tod transfer case SSANGYONG MUSSO 2003 Owner's Manual

TRANSFER CASE (TOD) 5D2-19
ClassificationEngine Type
Transmission/Vehicle Type Axle Ratio
Tire Size
Coding Required
1. Replacement of TOD control unit.
2. Adjustment by input error.
3. Change of tire specification.
Items
Gasoline Engine (E32) 661 Diesel Engine
661LA Diesel Turbo Engine
662 Diesel Engine
662LA Diesel Turbo Engine Manual Transmission
Automatic Transmission MUSSO
KORANDO 3.734.554.895.38 5.86
P215 P235P255P275
Coding Method
1. Check and record engine type, axle ratio and tire size.
2. Ignition “OFF ”.
3. Connect SCANNER with diagnosis connector in engine room.
4. Ignition “ON ”.
5. Read the current memorized specification in TOD control unit.
6. Compare memorized specification with the checked record. If not matched, perform a coding.
7. Read again memorized coding specification in TOD control unit for confirmation of coding.
8. Check coding specification whether it matches with vehicle or not. If not, perform a coding again.
Coding items

5D2-20 TRANSFER CASE (TOD)
ELIMINATE THE MEMORIZED FAULT CODE When diagnose by SCANNER, it is required that you make adequate service on defects against all fault codes. And thenyou should delete the memorized fault codes in TOD control unit using SCANNER as follows;
1. Connect SCANNER with diagnosis connector.
2. Select “trouble code clear ” in SCANNER.
3. In “trouble code clear ” screen, press “enter ” key to erase
the fault code.
4. Confirm deletion of fault code and, if not, repeat 2.-3. process.

TRANSFER CASE (TOD) 5D2-21
DIAGNOSIS Malfunction interior TOD control unit ; fault code 1714
Phenomenon
1. When ignition “ON ”, “4WD CHECK ” lamp illuminates
continuously.
2. On diagnosis by SCAN-100, it displays fault code “1714 ”.
Cause ; Error of EEPROM checksum in TOD control unit
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check power supply for TOD control unit. 1. Disconnect 30 pin connector from TOD control unit.
2. Ignition “ON ”.
3. Using multi-tester, measure voltage between pin 5(+)
and 17/18 (-). - Specified value - Measured value is within specified range ? 11-14 Vdc
Ye sNo Perform A2 stagePerform A3 stage
Check connection status in TOD control unit connector.
1. Check connection status.
- Is it connected exactly?
2. In case of mal-connection, connect tightly then perform the follows.
a. Delete fault code using Scan-100.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by Scan-100.
- Does it display fault code “1714 ”? Ye s
No
Ye s No
Check short of 10A fuse (fuse No.20).
1. Detach No.20 fuse from engine room fuse box.
2. Check the existence of short.
- Is fuse normal? Yes
No
Check ground of TOD control unit.
1. Ignition “ON ”.
2. Check voltage between 4/19 (+) pin and 17/18 (-)
using multi-tester (keep connection status).
- Specified value (battery is good)
- Measured value
3. Check short between 17/18 pin and body after disconnect 30 pin connector.
- Is resistance " "? 12Vdc (battery
voltage)
Ye s
No
Ye sNo
A1 A2 A3 A4
Perform A3 stage Perform A2 stage Perform A3 stage Normal system Perform A4 stage Replace fuse, then perform A1 stage Perform A4-3 stage Replace TOD controlunit Repair ground wiring Ground is O.K., perform A5 stage

5D2-22 TRANSFER CASE (TOD)
Check function of TOD control unit.
1. Even A1, A2, A3 and A4 test, if you could not find defect,it is required to replace TOD control unit on basis of below phenomena.
a. ”4WD CHECK ” lamp illuminates continuously when
ignition “ON ”.
b. Shift is not possible even 4H/4L switch operation.
c. Upon diagnosis by Scan-100, it displays on “impossible communication with TOD control unit ”
or fault code “1714, 1715, 1716 ”.
- Do occur the above defects? Ye s
No Replace TOD control unit Normal system
A5 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure

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.

