SSANGYONG MUSSO 2003 Service Manual

5D2-12 TRANSFER CASE (TOD)Pin1 2345 6 78
Function
Motor HI-LO Motor LO-HI EMC
Battery (+)
Ignition
Position Return
Diagnosis Display - Pin
9
10 11
1213 14 1516 Function
HI / LO Switch Position 2
Front Speed
TPS Supply (Diesel) Speed/TPS Return
Motor HI-LOMotor LO-HI
Speed Reference Pin
1718192021 22 2324 Function
GroundGround
Battery (+) K-LINE
4L Illumination
CAN-HCAN-L
Auto T/M, Neutral Pin
2526272829 30 - - Function ABS Input
Brake Switch
Position 1 Position 3
Rear Speed
Position 4 --
TOD CONTROL UNIT
Shape and function of TOD Control Unit

TRANSFER CASE (TOD) 5D2-13
Speed Sensor/Clutch Coil and Motor Connector Speed senso /clutch coil and shift motor connector locate upper backside transfer case (upper part of shift motor).
- Shift motor connector : Black
- Speed sensor and clutch coil connector : White
Shift Mtor Connector Speed Sensor/Clutch Coil ConnectorRear View for Connector
Pin A B
CD
EF
G Function
Position 4Motor (Counter-Clockwise)Position 3Position 2 Position 1 Position RetumMotor (Clockwise) Pin
HI
J
K L
M N Function
Clutch Coil (EMC) Front Speed ReturnFront SpeedFront Speed Sensor Supply Rear Speed Sensor Supply Rear SpeedRear Speed Return
Rear View for Connector

5D2-14 TRANSFER CASE (TOD)


Motor HI-LO(clockwise)
Motor LO-HI(counterclockwise)
PIN 13
CONTROL UNIT DIAGRAM
TOD CONTROL UNIT
14

TRANSFER CASE (TOD) 5D2-15
DIAGNOSIS
While the TCCU is active it periodically monitors its inputs and outputs. If a fault is detected the “4WD CHECK ” lamp
is illuminated and a fault code is stored in the TCCU memory.
When requested, fault codes are downloaded to a diagnostic connector (K-line) serial communications using SCAN- 100. DIAGNOSTIC TESTS 1.TCCU Internal Function
When the Ignition is turned on the TCCU tests its ROM and RAM. If there is a fault, the TCCU immediately resets itself and re-tests the ROM and RAM. If the fault persists the TCCU continues to reset and re-test until the fault is corrected or the ignition is turned off. All TCCU functions are inhibited until the fault is corrected. The “4WD
CHECK ” lamp is not illuminated if there is a ROM or RAM fault.
If the ROM/RAM passes the EEPROM memory is tested. If there is a fault the “4WD CHECK ” lamp is illuminated
and the TCCU continues to operate using the default calibration data stored in ROM. Fault codes are not storedwhen there is an EEPROM fault.
An EEPROM fault can only be cleared by cycling ignition off-on.
2.Shift Motor Assembly Test If the TCCU detects a shift motor or position encoder fault continuously for one second the ‘4WD CHECK ” lamp is
turned on and the appropriate fault code is stored in memory.
a. A shift motor fault when the motor is off is defined as follows:
Motor H-L shorted to GroundMotor L-H shorted to GroundMotor open circuit
b. A shift motor fault when the motor is energized is defined as follows: Motor H-L shorted to GroundMotor L-H shorted to GroundMotor H-L shorted to Motor L-H Motor open circuit
c. A position encoder fault is defined as follows: Any position code which does not correspond to the valid 9 codes. A short to ground on any of the encoder lines.
d. If no shifts are in progress when a failure occurs the TCCU will not respond to any shift commands.
e. If a shift command has been received, but not acted upon when a failure occurs the TCCU will cancel the command and not respond to any subsequent shift commands.
f. If a shift command is in progress when an invalid position code is confirmed it will be halted and the TCCU will turn the motor toward the high position. Afterwards the TCCU will not respond to any shift commands.

