control)
Vehicle Speed Sensor (FR, FL)
Crankshaft Position Sensor
Suspension •Height Control Indicator Light
Door Courtesy Switches Control
•Height Control OFF Indicator Light
Stop Light Switch ECU OFF

•Height Control Switch

•Height Control
OFF Switch Tank Solenoid
Compressor Valve Height Control
Relay Sensor (RH)
Pneumatic
Height Gate Cylinder (RH)
Pneumatic
Control Solenoid
Tank
Cleaner M Valve Pneumatic
Cylinder (LH)

Dryer Height Control

Compressor Leveling Solenoid Valve Sensor (LH)
Exhaust Solenoid Valve

: Air Flow Passage

: Input Signal
: Output Signal
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Chassis
 Suspension System
• Rear Air Suspension
– Layout of components
Tank Solenoid Valve Pneumatic Tank
Height Control
Leveling Sensor (RH)
Solenoid
Valve

Gate
Solenoid
Valve Pneumatic
Cylinder (RH)

Exhaust
Solenoid Valve
Compressor Height Control
Dryer and Motor Cleaner
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Chassis
 Suspension System
• Rear Air Suspension
– Layout of components
Height Control
Indicator Light
Engine
OFF ECU
Height Control
Indicator OFF
Light
Height
Skid Control
Control
ECU*
OFF
Switch
Suspension
Control ECU
Height
Stop Light Control
Switch Switch

*: with VSC model

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Chassis
 Suspension System
• Rear Air Suspension
– Type of height control

Type of Height Control Function and Control

Maintains vehicle height at a constant level regardless of
Automatic Leveling Function
the passenger and luggage weights
The vehicle height can be control three modes of “H”,
Height Control Function
“N” and “L” with the height control switch
The “N” mode is automatically selected when the vehicle
Vehicle Speed Sensing Operation speed exceeds about 12 km/h (7 mph) or over in the “L”
mode/30 km/h (19 mph) or over in the “H” mode.
IG Key OFF Operation Rear height adjustment after passenger off
The vehicle height control is cancelled in the fixed level
Height Control Cancel Operation
when cancel switch is turned
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Chassis
 Suspension System
• Rear Air Suspension
– Compressor & motor with dryer

Motor performance
improvement

Clean air is introduced

from cabin

From the Cabin

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Chassis
 Suspension System
• Rear Air Suspension
– Height control valves
To Pneumatic
Tank Cylinder (LH)
Solenoid
Valve
To Pneumatic
Cylinder (RH)
Gate Solenoid Valve:
Opens/closes the
Leveling
compressed air path
Solenoid
between the right and
Valve
left pneumatic cylinder
From Compressor
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Chassis
 Suspension System
• Rear Air Suspension
– Vehicle speed sensing control
 Vehicle height can be selected when the
vehicle speed is following conditions
Select Vehicle Height Vehicle Speed
“N” Position  “HI” Position 50 km/h (31 mph) or less
“N” Position  “LO” Position 12 km/h (7 mph) or less

“HI” Position
[(+40 mm (1.6 in.)]
[(+30 mm (1.2 in.)]*
“N” Position
“LO” Position
[(-30 mm (1.2 in.)]

*: Only for –W model

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Chassis
 Suspension System
• Rear Air Suspension
– Rear air suspension system failure
 If a malfunction occurs in the rear air
suspension system
The “N” mode is
automatically
selected

The height control

OFF “OFF” indicator
light blinks
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Chassis
 Brake
• Front and Rear Brakes
– Overall

15-inch Ventilated Disc

17”-inch Ventilated Brake and Floating Single
Disc Brake and Fixed Piston Type Caliper
(Opposed) 4-piston
Type Caliper
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Chassis
 Brake
• Brake Specifications
With VSC with ABS without ABS

Master Type Single Tandem 

Cylinder Diameter [mm (in.)] 22.22 (0.87) 20.64 (0.81) 
Brake
Type Hydraulic 10” Single 
Booster
Type 17” Ventilated Disc  
Front
Brake Wheel Cylinder Dia. [mm (in.)] 45.4 (1.79) x 4  
Rotor Size (D x T) [mm (in.)] 338 x 28 (13.30 x 1.10)  
Type 15” Ventilated Disc  
Wheel Cylinder Dia. [mm (in.)] 48.1 (1.89)  
Rear
Brake Drum Inner Dia.[mm (in.)]   
312 x 18
Rotor Size (D x T) [mm (in.)]  
(12.28 x 0.71)
Brake Control Valve Type EBD EBD LSPV & BV
ABS+BA+A-TRC ABS
Control Function 
+VSC+DAC*+HAC* +BA (Mechanical)

*: Only for Automatic Transmission

VSC: 1GR-FE, 1KD-FTV and 1KZ-FE (Except -_) engines as OPT
ABS: Except 5L-E engine as OPT (-W [German] as STD)
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Chassis
 Brake System
• Hydraulic Brake Booster and Master Cylinder

Basic construction and operation

are the same as previous model
(accumulator size and location
has been changed)