TRANSFER CASE (TOD) 5D2-25
Error in electro - magnetic clutch : fault code “1721 ”, “1722 ”
Phenomenon
1. Upon diagnosis by SCAN-100, it displays on fault
codes “1721,1722 ”.
Cause
1. Defect in electro - magnetic clutch
2. Defect in connector or wiring
- Open or short from EMC to the supply : 1721
- Short EMC to ground : 1722
Ye sNo
C1
Ye sNo
Ye s
No
11-15Vdc Ye s
No
C2
Ye sNo
Test Stage / ContentsResult
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check relevant connector connection status.
1. Check relevant connector connection status with TOD
control unit.
- Does it connect correctly ?
2. Check connection status of speed sensor and clutch coil connector (7 pin) in transfer case.
- Does it connect correctly ?
3. In case of bad connection, connect it correctly then perform the follows :
a. Delete the memorized fault code in control unit withScan - 100.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by SCAN-100
- Does it display on fault codes “1721,1722 ” ?
Check supply voltage into electro-magnetic clutch.
1. Ignition “ON ”
2. Measure voltage between pin 4/19(+) and 17/18(-) in TOD control unit connector.
- Specified value
- Measured value is within specified range ?
3. If the specified value would not be measured, perform the follows :
a. Check battery voltage (charging condition)
b. Check open circuit on No.13 fuse (20A)
c. Check relevant wires.
- Is the above 3a, 3b, 3c normal ? Perform C1-2 stage Perform C1-3 stage Perform C2 stage Normal system
Perform C2 stage Perform C1-3 stage Perform C3 stage Perform C2-3 stage Perform C3 stage

Charging/ Replace battery
Replace fuse
Repair wires

5D2-26 TRANSFER CASE (TOD)0Vdc
11 - 15Vdc
Ye s
No
2.5
Ye s No
C3 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check resistance of electro-magnetic clutch.
1. Disconnect 30 pin connector from TOD control unit.
2. Measure resistance between pin 3 and 7 in wiring
connector using multi-tester.
- Specified value
- Measured value is within specified range? Perform C4 stage

0 : short
: open
C4 Check operational voltage of elector-magnetic clutch.
1. Ignition "ON"
2. Measure voltge between pin 3(+) and 17(-)in TOD control unit connector.
- Specified value 4WD high 4WD low
- Measure value is within specified range ? Replace TODcontrol unit Replace wire

TRANSFER CASE (TOD) 5D2-27
Defect in speed sensor : fault code 1731, 1732, 1733, 1734, 1735,1736
Phenomenon
1. Upon diagnosis by SCANNER, it displays on fault code
1731, 1732, 1733, 1734, 1735 and 1736.
2. “4WD CHECK ” lamp illuminates continuously when
ignition “ON ”.
Cause
1. Defect of speed sensor (front, rear).
2. Defect of power supply.
4.75-5.25Vdc
Ye sNo
D1
Ye s
No
D2
Ye s
Ye s
Ye sNo
D3 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check power supply of speed sensor.
1. Ignition
“ON ” or driving mode
2. Measure supply voltage between pin 16 (+) and 13 (-) in
TOD control unit connector using digital multi-tester.
- Specified value
- Measured value is within specified range ?
Check connection status of connector.
1. Check connection status of speed sensor/clutch coil connector and TOD control unit connector.
- Does it connect correctly ?
2. In case of bad connection, connect it correctly then perform the follows:
a. Delete the memorized fault code in control unit by
SCANNER.
b. Ignition “OFF ”.
c. Ignition “ON ”.
d. Diagnose by SCANNER.
- It does not display fault code.- It displays one or more fault code among 1731 to1736.
Check output wave of front and rear speed sensor.
1. Upon driving mode.
2. Check output wave of each speed sensor by SCANNER.
3. Is it normal on output wave ? Perform D3 stage Perform D2 stage
Perform D3 stagePerform D2-2 stage Normal system Perform D3 stage Perform D4 stage Replace speed sensor then perform D2-2 stage

5D2-28 TRANSFER CASE (TOD)
Ye sNo
D4 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check output voltage of front and rear speed sensor.
1. Upon driving mode
2. Measure output voltage of front and rear speed sensor
by multi-tester. Check voltage whether it varies withinspecified range.
- Specified value Front speed sensor
: Pin 11(+), 13(-) in TOD control unit connector
 Rear speed sensor: Pin 29(+), 13(-) in TOD control unit connector- Measure value is within specified range ? Check function ofcontrol unit.
It necessary, replace then delete fault codes and re- diagnose . Perform D5 stage
Ye s
No
D5
Check short/open in cable.
1. Ignition"OFF"
2. Disconnect TOD control unit connector
3. Make a test for open circuit between pin 11 and 13, 16 and 13, 29 and 13 in wiring connector by multi-tester.
- Is there a resistance of " " ?
4. Make a test for short between pin 11 and ground 13 and ground, 29 and ground by multi-tester.
- Is there a resistance of " " ? Repair wire Perform D5-4 stge
Ye s No Wiring short, repairPerform D3 stage, then delete fault codes with rediagnosis