5D2-16 TRANSFER CASE (TOD)g. If the shift motor/position encoder assembly failure (other than a motor failure which occurs when the motor isenergized) recovers continuously for one second the TCCU will function normally. The “4WD CHECK ” lamp is
turned off but the fault code will remain in memory.
h. A motor failure (i.e. open or short circuit) which occurs when the motor is energized can only be cleared by cycling the ignition off-on.
3. Front Speed Sensor Test If a Front Speed Sensor fault is detected continuously for 0.5 second the “4WD CHECK ” lamp is illuminated. The
TCCU then responds as follows:
a. If the system is in High Range the TCCU uses the Rear Speed Sensor to determine the EMC Touch Off level and wheel slip control is suspended.
b. If the system is in Low Range, the EMC Duty Cycle is set to maximum (independent of vehicle speed) until the system is shifted out of 4L.
c. All Electric Shift activity is halted until the Ignition is cycled. If a shift is in progress it will be completed.
If the Front Speed Sensor recovers continuously for O.5 second the TCCU will function normally. The “4WD
CHECK ” lamp is turned off but the fault code will remain in memory.
4. Rear Speed Sensor Test If a Rear Speed Sensor fault is detected continuously for 0.5 second the “4WD CHECK ” lamp is illuminated. The
TCCU then responds as follows:
a. If the system is in High Range the TCCU uses the Front Speed Sensor to determine the EMC Touch Off level and wheel slip control is suspended.
b. If the system is in Low Range, the EMC Duty Cycle is set to maximum (independent of vehicle speed) until the system is shifted out of 4L.
c. All Electric Shift activity is halted until the Ignition is cycled. If a shift is in progress it will be completed.
If the Rear Speed Sensor recovers continuously for 0.5 second the TCCU will function normally. The “4WD
CHECK ” lamp is turned off but the fault code will remain in memory.
5. Both Speed Sensor Faulty If both the Front and Rear Speed Sensors are faulty continuously for 0.5 seconds the “4WD CHECK ” lamp is
illuminated. The TCCU then responds as follows:
a. If the system is in High Range the TCCU sets the EMC Touch Off level based on a vehicle speed of 0 and wheel slip control is suspended.
b. If the system is in Low Range, the EMC Duty Cycle is set to maximum until the system is shifted out of 4L.
c. All Electric Shift activity is halted until the Ignition is cycled. If a shift is in progress it will be completed.
If both Speed Sensors recover continuously for 0.5 second the TCCU will function normally. The “4WD CHECK ”
lamp is turned off but the fault code will remain in memory.
6. EMC Test The EMC is tested for open circuit or short circuit to ground. If a fault is detected continuously for 0.8 second the “4WD CHECK ” lamp is turned on and all TOD TM
activity is halted.
If the EMC recovers continuously for 0.8 second the TCCU will function normally. The “4WD CHECK ” lamp is
turned off but the fault code will remain in memory.

TRANSFER CASE (TOD) 5D2-17
ClassificationTCCU
EMC
Speed Sensor
Shift Motor
Position Encoder
DIAGNOSTIC TROUBLE CODES (DTC
’s)
1. Diagnostic Trouble Code Retention The first time a fault is detected a DTC is stored in the TCCU ’s
Non-Volatile memory. This DTC will remain in memory until the TCCU is instructed to erase DTC ’s by SCAN-100. DTC ’s
will not be erased by disconnecting power to the TCCU.
2. Diagnostic Trouble Code AssignmentsCode 1714 171517161721 1722 1731173217331734 1735 173617411742 1743 1750175117521753 1754 Description
EEPROM Checksum Fault TPS Loss of Signal
TPS Out of Range
EMC Open / Short to Battery
EMC Short to ground
Front Speed Sensor Voltage Low
Front Speed Sensor Voltage High
Rear Speed Sensor Voltage Low
Rear Speed Sensor Voltage High
Speed Sensor Reference Voltage Low
Speed Sensor Reference Voltage High Motor Open / Shorted to Battery
Motor Output Shorted to Ground
Shift System Timeout
General Position Encoder Fault (Invalid Code) Position 1 Shorted to Ground Position 2 Shorted to GroundPosition 3 Shorted to Ground Position 4 Shorted to Ground

