sensor SSANGYONG MUSSO 2003 Service Manual

AUTOMATIC TRANSMISSION 5A-65
If the gear lever is incorrectly adjusted, the transmission may shift gears on bumpy road surfaces.
6 Transmission Oil Temperature Sensing FaultAll shifts will be firm until the transmission has warmed up, because a high transmission oil temperature is
assumed.
If a fault is undetected, the temperature is likely to be evaluated as being lower than actual, resulting in softer shifts with ‘end bump ’ (very firm feel at the end of the shift).
7 Mode Setting Fault All shifts will occur as if the mode is set to ‘NORMAL ’ .
The mode indicator will always be off indicating that ‘NORMAL ’ mode is selected.
The mode indicator will not respond to changes in switch setting.
If a fault is undetected, the mode as indicated by the mode indicator is not likely to respond to the mode switch.
8 Battery Voltage Sensing Fault
If the battery voltage is low then shifts to first gear are inhibited.9 the battery voltage is high (>16.5V) then the transmission goes into limp home (LHM) mode.
If a fault is undetected, the transmission is likely to incorrectly evaluate an ON/OFF solenoid fault resulting in limp home mode (LHM) operation.
9 ON/OFF Solenoid Fault (Solenoids 1,2,3 and 4)
The transmission adopts its limp home mode (LHM) operation, described above. However, if solenoid 1 is faulty then
the fourth gear LHM strategy will be adopted independent of vehicle speed.
If a fault is undetected, the operation of the transmission is dependent on which solenoid is actually faulty. The
characteristics for different solenoid fault conditions are listed in table 6.1.2.
10 ON/OFF Solenoid Fault (Solenoids 6,7)
If solenoid 6 is found faulty it is always disabled resulting in high line pressure being applied continuously.
If solenoid 7 is found faulty it is disabled resulting in the transmission being locked always.The transmission does not go into LHM.
11 Variable Pressure Solenoid Fault The transmission adopts its LHM operation.
If a fault is undetected, the transmission shift feel is likely to be poor for all shifts.
12 Software Fault
The transmission adopts the third gear LHM strategy of operation, independent of vehicle speed. The operation of
the TCU under this condition is difficult to predict. Its operation may be erratic.
If a fault is undetected, the operation of the TCU is likely to be erratic.
13 Power Supply Fault
The transmission adopts the third gear LHM strategy of operation, independent of vehicle speed. If there is an
intermittent power supply connection, the TCU will power-up in fourth gear and then shift to the appropriate gear to
satisfy the conditions present. The power supply is not monitored for fault evaluation.
All faults except for solenoid faults can be recovered without having to turn the TCU off and back on. However, in
general the recovery requires that no faults are present for a period of time (approx. 3 or 30 seconds). Recovery from
a fault will not clear the fault from the keep alive memory
14 Transmission Sump Temperature Exceeding 135°C
The converter lockup clutch will be applied at lower speeds, causing a shudder through the vehicle.
The mode indicator will flash in some vehicles.
These faults can be due to the transmission oil overheating or due to an incorrect signal received from the temperature
sensor.

AUTOMATIC TRANSMISSION 5A-67
Table 6.1.3 - Diagnostic Trouble Messages
Description / Cause
There have been no faults recorded since the TCU was last cleared. If
the fault history has never been cleared, then there have been no
faults recorded since the TCU was originally powered up.There is an internal fault within the TCU.
The voltage measured by the TCU corresponding to the battery sup-
ply voltage has been outside the range of the maximum operatingvoltage of 16.5 volts.
The minimum operating voltage depends on the transmission tem-
perature but is typically between 8-9 V for a warm transmission.
The voltage measured by the TCU from the throttle potentiometer has been outside acceptable levels.
This would typically indicate a loose connection in the wiring to, or
within, the throttle sensor which has caused the signal at the TCU to
read 0V or 5V.
The voltage measured by the TCU across the temperature Input ter-
minals has been outside acceptable levels.
This would typically be caused by a loose connection or short to ground
in the wiring to, or within, the temperature sensor which has caused
the signal at the TCU to read 0V or 5V. The voltage measured by the TCU across the shift lever input termi- nals has been outside acceptable levels for a significant length of
time. This would typically be caused by a loose connection or short to
ground in the wiring to, or within, the inhibitor switch which has caused
the signal at the TCU to read 0V or 5V.
The signal from the ignition, of ignition pulses, has either been non- existent or has been unreliable.
There are two reasons this fault could occur. The first is due to a lack
of ignition pulses when other TCU inputs would indicate that the en-
gine is running, that is the gear lever is in a driving position, the throttle is applied and vehicle speed increasing. The second cause of this (aunt is the frequency of the pulses of theignition pulse input to the TCU indicate an unachievable engine speed.
The pulses from the shaft speed sensor have either been non-exis-tent or have been unreliable.
There are three reasons this fault could occur. The first is due to a sudden loss of speedometer pulses at a time when they were fre quent,thus indicating an unachievable degree of deceleration of the drive
line. The second cause of this fault is that the frequency of the pulses
on the shaft speed sensor input to the TCU indicate an unachievable
propeller shaft speed. The third is the presence of a high engine speed
in a driving gear with no speedometer pulses.
Condition
Test Pass
Transmission Control Module Fault
Battery Voltage InputFault Throttle Input Fault
Temperature Input FaultShift Lever Position Input Fault(Inhibitor/PRNDL Switch) Engine Speed Sensor Fault Shaft Speed Sensor Fault(Speedo Sensor)Solenoid 1 2 3 4567 8