Model New Model Previous Model

Master Type Single 
Cylinder Diameter [mm (in.)] 22.22 (0.87) ---
Brake
Type Hydraulic 
Booster
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Chassis
 Brake
• Master Cylinder and Brake Booster
– Small diameter and long stroke type
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Chassis
 Brake
• Mechanical BRAKE ASSIST
– To improve brake performance and
effectiveness of BRAKE ASSIST function

Hook Slide Valve Operation

Rod
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Chassis
 Brake
• Mechanical BRAKE ASSIST
– No brake pedal operation
Control Valve “Open”

Constant
Pressure
Chamber

Air Valve “Close”

Variable Pressure Chamber
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Chassis
 Brake
• Mechanical BRAKE ASSIST
– Depress brake pedal (BA not operating)
Control Valve “Close”

Constant
Pressure
Chamber
PUSH

Power
Piston Operation
Air Valve “Open” Rod

Variable Pressure Chamber

Power Piston Speed = Operation Rod Speed

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Chassis
 Brake
• Mechanical BRAKE ASSIST
– Depress brake pedal (BA not operating)
Control Valve “Close”

Constant
Pressure
Chamber
PUSH

move

Power
Piston Operation
Air Valve “Open” Rod

Variable Pressure Chamber

Power Piston Speed = Operation Rod Speed

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Chassis
 Brake
• Mechanical BRAKE ASSIST
– Depress brake pedal (BA operating)
Control Valve “Close”

Constant
Pressure
Chamber
PUSH

Power
Piston Operation
Air Valve “Open” Rod

Variable Pressure Chamber

Power Piston Speed < Operation Rod Speed

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Chassis
 Brake
• Mechanical BRAKE ASSIST
– Depress brake pedal (BA operating)
Control Valve “Close”

Constant
Pressure
Chamber
PUSH

move

Power
Piston Operation
Air Valve “Open” Rod

Variable Pressure Chamber

Power Piston Speed < Operation Rod Speed

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Chassis
 Brake System
• Brake Pedal
– Double-link type variable lever ratio brake pedal
is used to provide excellent brake feeling

Reduce Provide ample

Brake pedal response
pedal effort
Pedal
Lever

Lever Ratio
Link

Brake
Pedal Pedal Stroke
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Chassis
 Brake Control System
• ABS with EBD, Brake Assist, A-TRC, VSC, DAC &
HAC System
– The following major changes from previous
model
Items New Model Previous Model
Brake Control System
DAC, HAC 
(Added Item)*
ABS Control 4-ch with 4 sensor 3-ch with 4 sensor
Brake Control Valve EBD P-valve
Speed Sensor Active Type Passive Type
Integrated in Separated of Yaw rate sensor
Yaw Rate Sensor*
deceleration Sensor and Deceleration sensor
Stop Light Control Relay* Available N.A

*: Only for Automatic Transmission

model with VSC
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Chassis
 Brake Control System
• System Diagram
(ABS with EBD, Brake Assist, A-TRC, VSC, DAC & HAC)
Master Cylinder Steering Angle Combination Meter
Pressure Sensor Sensor
Magnetic Stop Light Switch
Rotor
ABS
Speed
Sensor Yaw Rate Sensor
Brake Deceleration Sensor
Fluid Level M Solenoid Relay
Warning Pump Motor L Position Switch
Relays Skid
Switch
Control
ECU Center Diff. Lock
DAC Switch*
Pressure Detection Switch
Switches
P/N Position Switch*
Brake Light
Control Relay* DLC3 Accelerator Pedal
Position Sensor
Throttle Control Engine Throttle Position Sensor
Motor ECU Crankshaft Position Sensor

*: Only for Automatic Transmission model

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Chassis
 Brake Control System Combination Meter
• Layout of Components (Various Indicators)

VSC 4WD
Warning Control
Buzzer Lever

Skid Control
ECU Deceleration
Sensor

Steering
Angle
Sensor

DAC
Stop Light Switch
Switch

DLC3 Center Diff. Lock Switch

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Chassis
 Brake Control System
• System Diagram (ABS with EBD and Brake Assist)

Brake Fluid Stop Light

Level Warning Switch
Switch
Magnetic
Rotor
Brake
Speed Actuator
Speed
Sensors Skid Sensors
Control
ECU

•Speedometer
•ABS Warning
Deceleration
DLC3 Light
Sensor
•Brake System
Warning Light
Combination Meter
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Chassis
 Brake Control System Combination Meter
• Layout of Components (Various Indicators)

Deceleration
Sensor

Stop Light
Switch

DLC3
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Chassis
 Brake Control System
• Speed Sensor (with VSC, ABS model)
– Type of speed sensor has been changed from
passive type to active type
Passive Type
Active Type
(Magnetic pick-up)
(Semiconductor)
MRE Coil
(Magnetic Resistance Element)

A
B IC

Magnetic Rotor Rotor

Magnet Yoke Magnet
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Chassis
 Brake Control System
• Speed Sensor
– Sensor location

[Magnetic Rotor] Magnetic Rotor Potion [Active Speed Sensor]

