ECU SSANGYONG MUSSO 2003 Manual Online

AUTOMATIC TRANSMISSION 5A-123
23. Holding the separator plate to the upper valve body toprevent the check balls from falling out, install the upper
valve body on the lower valve body. Install all screws finger tight then tighten the screws to specification in the
prescribed sequence. Refer to figure 8.58.
24. Install solenoids 1,2,3,4 and 6. Ensure the solenoid is firmly secured by the retainer and that the screw is tightened to specification.
25. Install solenoid 5. Ensure that the solenoid is pushed firmly into the valve body by the retainer. NoticeThe wiring loom ground wire eyelet terminal is secured
beneath the solenoid retainer.
26. Install the line pressure relief valve, tapered end first, (refer to figure 8.59), and the spring and disc. Secure with theretaining pin.
Figure 8.58 - Tightening Sequence Upper to Lower Valve Body
Figure 8.59 - Line Pressure Relief Valve

AUTOMATIC TRANSMISSION 5A-125
30. Align the valve body assembly on the transmission caseand install the manual valve lever to manual valve link. Fit
the long end of the link to the manual valve first. Install the
securing bolts and tighten to specification in the specified
sequence. Refer to figure 8.61.
31. Check the alignment of the detent roller and the manual lever quadrant.
32. Connect the solenoid wiring as detailed below: Solenoid 1 - red
Solenoid 2 - bIue
Solenoid 3 - yellow
Solenoid 4 - orange
Solenoid 5 - green
Solenoid 6 - violet (Refer to figure 8.62.)
Notice All hardware must be correctly installed and torqued to specification.
Figure 8.61 - Tightening Sequence Valve Body to Case

5A-126 AUTOMATIC TRANSMISSION
Oil Filter and Pan Assembly Notice
1. Replace the filter whenever rebuilding a transmission where a significant amount of mechanical damage hasoccurred.
2. To aid the assembly of the pan gasket, use a small amount of Vaseline at the pan/gasket interface. This ensures that the gasket remains on the pan ridge. Do not over torque pan bolts as this may distort the pan and cause leaks.
3. Ensure that the internal line pressure plus in the valve body is fitted.
To assemble the oil filter and pan assembly (refer to figures 8.63 and 8.64), proceed as follows.
1. Lubricate the oil filter sealing ring with automatic transmission fluid.
2. Carefully assemble the oil filter to the valve body. The spigot must not lean on one side while being fitted. Refer to figure 8.63.
3. Secure the oil falter assembly with the retainer.
4. Check that the magnet is located in the dimple in the comer of the oil pan.
5. Assemble the gasket on the pan lip. The gasket must be free of any distortion when installed.
6. Fit the oil pan assembly to the transmission case and tighten the securing bolts to specification and sequence (refer to figure 8.65). Do not over torque.

AUTOMATIC TRANSMISSION 5A-127
Torque Converter and Housing Assembly
To assemble the torque converter and housing assembly, proceed as follows.
1. Locate the torque converter housing on the transmissionmain case.
2. Install and tighten the securing bolts to specification. NoticeAll the hardware must be correctly installed and torqued to specification.
3. Fit the converter ensuring that the tangs are engaged in the pump gear. Ensure that the tangs do not contact thepump seal.
Figure 8.1 - Torque Specifications
Torque Specifications
Torque converter housing to case Extension housing to case Rear servo coverPan to caseInhibitor switch to caseCooler connectors
Transmission filler plug Output flange lock nut (RWD models)Centre support to caseCam plate to case (parking pawl)
Valve body to case Upper valve body to lower valve bodyON/OFF solenoid retainers
Variable pressure solenoid retainerLine pressure plug Detent spring Pump cover to casePump cover plate to pump coverPump to pump adaptorPump cover plate to crescent Adaptor to case N

m
54 - 68 54 - 6825 - 35 4 - 6
2.3 - 3.4 30 - 3530 - 35
100 - 110
20 - 27 16 - 228 - 13
11 - 16 8 - 12 8 - 12
4 - 7
20 - 2224 - 3413 - 1624 - 27 13 - 16 25 - 35

