sensor SSANGYONG MUSSO 2003 Service Manual

5D2-38 TRANSFER CASE (TOD)
SPEED SENSOR IN FRONT AND REAR PROPELLER SHAFT Replacement Procedure
1. Disconnect (-) cable from battery.
2. Detach shift motor assembly.
3. Disconnect front and rear speed sensor connector (white 3pin) upper backside transfer case.
4. Disconnect speed sensor connect from locking sleeve by pushing.
5. Disconnect wire stick cap from the detached connector.
6. Unscrew rear speed sensor mounting bolt (M10) from upper side of rear case flange.
7. Detach sensor from transfer case by lifting up using tool. Notice
When disconnect sensor, make sure on adequate pressure due to sensitiveness with shock.
8. Disconnect taping from both protection tube ends that wrap 3 wires of speed sensor and 1 wire of clutch coil.
9. Disconnect tube.

TRANSFER CASE (TOD) 5D2-39
10. Disconnect pin and wire from speed sensor connector bypulling sticking long-nose plier into “L” pin in connector.
11. On the same way, disconnect pin and wire “M” and “N”
from connector. Notice Do not touch the wires related with EMC.
12. Prepare new speed sensor.
13. Connect 3 pins with wires of speed sensor to coincide with each connection position.
14. Using long-nose plier, connect tightly by pulling pins.
15. Apply rubber cap into connector using long-nose plier not to detach.
16. Connect protection tube with wire.
17. Tape both ends of tube.
18. Putting rear speed sensor into hole, connect exactly pushing both ends.
19. Screw 1 unit of bolt (M10). Installation Notice
Tightening Torque 9 - 11 Nm
20. Connect speed sensor connector, then locking sleeve. Reference Front propeller shaft should be premised by removal of
shift motor.
After disconnecting shift motor, procedure of replacement on sensor assembly of accords with one of rear speed
sensor.

5D2-42 TRANSFER CASE (TOD)1 Bearing
2 Bushing
3 Carrier Assembly
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Output Shaft Thrust Washer
8 Bearing
9 Retaining Ring
10 Snap Ring
11 High-low Collar
12 Rear Output Shaft
13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Assembly
17 Thrust Washer
18 Sprocket, Drive (24T)
19 Clutch Pack Assembly
20 Insulator Washer
21 Armature
22 Snap Ring
23 Wave Washer
24 Apply Cam
2 5 Ball
26 Cam and Coil Assembly
27 Nut, Metric
28 Output Shaft Yoke Washer
29 Oil Seal
30 Case Flange
31 Bolt
32 Upper Speed Sensor (Rear)
33 Nut
34 Washer
37 Bolt
38 Tag, Identification
39 Thrust Bearing
40 Clutch Coil Assembly
41 Fork, Reduction Shift 42 Shift Rail
43 Shaft, Shift
44 Spacer
45 Torsion Spring
46 Shift Cam
47 Transfer Case Shift Motor
48 Bolt
49 J-clip
50 Connector Retainer
51 Bolt
52 Support Stud
53 Lower Speed Sensor (Front)
54 Plug
55 Identification Decal
56 Cover
57 Tone Wheel, Lower
58 Chain, Drive
59 Sprocket, Driven (24T)
61 Magnet
62 Case
63 Case Flange and Output Shaft
64 Barb, Breather
68 Spiral Pin
69 Oil Seal
70 Pin, Dowel
71 Ring Gear
72 Retaining Ring
73 Snap Ring
74 Bearing
75 Snap Ring
76 Bearing
77 Speedometer Drive Gear
78 Facing, Shift Fork
79 Upper Tone Wheel
80 Oil Seal
81 Bearing Sleeve
82 Bearing

TRANSFER CASE (TOD) 5D2-43
Disassembly Procedure
1. Disconnect transfer case from vehicle
2. Using a 30mm thin-wall socket, first remove the rear outputnut, output shaft yoke washer, oil seal then the case flange.Installation Notice
27 Nut
28 Washer
30 Case Flange
Tightening Torque 137 - 196 Nm
3. Disconnect shift motor/clutch coil connector and speed sensor connector from upper bracket of transfer case. Notice
When disconnect connector, pull forwards grasping connector housing.
4. Remove outer tube on speed sensor connector.
5. Remove wire supporting cape back side of speed sensor connector.
6. Disconnect pin of clutch coil wire (yellow) from speed sensor connector (white 7 pin) using long-nose plier.
7. Remove shift motor.
Notice
When remove shift motor, pay attention to the location of
triangular slot and shaft in transfer case inside motor.
8. Disconnect front and rear speed sensor.

