sensor SSANGYONG MUSSO 1998 Workshop Repair Manual

5A-64 AUTOMATIC TRANSMISSION
Default Transmission Operating Modes
The TCU relies on accurate information from its inputs and complete control of its outputs to effectively control the
transmission. To ensure that it has both valid inputs and functioning outputs, the TCU carries out both hardware and
software fault detection routines. The TCU will respond to any faults detected by adopting the operating modes which
are detailed below.
The following symptoms of faults are the most obvious results of each fault under ‘normal’ conditions.
There is always the possibility that a fault may not be detected. If undetected fault conditions are present, the
operation of the transmission is difficult to predict.
1 Throttle Fault
lAll shifts will occur as if a nominal throttle (approx. 44%) were applied for shift scheduling.
lAll shifts will be firm as full throttle and hence high engine torque is assumed.
lThe torque converter will be unlocked at all times.
lAll downshifts initiated by the shift lever will occur as though they were ‘automatic’ shifts. That is the engine
braking effect will not occur until near the end of the shift.
lLine pressure will always stay high (solenoid 6 OFF) to cope with assumed high throttle/torque.
If a fault is undetected, the percent throttle is most likely to be interpreted as higher than actual, resulting in late
upshifts, early downshifts, firm shifting and a harsh 3-1 shift when stopping.
2 Throttle Not Learnt Fault
The transmission operates from default throttle calibration values which results in the evaluation of the throttle being
higher (more open) than it is. There(ore at zero throttle settings, the transmission may calculate that sufficient throttle
opening is present to justify high line pressure and switch solenoid 6 to OFF.
Other symptoms are:
a. late upshifts and
b. lock-up maintained at zero throttle when the vehicle speed is sufficiently high.
3 Engine Speed Fault
lAll shifts will be firm because an engine speed corresponding to peak engine torques is assumed.
If a fault is undetected, the engine speed is likely to be interpreted as stalled resulting in soft shifting possibly with an
end of shift bump.
4 Vehicle Speed Sensor Fault
lAll shifts will be controlled by the shift lever with skip downshifts disabled and downshifts only allowed if the
engine speed is low. Fourth gear will be inhibited.
lThe torque converter will be unlocked at all times.
If a fault is undetected, the vehicle is likely to be interpreted as being stationary resulting in first gear operation at all
times. Note that speedometer transducer faults are likely to cause the vehicle’s speedometer to become inoperative.
5 Gear Lever Fault (Inhibitor/PRNDL Switch)
lThe gear lever is assumed to be in the Drive position.
lThe transmission is limited to 2nd,3rd, and R gears only.
lThe rear band will apply at all times when the lever is shifted to P, R or N. (B2 inhibition and reverse lockout
protection is disabled.)
lThe torque converter will be unlocked at all times.
lManually (gear lever) initiated downshifts will not be available.
If a fault is undetected, the gear lever position is likely to be interpreted as being higher than actual. Where Park is the
highest position and Manual 1 is the lowest, the result being the availability of higher gears than selected by the gear
lever.

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 Fault
lAll 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
lAll shifts will occur as if the mode is set to ‘NORMAL’.
lThe mode indicator will always be off indicating that ‘NORMAL’ mode is selected.
lThe 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
lThe converter lockup clutch will be applied at lower speeds, causing a shudder through the vehicle.
lThe 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 operating
voltage 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 the
ignition 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 Input
Fault
Throttle Input Fault
Temperature Input Fault
Shift Lever Position
Input Fault
(Inhibitor/PRNDL Switch)
Engine Speed Sensor
Fault
Shaft Speed Sensor
Fault
(Speedo Sensor)Solenoid
1
2
3
4
5
6
7
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.
Notice
Refer to sefadf3fnosfs list.

5A-76 AUTOMATIC TRANSMISSION
Action
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck voltage between terminal 27 and 29 of TCU,
- Standard value : 0.2 - 4.7V
lCheck TPS.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck engine speed sensor.
lCheck resistance between terminal 8 and 24 of TCU (when the
connector is disconnected).
- Standard value : 1 .9 - 0.2 k
W
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck vehicle speed sensor.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck engine speed sensor.
lCheck inhibitor switch resistance between terminal 34 and 37 of
TCU(when the connector is disconnected).
- Standard value : 1st gear - 4 - 4.4 k
W
2nd gear - 4,8 - 2.2 kW
3rd gear - 3 - 3.4 kW
D gear - 4.5 - 4.g kW
N gear - 6.8 - 7.2 kW
R gear - 10.8 -11.2 kW
P gear - 18.6 - 19 kW
lCheck voltage between terminal 31 and 37 of TCU.
- Standard value : 0-5V(P,R,N,D,L)
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck mode switch.
lCheck condition between terminal 1 and 13 of TCU.
Winter mode :12V, Normal mode : Open status, Power mode : 0V
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck voltage between terminal 32 and 38 of TCU.
- Standard value : 0-5V
lCheck oil temperature sensor.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck battery condition.
lCheck 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
P1707
P1708
Self-diagnosis List

AUTOMATIC TRANSMISSION 5A-77
Action
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck 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
lCheck cable for open / short,
lCheck connection of other connectors.
lCheck 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
lFully depress accelerator pedal for 5 seconds(ignition key is ON).
lRelease accelerator pedal.
lDepress brake pedal and start the engine in ‘P’ position.
lDepress brake pedal and idle the engine for 5 seconds in ‘D’
position.
lShift into ‘D’ position and determine fault code for throttle initial-
ization.
lComplete the initialization.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck resistance between terminal 1 and 34 of TCU(when the
connector is disconnected).
- Standard value : 26 - 30
W
lCheck solenoid.
lCheck cable for open / short.
lCheck connection of other connectors,
lCheck resistance between terminal 1 and 40 of TCU (when the
connector is disconnected).
- Standard value : 26 - 30
W
lCheck solenoid.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck resistance between terminal 1 and 41 of TCU (when the
connector is disconnected).
- Standard value : 26 - 30
W
lCheck solenoid.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck resistance between terminal 1 and 33 of TCU (when the
connector is disconnected),
- Standard value : 26 - 30
W
Possible Cause
Air conditioner switch
Kick down switch
Pedal
Vehicle ID
VPS offset
Throttle position sensor
initialization
Solenoid 1
Solenoid 2
Solenoid 3
Solenoid 4 Symptom
P1710
P1712
P1713
P1714
P1715
P1716
P1733
P1734
P1735
P1736

5A-82 AUTOMATIC TRANSMISSION
MAINTENANCE 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,4L
DIAGNOSIS
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 ChainAction
Check sliding parts, replace if necessary.
Noise in 4WD Operation
Checks
Improper or low oil
Loosened bolts or mounted parts
Noisy T/C bearing
Noisy gearsAction
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 PressureAction
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 Case
Leakage from Other Parts
Breather Clogging
Improper or too much Oil
Loosened 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.
lTCCU
lShift motor
lMagnetic synchronizer clutch
lSpeed sensor
lHub solenoid
lSelector switch
lMotor position sensor
3. Transfer case system is malfunctioning when:
l4H ,4L indicator lights are remain on after 0.6 second
when turning the ignition switch ‘ON’
l4H,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 malfunctioning
parts 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.
Notice
Before replacing the malfunction parts with defective code,
check the wires and connectors for proper condition.