ECU SSANGYONG MUSSO 1998 Workshop Repair Manual

AUTOMATIC TRANSMISSION 5A-125
30. Align the valve body assembly on the transmission case
and 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:
lSolenoid 1 - red
lSolenoid 2 - bIue
lSolenoid 3 - yellow
lSolenoid 4 - orange
lSolenoid 5 - green
lSolenoid 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 has
occurred.
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 transmission
main case.
2. Install and tighten the securing bolts to specification.
Notice
All 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 the
pump seal.
Figure 8.1 - Torque Specifications
Torque Specifications
Torque converter housing to case
Extension housing to case
Rear servo cover
Pan to case
Inhibitor switch to case
Cooler connectors
Transmission filler plug
Output flange lock nut (RWD models)
Centre support to case
Cam plate to case (parking pawl)
Valve body to case
Upper valve body to lower valve body
ON/OFF solenoid retainers
Variable pressure solenoid retainer
Line pressure plug
Detent spring
Pump cover to case
Pump cover plate to pump cover
Pump to pump adaptor
Pump cover plate to crescent
Adaptor to caseNlm
54 - 68
54 - 68
25 - 35
4 - 6
2.3 - 3.4
30 - 35
30 - 35
100 - 110
20 - 27
16 - 22
8 - 13
11 - 16
8 - 12
8 - 12
4 - 7
20 - 22
24 - 34
13 - 16
24 - 27
13 - 16
25 - 35

TRANSFER CASE (TOD) 5D2-23
Error of signal in engine throttle position ; fault
code 1715, 1716
lPhenomenon
1. Upon diagnosis by SCAN-100, it display on 1715,
1716 codes.
lCause
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 s
No
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
115-125W
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
115-125W
Ye s
No Test Stage / Contents
Result
Stage Test Contents and ProcedureSpecified Value
/Yes/NoCountermeasure
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 s
No B4
B5
Ye s
No
B6
4.75-5.25Vdc
Ye s
No
B70.3-0.9Vdc
4.6-4.9Vdc
Ye s
No
4.6-4.9Vdc
0.3-0.9Vdc
Ye s
No Test Stage / Contents
Result
Stage Test Contents and ProcedureSpecified Value
/Yes/NoCountermeasure
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 body
actuator or check
cable Perform B1, B2, B3
stages
Perform 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 s
No
Ye s
No
Ye s
No E3
Ye s
No E4
Ye s
No E5Test Stage / Contents
Result
Stage Test Contents and ProcedureSpecified Value
/Yes/NoCountermeasure
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 0W ?
4. Perform the short test between No.1/No.14 Connector
and body, No2/No.15 connector and body.
- Is there resistance of 0W ?
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 and
No.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 fault
is 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 motor
or delete fault code
and rediagnosis
system.

TRANSFER CASE (TOD) 5D2-31
Position incoder and position 1,2,3,4 malfunction
:Fault code®1750,1751,1752,1753, 1754
lPhenomenon
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.
lCause
The portion of position incoder malfunction, each wiring is
shorted with ground.
Ye s
No
F1
Ye s
No
Ye s
No F2Test Stage / Contents
Result
Stage Test Contents and ProcedureSpecified Value
/Yes/NoCountermeasure
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 0W?Perform F2 stage
Perform F1-2 stage
Perform F2 stage
Normal system
Repair or replace
due to wiring short
1. Replace the
motor Ass’y due
the defective
position incoder
portion.
2. And then, perform
F1-2 stage.

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 tapping
the face of the input shaft against a wooden block to make
sure the snap ring is installed.
8. Remove all traces of gasket sealant from the front case
and mounting adapter mating surfaces. Install a bead of
gasket 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.
lDo not disassemble oil pump. It is serviced only as an
assembly. Check the pump to make sure the pump
rotates freely.
lDo not remove the plastic insert from the bore of the
new pump. Discard it after it slides out during pump
installation to the rear output shaft.
lWhile 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.

5D2-52 TRANSFER CASE (TOD)
32. Install shift shaft oil seal if it is not installed.
33. Using pliers equipped with soft jaws, rotate the triangular
shaft so it is aligned with the triangular slot in the transfer
case shift motor. If triangular shaft will not rotate, rotate
the rear output shaft.
34. Slightly loosen the two nuts that attach the slotted support
bracket to the end of the motor house.
35. Apply Black Non-Acid Cure Silicone Rubber or equivalent
to motor housing base and install on transfer case.
36. Install the transfer case shift motor and three bolts along
with speed sensor wire harness bracket and tighten.
Notice
The wire harness must be routed as shown to provide
clearance and to prevent the wire harness from grounding
the damper.
37. Holding the slotted support bracket tight against the motor
housing end, secure the bracket to the transfer case,
tightening the bolt with lockwasher to 8-11 Nm (72-96 lb-
in).
38. Retighten the two nuts that attach the slotted support
bracket to the end of the motor.
39. Install the clutch coil wire terminal and sensor wires.

8A-4 SEAT BELT
GENERAL DESCRIPTION
AND SYSTEM OPERATION
DRIVER SEAT BELT WARNING
The driver's safety belt incorporates a safety belt reminder
light in the instment cluster remind the driver if the safety belt
is not fastened when the ignition is turnd ON.
OPERATION AND FUNCTIONAL
CHECKS
Caution:
lKeep sharp objects and potentially damaging objects
away from the seat belts.
lAvoid bending or damaging any portion of the buckle
or the latch plate.
lDo not bleach or dye the belt webbing. Use only mild
soap and water in order to clean the belts.
lWhen installing the seat belt anchor bolts and the
screws, start the bolts and screws by hand in order
to prevent crossthreading.
lDo not attempt any repairs on the retractor
mechsemblies with new assemblies.
lReplace any belts that are cut r damaged in any way.
1. Inspect all saet belt anchor bolts and the screw in order to
verify that they are secure.
2. Inspect the seat belt buckle. The buckle must lock and
unlock easily.
3. After inserting the latch into the buckle, tug sharply on the
belt. The buckle must remain locked.
4. Fully extend the shoulder belt portion to make sure that
there is no twisting or tears in the belt.
5. Let the shoulder belt retract fully. The belt should retract
easily.