AUTOMATIC TRANSMISSION 5A-73
Table 6.2.3 - Shift Quality Faults
Action
Check the resistance. Replace the inhibitor
switch as necessary.
Inspect and replace the sensor as necessary.
Inspect and adjust the band as necessary.Inspect and replace the ’0’rings as necessary.
Inspect, repair or replace S5 as necessary.
Inspect, repair or replace S1 or S4 as neces-
sary.
Inspect, repair or replace the BAR as neces-
sary.
Inspect and repair as necessary.
Inspect and clean CCCV.
Inspect, repair or replace as necessary.
Possible Cause
Faulty inhibitor switch.
Faulty throttle position sensor. Incorrect front band adjustment.Damaged front servo piston ’0’rings.
Faulty or damaged variable pressure so- lenoid (S5). Faulty S1 or S4 solenoid. Faulty band apply regulator valve (BAR). Misassembled front servo return spring. Jammed converter clutch control valve(CCCV).Faulty solenoid 7.Symptom
Harsh 1-2 shift stalls when Drive
or Reverse selected Shudder
on Rolldown

AUTOMATIC TRANSMISSION 5A-75
SELF DIAGNOSIS TEST
1. Turn the ignition switch to “OFF ” position.
2. Connect the scanner harness connector to the engine compartment diagnosis socket.
3. Turn the ignition switch to “ON ” position.
4. Select “Electronics control vehicle diagnosis ” from the
function selection display and press “Enter ”.
5. Select “Musso(98 face lift) ” from the vehicle model selection
model selection display and press “Enter ”.
6. Select “Transmission control unit(TCU) ” from the control
system selection and press “Enter ”.
7. Select “Self-diagnosis ” from diagnosis items.
Notice
Check sensor output value displays if necessary.
8. Determine the fault code and check the detective Items. NoticeRefer to sefadf3fnosfs list.

5A-76 AUTOMATIC TRANSMISSION
Action
Check cable for open / short.
Check connection of other connectors.
Check voltage between terminal 27 and 29 of TCU,
- Standard value : 0.2 - 4.7V
Check TPS.
Check cable for open / short.
Check connection of other connectors.
Check engine speed sensor.
Check resistance between terminal 8 and 24 of TCU (when the connector is disconnected).
- Standard value : 1 .9 - 0.2 k
Check cable for open / short.
Check connection of other connectors.
Check vehicle speed sensor.
Check cable for open / short.
Check connection of other connectors.
Check engine speed sensor.
Check inhibitor switch resistance between terminal 34 and 37 of TCU(when the connector is disconnected).
- Standard value : 1st gear - 4 - 4.4 k
2nd gear - 4,8 - 2.2 k
3rd gear - 3 - 3.4 k
D gear - 4.5 - 4.g k
N gear - 6.8 - 7.2 k
R gear - 10.8 -11.2 k
P gear - 18.6 - 19 k
Check voltage between terminal 31 and 37 of TCU.
- Standard value : 0-5V(P,R,N,D,L)
Check cable for open / short.
Check connection of other connectors.
Check mode switch.
Check condition between terminal 1 and 13 of TCU.
Winter mode :12V, Normal mode : Open status, Power mode : 0V
Check cable for open / short.
Check connection of other connectors.
Check voltage between terminal 32 and 38 of TCU.
- Standard value : 0-5V
Check oil temperature sensor.
Check cable for open / short.
Check connection of other connectors.
Check battery condition.
Check alternator.
Possible Cause
Throttle position sensor
Engine RPM
Vehicle speed Shift lever
W, E, P mode switch T/M oil temperature Battery voltage
Symptom
P1702 P1703 P1704 P4705 P1706 P1707P1708
Self-diagnosis List