5D2-18 TRANSFER CASE (TOD) CODING
Coding Tool SCANNER
Connection of Coding Tool Construct SCANNER into diagnosis connector (20 pins) near fuse box in engine room as below figure.
1 Diagnosis Connector2 SCANNER
Notice Coding ; An input activity of data for the proper performance by matching specification, devices andsystem with control unit.

TRANSFER CASE (TOD) 5D2-19
ClassificationEngine Type
Transmission/Vehicle Type Axle Ratio
Tire Size
Coding Required
1. Replacement of TOD control unit.
2. Adjustment by input error.
3. Change of tire specification.
Items
Gasoline Engine (E32) 661 Diesel Engine
661LA Diesel Turbo Engine
662 Diesel Engine
662LA Diesel Turbo Engine Manual Transmission
Automatic Transmission MUSSO
KORANDO 3.734.554.895.38 5.86
P215 P235P255P275
Coding Method
1. Check and record engine type, axle ratio and tire size.
2. Ignition “OFF ”.
3. Connect SCANNER with diagnosis connector in engine room.
4. Ignition “ON ”.
5. Read the current memorized specification in TOD control unit.
6. Compare memorized specification with the checked record. If not matched, perform a coding.
7. Read again memorized coding specification in TOD control unit for confirmation of coding.
8. Check coding specification whether it matches with vehicle or not. If not, perform a coding again.
Coding items

5D2-20 TRANSFER CASE (TOD)
ELIMINATE THE MEMORIZED FAULT CODE When diagnose by SCANNER, it is required that you make adequate service on defects against all fault codes. And thenyou should delete the memorized fault codes in TOD control unit using SCANNER as follows;
1. Connect SCANNER with diagnosis connector.
2. Select “trouble code clear ” in SCANNER.
3. In “trouble code clear ” screen, press “enter ” key to erase
the fault code.
4. Confirm deletion of fault code and, if not, repeat 2.-3. process.

TRANSFER CASE (TOD) 5D2-21
DIAGNOSIS Malfunction interior TOD control unit ; fault code 1714
Phenomenon
1. When ignition “ON ”, “4WD CHECK ” lamp illuminates
continuously.
2. On diagnosis by SCAN-100, it displays fault code “1714 ”.
Cause ; Error of EEPROM checksum in TOD control unit
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check power supply for TOD control unit. 1. Disconnect 30 pin connector from TOD control unit.
2. Ignition “ON ”.
3. Using multi-tester, measure voltage between pin 5(+)
and 17/18 (-). - Specified value - Measured value is within specified range ? 11-14 Vdc
Ye sNo Perform A2 stagePerform A3 stage
Check connection status in TOD control unit connector.
1. Check connection status.
- Is it connected exactly?
2. In case of mal-connection, connect tightly then perform the follows.
a. Delete fault code using Scan-100.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by Scan-100.
- Does it display fault code “1714 ”? Ye s
No
Ye s No
Check short of 10A fuse (fuse No.20).
1. Detach No.20 fuse from engine room fuse box.
2. Check the existence of short.
- Is fuse normal? Yes
No
Check ground of TOD control unit.
1. Ignition “ON ”.
2. Check voltage between 4/19 (+) pin and 17/18 (-)
using multi-tester (keep connection status).
- Specified value (battery is good)
- Measured value
3. Check short between 17/18 pin and body after disconnect 30 pin connector.
- Is resistance " "? 12Vdc (battery
voltage)
Ye s
No
Ye sNo
A1 A2 A3 A4
Perform A3 stage Perform A2 stage Perform A3 stage Normal system Perform A4 stage Replace fuse, then perform A1 stage Perform A4-3 stage Replace TOD controlunit Repair ground wiring Ground is O.K., perform A5 stage