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Chassis
 Brake Control System
• Speed Sensor
– Comparison of Active speed sensor and Passive
speed sensor
Sensor Type Active Speed Sensor Passive Speed Sensor
Vehicle
Detection Detection speed = Approx. 0 km/h Detection speed more than 3km/h
Speed
Rotation
Possible to judge the rotation Impossible to judge the rotation
Direction
direction direction
Detection
Magnetic rotor integrates to axle
Compact bearing
—
Body Compact and Lightweight body
(weight 1/3)
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Chassis
 Brake Control System
• Speed Sensor
– Detection method of vehicle speed
Active Speed Sensor Passive Speed Sensor
(0 km/h or above is detect) (3 km/h is detect)

Vehicle
Vehicle

No Detecting
Speed

Speed
Digital Analog Output
Output

Sensor
Output
Sensor

Output

Time Time
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Chassis
 Brake Control System
• Speed Sensor
– Detection method of rotation direction
Output

Output
Sensor

Sensor

Click! Time Time

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Chassis
 Brake Control System
• Yaw Rate and Deceleration Sensor
– Deceleration sensor has been integrated in the
yaw rate sensor
Deceleration
Sensor (G Sensor)

Yaw Rate
Sensor
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Chassis
 Brake Control System
• Switching and Control Solenoid Valves
– The resistance value of the solenoid valve coil is
changed to extend the the continual operation

Regulator cut solenoid Accumulator cut solenoid

Solenoid Continuation
Pressure holding solenoid Master cylinder cut solenoid
Valve Operation Time
(4-wheels) (FL/FR)
GX470 Approx. 7.2  Approx. 4.3  3 minutes
Conventional
Approx. 5.0  Approx. 3.7  50 seconds
Type

NOTE
When the voltage is 13 V:
New Model: 7.2  x 7.2  x 1.81 A = 23.58 W
Previous Model: 5  x 5  x 2.60 A = 33.8 W
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Chassis
 Brake Control System
• Master Cylinder Pressure Sensor
– Master cylinder pressure sensor is included in
detection of diagnostic function

DTC Detection Item

C1246 / 46 Master cylinder pressure sensor output signal malfunction
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Chassis
 Brake Control System
• DAC (Downhill Assist Control) System
– Overall
 The down hill assist control system is a system
that assists the deceleration when driving
down a steep hill

[Controls to constant speed driving]

Wheel Rotation
Target Vehicle Speed
Direction
Forward 5-7 km/h (3-4 mph)
Backward 3-5 km/h (2-3 mph)
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Chassis
 Brake Control System
• DAC (Downhill Assist Control) System
– Operating condition
(All the following conditions are cleared)
DAC Indicator 4WD Control
25km/h > Lever “L” Slip Indicator
Turn ON Vehicle Speed Blinking
> 5 km/h L
N
H

Brake
DAC
Control
Switch
No Accelerator and Brake
ON
Pedals operation
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Chassis
 Brake Control System
• DAC (Downhill Assist Control) System
– DAC indicator blinks

Indicator Function
Blinks to alert the driver when the following conditions:
•Skid control ECU detects an malfunction in the DAC system
Blinking •Operation of the DAC system is momentarily interrupted in order
to protect the brake actuator
•When the 4WD control switch is shifted to positions other
than L range
Although DAC system operation at the time of the following
conditions, DAC indicator is blinked and the thing of cautions is
alert the driver
•Transmission shift lever is shifted to “N” position
•DAC switch turned OFF when the DAC system operating
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Chassis
 Brake Control System
• HAC (Hill-start Assist Control) System
– Overall
 When starting to move up the hill slope, the
system prevents the vehicle from rolling
backward in the interval while change the
pedal operation from
brake pedal to
accelerator pedal

Brake is applied to stop

the vehicle slope off
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Chassis
 Brake Control System
• HAC (Hill-start Assist Control) System
– Operating condition
(All the following conditions are cleared)
Slip Indicator
Blinking and
Shift Position Vehicle Speed
Buzzer Sound
“D, 4, 3, 2 or L” > 0 km/h

Each wheel Brake

rotation opposite Control
NOTE: to vehicle moving
Slow Back
Do not operate “R” position
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Chassis
 Brake Control System
• Active TRC
– If the tires start to spin, an effect similar to LSD
(Limited Slip Differential) is obtained by
applying the brake

Click!
Movie
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Chassis
 Brake Control System
• Active TRC
– In this system, the center differential does not
need to be locked as compared with the
conventional 4WD vehicle, and smooth
cornering is realized (without tight corner
braking phenomenon)

– High traction
performance
(same as 4WD)
– Smooth handling
(same as 2WD)
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Chassis
 Steering
• Overall
– Internal-external tube bushings has been
adopted to facilitate a natural steering feeling

Internal-external
Tube Bushing
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Chassis
 Steering
• Variable Gear Ratio Type Rack Bar
– Gear ratio near the end position of the rack bar
is shorter than near the neutral steering position

Neutral Position
End
Position

Steering Stroke Ratio

Hollow Type
Steering Rack Bar
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Chassis
 Steering
• Specification

Item New Model Previous Model

Gear Ratio (Overall) 15.8 20.0
No. of Turns Lock to Lock 3.04 3.54
Fluid Type ATF Type DEXRON® II of III 