An Experimental Method for Determining Synchronizer Loads for 4WD Transfer Cases

The main objective of modern synchronizer design for part-time four-wheel drive transfer cases is to enable smooth and reliable shifting performance with a minimum of driver effort. One of the primary challenges faced by designers is obtaining maximum synchronizing torque and energy capacity while minimizing complexity and cost. In order to meet these requirements, an in-depth understanding of the varying torque and energy loads imposed by the vehicle's front driveline components is required. This paper presents a method for experimentally determining these varying loads and describes their significance in transfer case synchronizer design.