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- 2025 Bronco Sport Badlands Sasquatch
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I was reading MY2025 tech documents. I asked ChatGPT to make it more in a forum format.
I think it's cool the AWD design Ford & Dana come up with especially all the mitigation that when through to save fuel or predict wheel slip!
Here's the summary:
Technical Analysis of the Bronco Sport Twin-Clutch AWD System
Overview
The Bronco Sportâs All-Wheel Drive (AWD) systemâspecifically on models with the Twin Active Torque Coupling Differentialâdemonstrates a thoughtfully engineered solution that balances traction, fuel efficiency, and dynamic handling. This is a front-wheel drive (FWD) biased, fully active AWD system capable of predictive torque transfer based on road conditions, driver input, and vehicle dynamics.
Key Components
1. Power Transfer Unit (PTU)
2. Rear Drive Unit (RDU) â Twin Active Torque Coupling
System Operation
Predictive and Reactive Control
Additional Features
Trail 1-Pedal Drive (T1PD)
The Bronco Sportâs Twin-Clutch AWD system is a well-balanced integration of mechanical efficiency and intelligent control. The ability to predict and seamlessly apply rear torque, disconnect the PTU for efficiency, and calibrate each component for consistent behavior highlights a mature, refined AWD strategy. It brings many of the benefits of full-time AWD and part-time 4WD without the compromises of either, making it a standout for vehicles in this class.
I think it's cool the AWD design Ford & Dana come up with especially all the mitigation that when through to save fuel or predict wheel slip!
Here's the summary:
Technical Analysis of the Bronco Sport Twin-Clutch AWD System
Overview
The Bronco Sportâs All-Wheel Drive (AWD) systemâspecifically on models with the Twin Active Torque Coupling Differentialâdemonstrates a thoughtfully engineered solution that balances traction, fuel efficiency, and dynamic handling. This is a front-wheel drive (FWD) biased, fully active AWD system capable of predictive torque transfer based on road conditions, driver input, and vehicle dynamics.
Key Components
1. Power Transfer Unit (PTU)
- Function: Transfers torque from the front-wheel drive system to the rear driveshaft.
- Features:
- Dog clutch and fork for on-demand engagement/disengagement.
- Reversible DC actuator motor.
- Gear reduction drive.
- Oil cooler and temp sensor (optional).
- Modes:
- Connected: Engaged by default at every key cycle; driveshaft spins.
- Disconnected: Disengaged to reduce parasitic drag when AWD isn't needed.
- Connecting/Disconnecting: Transitional states using clutch speed matching and actuator motor.
2. Rear Drive Unit (RDU) â Twin Active Torque Coupling
- Function: Electronically modulates torque distribution to each rear wheel.
- Components:
- Dual brushless DC actuator motors (A and B).
- Multi-plate clutch pack.
- Ball ramp system for torque application.
- Speed sensor and angular position feedback.
- Modes:
- Economy Mode: Clutch open, no torque to rear axle (FWD only).
- Connect Mode: Light clutch preload ('kiss point') to synchronize axle speed.
- Torque Mode: Full torque transfer based on AWD module commands.
System Operation
Predictive and Reactive Control
- The AWD module monitors sensors (wheel speed, yaw, throttle, steering, etc.) and predicts the need for AWD.
- Torque is preemptively sent to the rear before slip occursâcritical for maintaining control in low-traction situations or during aggressive handling.
- Updates occur every 10ms, ensuring real-time responsiveness.
- PTU and RDU Heat Protection Modes:
- AWD torque is reduced or disconnected to prevent component damage.
- The system uses thermal models or physical sensors to monitor temps.
- Messages like "AWD Temporarily Disabled" inform the driver of protective action.
Additional Features
Trail 1-Pedal Drive (T1PD)
- Uses the ABS and hydraulic braking system to simulate engine braking and assist in low-speed crawling.
- Ideal for rock crawling or steep descents, eliminating the need for left-foot braking.
- RDU clutch characteristics are barcoded and must be programmed into the AWD module for correct torque calibration.
- Prevents mismatched behavior when components are replaced, maintaining system integrity.
- FWD Bias: The system defaults to FWD for fuel efficiency.
- Engagement Time: Approximately 100â150 ms for PTU clutch to engage.
- Seamless Operation: Designed to eliminate wheel speed differences on launch and provide smooth torque transitions without driveline shock.
- While some driveline shock is theoretically possible with dog clutch engagement, Fordâs system synchronizes rotation speeds during Connecting Mode, reducing wear and shock load.
- The ball ramp system adds a mechanical advantage, amplifying torque application through clutch pack engagement without large electrical current demand.
- Tire Matching: Mismatched tires or prolonged use of a compact spare disables AWD functionality to protect components.
- Service Awareness: Technicians must reprogram the AWD module with new RDU barcode data to prevent drivability issues or component wear.
The Bronco Sportâs Twin-Clutch AWD system is a well-balanced integration of mechanical efficiency and intelligent control. The ability to predict and seamlessly apply rear torque, disconnect the PTU for efficiency, and calibrate each component for consistent behavior highlights a mature, refined AWD strategy. It brings many of the benefits of full-time AWD and part-time 4WD without the compromises of either, making it a standout for vehicles in this class.
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