TRANSFER CASE (TOD) 5D2-23
Error of signal in engine throttle position ; fault code 1715, 1716
Phenomenon
1. Upon diagnosis by SCAN-100, it display on 1715,
1716 codes.
Cause
1. Bad communication line between E/G ECU and CAN.
2. Defect of TOD control unit.
3. Defect of E/G ECU.
Check connection status of connector through CAN communication line.
1. Check connection of connector.
- Does connector connect correctly between TOD
control unit and E/G ECU?
2. In case of bad connection, connect correctly then
perform the follows ;
a . Delete the memorized fault code using SCANNER.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by SCANNER.
- Does it display fault codes “1715 ” or “1716 ”. Ye s
No
B1
Ye sNo
Check connection status of CAN communication line towards E/G ECU.
1. Ignition “OFF ”.
2. Disconnect 30 pin connector towards TOD control unit.
3. Measure resistance between pin No.22 and 23 in wiring connector using multi-tester.
- Specified value
- Measured value is within specified range?
B2
115-125
Ye s
No
Check connection status of CAN communication line towards TOD control unit.
1. Ignition “OFF ”.
2. Disconnect coupling of E/G ECU (gray, 1-60 pin).
3. Measure resistance between pin No.37 and 38 in coupling using multi-tester.
- Specified value
- Measured value is within specified range?
B3
115-125
Ye s
No
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Perform B2 stage Perform B1-2 stage Perform B2 stage Normal system
Perform B3 STAGE Perform B4 stage, check and replace E/ G ECU
Perform B5 STAGE Replace TOD control unit

5D2-24 TRANSFER CASE (TOD)
Ye sNo
B4
B5
Ye s
No
B6 4.75-5.25Vdc
Ye s
No
B7 0.3-0.9Vdc 4.6-4.9Vdc
Ye s
No
4.6-4.9Vdc0.3-0.9Vdc Ye s
No
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check CAN communication line by diagnosis of E/G ECU.
1. Diagnose E/G ECU with SCANNER.
2. Does it display on fault code
“27 ” ?
Check power supply and signal output on throttle valve position sensor (potentiometer) 1,2.
1. Diagnose E/G ECU with SCANNER. - Fault codes : 104, 105, 108, 109, 119, 185 Does it display on above code ?
Check power supply (5V) of throttle valve position sensor.
1. Ignition “ON ”
2. Measure voltage between pin 112(+) and 84(-) keeping coupling connection status using multi - tester.
- Specified value
- Measured value is within specified range ?
Check output signal from throttle position sensor 1 and 2.
1. Keep E/G idle status.
2. Measure output voltage between pin 87 (+) and 84 (-) keeping E/G ECU coupling connection status using multi-
tester. (potentiometer 1)
- Specified value min. acc. Pedal max. acc. Pedal
- Measured value is within specified range ?
3. Measure output voltage between pin 85 (+) and 84 (-) keeping E/G ECU coupling connection status using multi-
tester. (potentiometer 2)
- Specified value min. acc. Pedal
max. acc. Pedal
- Measured value is within specified range ? Replace TOD control unit Replace throttle bodyactuator or check cable
Perform B1, B2, B3 stagesPerform B5 stage Perform B6 stage Replace TOD control unit or perform A1- A5 stages Perform B7 stage Replace E/G ECU or perform B1-2 stage after checking cable. Perform B7-3 stage Replace throttle body actuator or check cable.

5D2-30 TRANSFER CASE (TOD)
Ye sNo
Ye s No
Ye s No
E3
Ye s
No
E4
Ye s
No
E5 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check the wiring of shift motor whether it is shorted or not.
1. Turn off the ignition switch.
2. Detach the 30pin connector from TOD control unit
3. Perform short test between the wiring connector No.1/ No.14 and No.2/No.5.
- Is there resistance of 0 ?
4. Perform the short test between No.1/No.14 Connector and body, No2/No.15 connector and body.
- Is there resistance of 0 ?
5. Execute E1 stage to check whether wiring is shorted between Hi-Low motor and LOW-HI motor.
- Is the provided voltage proper ?
Check the resistance of shift motor 1. Turn off the ignition switch.
2. Measure the resistance between No.1/No.14 and No.2/ No.15 connector after detaching 30pin connector of TOD
control unit Or, check the resistance between No.G andNo.B after detaching motor connector of T/C side.
- Specified value
- Measured value is within specified range ?
Execute the test after detaching shift motor, when the faultis not solved after executing E1~E4 stage. 1. Detach the motor connector from T/C.
2. Remove the shift motor.
3. Connect motor connector with the removed shift motor.
4. Operate the 4H/4L switch. - Does motor rotate ? Hi-Low motor and Lo-Hi wiring are
shorted each other. Repair or replace.Perform E3-4 stage. Related wiring is shorted with ground.Repair or replace. Perform E3-5 stage. Perform E4 stage. Wiring is shorted. Repair or replace. The defective T/C or perform E5 stage. Replace the shift
motor.
Check and fix due to the defective T/C ass ’y.
Replace the motoror delete fault codeand rediagnosis system.