TRANSFER CASE (TOD) 5D2-51
25. Install the pin on the tang end of the helical cam into thehole in the front case. Position the torsion spring tangs so that they are pointing toward the top side of the transfer case and just touching the high-low shift fork. CAUTIONDo not bend the helical cam during installation to the front case because of possible damage to the pin at the tangend of the motor shaft.
26. Install the shift rail through the high-low shift fork and make sure that the reverse gear shift rail is seated in the frontcase bore.
27. Install upper and lower speed sensors into the cover. Feed the coil wire through the upper speed sensor wire shield.
2 8. Install upper tone wheel, speedometer gear and rear output seal. Use Output Shaft Seal Replacer and Driver orequivalent to install seal.
29. Coat the mating surface of the front case with a bead of Black Non-Acid Cure Silicone Rubber or equivalent.
30. The following procedure must be followed prior to installing the rear case onto the front case half:
a. Align the output shaft with the rear case output shaft bore.
b. Align the helical cam with the rear case motor bore. If difficulty is encountered with seating the rear case, tap
the rear output shaft with a sharp blow using a rubber
mallet in a direction away from the triangular shaft whilepushing down on the rear case.
Tightening Torque 25 - 37 Nm
31. Install the bolts retaining the case halves and tighten.

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 triangularshaft 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. NoticeThe 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.

FATC-HAVC 7D-3
SERVICE SPECIFICATIONSResistance (25 °C)
Voltage Rating Current RatingResistance (25 °C)
Voltage Rating Current Rating Resistance (25 °C)
Voltage RatingCurrent Rating
Application
Incar Sensor Ambient Sensor
Coolant Temperature Sensor
Description
Input Section
2.186k
±0.07k
5V
3mA
1.0k ±0.03k
5V
3mA
0.55k ±0.02k
5V
3mA
Current Rating (at 12V) LOCK CurrentCurrent Rating (at 12V)LOCK CurrentCurrent Rating (at 12V) LOCK Current IcPc
Application
Intake Actuator Mode Actuator Mix Actuator Power TRBlower Motor Power Consumption
Description
Output Section
70±30mA
Less than 500mA 100±40mA
Less than 500mA 100±40mA
Less than 500mA 30A
200W 220W

FATC-HAVC 7D-5
FATC BLOCK DIAGRAM
INCAR SENSOR
AMBIENT SENSOR
WATER TEMPERATURE SENSOR
SUN LOAD SENSOR
TEMPERATURE SWITCH
BLOWER SWITCH
MODE SWITCH
DEFROSTER SWITCH
INTAKE SWITCH
AUTO SWITCH
A/CON SWITCH
OFF SWITCH
TEMP DOOR POSITION FEEDBACKVOLTAGE
POWER TRANSISTOR COLLECTORVOLTAGE
VFD
MAX HI RELAY
POWER T/R
BLOWERMOTOR
ECUCOMPRESSOR
MIX ACTUATORMIX DOOR
INTAKE ACTUATORINTAKE DOOR
MODE ACTUATORMODE DOOR
Airconditioner output
C ON
T
RO L
UN I
T

7D-8 FATC-HAVC Self-diagnosis Method
Ignition switch “ON ”
Press the intake switch more than 4 times within
2 seconds while pressing the AUTO switch
Self-diagnosis will start after turning off all displays on VFD for 2.5 seconds
Self-diagnosis items check (continuous action)
Airconditioner control
Self-diagnosis items check
(step action)
Press AUTO Press AUTO Press OFF
Press OFF
DIAGNOSIS TEST
FATC airconditioner system has self-diagnosis function.
Turn the ignition switch ON and press intake switch more than 4 times within 2 seconds while the AUTO switch is
1 AUTO Switch
2 Intake Switch
3 OFF Switch 4 Airconditioner Switch
5 Set temperature Display
pressed, then it will diagnose incar sensor, ambient
sensor, water temperature sensor and temperature actuator for open/short and will display numerical fault code on the set temperature display of VFD.
DIAGNOSIS

FATC-HAVC 7D-9
Diagnosis Item and Fault Code Self-diagnosis Display
1. Data will be displayed at the set temperature display as 2-digit number during self-diagnosis function and other settemperature displays will be OFF.
2. Display of self-diagnosis fault code will be blinking fault code number in the intervals of 0.5 sec.
3. Following fault code number will be displayed at the set temperature display during self-diagnosis function.
4. If no defective, normal display number (00) will blink. Display during continuous action
A. Normal or 1 fault (00 or 11) 15: coolant Sensor Open
16: coolant Sensor Short
17: temperature Actuator Open/Short
18: temperature Actuator Drive Fault
00: normal
11: incar Sensor Open
12: incar Sensor Short
13: ambient Sensor Open
14: ambient Sensor Short
B. Multiple faults (11,13,15.........) Display during step action
A. Normal or 1 fault : the same as continuous action
B. Multiple faults

0.1 sec. 0.1 sec.
0.5 sec.
ON
0.5 sec.OFF
ON
OFF
Display
Buzzer
0.5 sec.Fault 13
0.5 sec.OFF
Fault 15
OFF
Display
Buzzer
Fault 13 Fault 17
Display Buzzer AUTO switch pressedFault
17 Fault 17
Airconditioner switchpressedFault11 Fault 11


0.1 sec. 0.1 sec.