AUTOMATIC TRANSMISSION 5A-77
Action
Check cable for open / short.
Check connection of other connectors.
Check voltage between terminal 4 and 11 of TCU.
- Standard value : when the A/C compressor is ON : 12V
when the A/C compressor is OFF : 0V
Check cable for open / short,
Check connection of other connectors.
Check voltage between terminal 1 and 12 of TCU.
- Standard value : when the kick down switch is ON : 12V
when the kick down switch is OFF : 0V
Fully depress accelerator pedal for 5 seconds(ignition key is ON).
Release accelerator pedal.
Depress brake pedal and start the engine in ‘P’ position.
Depress brake pedal and idle the engine for 5 seconds in ‘D’
position.
Shift into ‘D’ position and determine fault code for throttle initial-
ization.
Complete the initialization.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 1 and 34 of TCU(when theconnector is disconnected).
- Standard value : 26 - 30
Check solenoid.
Check cable for open / short.
Check connection of other connectors,
Check resistance between terminal 1 and 40 of TCU (when theconnector is disconnected).
- Standard value : 26 - 30
Check solenoid.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 1 and 41 of TCU (when theconnector is disconnected).
- Standard value : 26 - 30
Check solenoid.
Check cable for open / short.
Check connection of other connectors.
Check resistance between terminal 1 and 33 of TCU (when theconnector is disconnected),
- Standard value : 26 - 30
Possible Cause
Air conditioner switch
Kick down switch Pedal
Vehicle ID
VPS offset
Throttle position sensor
initialization
Solenoid 1 Solenoid 2Solenoid 3Solenoid 4
Symptom
P1710 P1712P1713 P1714P1715P1716 P1733 P1734P1735 P1736

5A-82 AUTOMATIC TRANSMISSIONMAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Tightening Torque 70 - 80 Nm
5. Remove the rear propeller shaft .
Installation Notice
REMOVAL & INSTALLATION OF TRANSMISSION
1. Disconnect the negative battery cable.
2. Disconnect the connectors from transfer case.
3. Disconnect the speedometer connector from transfer case.
4. Disconnect the inhibitor and Sear position sensor connector.
6. Unscrew the eight bolts and two nuts, and remove the cross member.

TRANSFER CASE (PART TIME 4408) 5D1-3
Cannot Front Wheel Drive when Shifted 4H,4LDIAGNOSIS
Electric Shift Problems
Action
Overhaul and check, replace if necessary. Overhaul and check for wear and damage.
Replace if necessary.
Check sliding parts, replace if necessary.
Checks
Faulty or Damaged TCCU, Speed Sensor, Motor, Clutch or Internal Wirings Damaged or Worn Shift Cam, Hub, Fork and Rail Shift Binding Shift Fork, Hub Collar or Gear
Checks
Broken Drive Chain Action
Check sliding parts, replace if necessary.
Noise in 4WD Operation
Checks
Improper or low oil Loosened bolts or mounted partsNoisy T/C bearing Noisy gears Action
Drain and replace with specified oil. Retighten as specified.Disassemble bearings and parts and check for wear or
damage. Replace if necessary. Check for wear and damage including speedometer
gear, replace if necessary.
Noise in 4H or 4L
Checks
Worn or Damaged Sprockets or Drive Chain
Incorrect Tire Pressure Action
Disassemble and check for wear and damage, replace
if necessary. Adjust tire pressure.
Transfer Case Oil Leakage
Action
Replace the case. Clean case and parts and check for leakage.
Remove breather hose and clean, replace if necessary.Use specified oil and adjust oil level.Retighten Use specified sealant and retighten. Replace
Checks
Cracked Transfer CaseLeakage from Other PartsBreather CloggingImproper or too much OilLoosened Sealing Bolts Improperly Applied Sealant Worn or Damaged Oil Seal

5D1-4 TRANSFER CASE (PART TIME 4408)SELF-DIAGNOSIS
SYSTEM DESCRIPTION
1. TCCU detects transfer case system malfunctions and indicates malfunctioning part(s) through flashing 4H,4L indicator lights.
Using a service connector, connect it to the diagnosis box in the engine room and read the flashing of the ‘4WD
CHECK ’ indicator light.
The flashing indicator light will show you defective code(s).
2. Identify 7 defective codes after reading the flashing indicator light.
TCCU
Shift motor
Magnetic synchronizer clutch
Speed sensor
Hub solenoid
Selector switch
Motor position sensor
3. Transfer case system is malfunctioning when: 4H ,4L indicator lights are remain on after 0.6 second when turning the ignition switch ‘ON ’
4H,4L indicator lights are continuously come on during driving.
4. If only 1 part is malfunctioning, ‘4WD CHECK ’ indicator light
will display defective code 3 times continuously.
5. If more then 2 part is malfunctioning, the first malfunctioning part will be displayed 3 times and following malfunctioningparts will be displayed .
6. To read defective code, connect the service connector and turn the ignition switch 'ON'.
7. After repairing, eliminate the defective code stored in the TCCU. NoticeBefore replacing the malfunction parts with defective code, check the wires and connectors for proper condition.

5D1-6 TRANSFER CASE (PART TIME 4408)
Diagnostic Table
Connect a service connector. If turn the ignition switch ‘ON ’
‘ 4WD CHECK ’ indicator light will come on for 0.6 second and
turn off for 3 seconds and then display a defective code 3
times continuously.
No. Defective Code
Malfunctioning Part
1
2 3 4
5 TCCU
Shift Motor
Synchronizer Clutch
Speed SensorHub Solenoid
4WD CHECK Light ON OFF
Defective Code
4WD CHECK Light ON OFF
Defective Code
4WD CHECKLight ONOFF
Defective Code
4WD CHECKLight ONOFF
Defective Code
4WD CHECK Light ONOFF
Defective Code