TRANSFER CASE (TOD) 5D2-31
Position incoder and position 1,2,3,4 malfunction :Fault code®1750,1751,1752,1753, 1754
Phenomenon The ‘4WD check ’ lamp can not go out when the ignition
switch positioned to ‘ON ’.
The fault code display 1750, 1751, 1752, 1753, 1754 by diagnosis of SCAN-100.
Cause The portion of position incoder malfunction, each wiring is shorted with ground.
Ye s
No
F1
Ye s No
Ye s
No
F2 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check the installation condition of connector.
1. Check the installation condition between 30 pin connector
of TOD control unit and motor connector of T/C portion.
- Is it installed properly ?
2. If the connector installation is improper, install properly and then execute follow procedure.
a. Delete the all fault code from memory by scan scope.
b. Turn off ignition switch.
c.Turn on ignition switch.
d. Rediagnosis the system.- Does the fault codes display one or more among
1750 ~ 1754. Check the each wiring whether it is shorted or not.
1. Turn off the ignition switch
2. Detach the 30 pin connector of TOD control unit.
3. Perform short test each connector, No.27 (Position 1), No.10 (Position 2), No.28 (Position 3),No.30 (Position
4), No.6 with body.
- Is there resistance of 0 ? Perform F2 stagePerform F1-2 stage Perform F2 stage Normal system Repair or replace due to wiring short
1. Replace the
motor Ass ’y due
the defectiveposition incoder portion.
2. And then, perform F1-2 stage.

5D2-44 TRANSFER CASE (TOD)
9. Remove the bolts that retain the front case to therear case. Make sure that the front case is facing downward so that the rear cover is facing upwards. Pry on the bosses and separate the front case fromthe rear case. Remove all traces of gasket sealantfrom the mating surfaces of the front case and rearcase.
10. If the speedometer drive gear is to be replaced, first remove the flange seal by prying and pulling thecurved-up lip of the flange seal. Do not damage thebearing, bearing cage or case. Remove and discardthe flange seal. Remove the speedometer drive gearand upper tone wheel.
69 Yoke to Flange Seal
75 Snap Ring
76 Bearing
77 Speedometer Drive Gear
79 Upper Tone Wheel
40 Clutch Coil
40a Clutch Coil Retaining Bolts
40b Wire
11. If the rear output shaft bearing requires replacing, removethe internal snap ring that retains the bearing in the bore. From the outside of the case, drive out the bearing.
12. Remove the three nuts and washers retaining the clutch coil assembly to the rear case. Pull the assembly, alongwith the O-ring and wire, from the case.
13. Remove bearing assembly from output shaft. Remove the clutch housing from the output shaft. Remove the balls and apply cam and wave washer from the output shaft. Remove snap ring from output shaft. Remove clutch pack assembly from output shaft.
25 Ball
26 Cam and Coil Assembly

5D2-48 TRANSFER CASE (TOD)
6. Install the front planet to the sun gear and input shaft.Install the internal snap ring to the planetary carrier.
7. Place the tanged snap ring in the case. Expand snap ring with snap ring pliers and install planetary carrier assembly. Check installation by holding the case and carefully tappingthe face of the input shaft against a wooden block to makesure the snap ring is installed.
8. Remove all traces of gasket sealant from the front case and mounting adapter mating surfaces. Install a bead ofgasket sealant on the surface of the front case.
9. Install the high-low shift fork and high-low collar as an assembly into the front planet. Notice Make sure that the nylon wear pads are installed on the shift fork and snapped securely into place.
12 Rear Output Shaft
13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Body
10. If new pump is used, align the flat of the output shaft and
the flat of the pump. Slide the pump onto the output shaft.
Do not disassemble oil pump. It is serviced only as an
assembly. Check the pump to make sure the pump
rotates freely.
Do not remove the plastic insert from the bore of the
new pump. Discard it after it slides out during pumpinstallation to the rear output shaft.
While turning the output shaft, prime the pump through
the oil filter pickup tube or housing inlet hole with clean
Automatic Transmission Fluid or equivalent.
11. Inspect the outside surfaces and bore of the oil pump. If there is no discoloration in the pump housing, gear or cover,and the pump bore and the lube holes of the output shaft show evidence of oil, the pump is working.