Body wiring SSANGYONG MUSSO 2003 Service Manual

4F-20 ANTILOCK BRAKE SYSTEM
Removal & Installation Procedure ABS Hydraulic Unit
1. Release the ABS wiring connector locking lever in arrowdirection and remove the connector. Notice
Do not force the connector when releasing in arrow
direction.
For installation of the connetor, align and firmly seat
the connector of the hydraulic unit and wiring connector while keeping the locking lever upward and then push it down.
2. Remove the hydraulic lines of the hydraulic unit. During removal, be careful not to drip brake fuid on the
body. Installation Notice
3. Unscrew hydraulic unit mounting nuts (2EA) and remove the unit from the bracket.Installation Notice
Tightening Torque 9 - 12 Nm
Removal of the ABS / ABD Unit Location : Under the front passenger's seat.
1. Remove the wiring connector of the ABS/ABD(or ABS:attached type) ECU.
2. Remove the ground wire.
3. Unscrew the mounting bolts and remove the ECU.
4. Installation should follow the removal precedure in reverse order.
Tightening Torque 12 - 16 Nm
Notice When carrying a new unit, never recline it over 30 °.

AUTOMATIC TRANSMISSION 5A-27
Shift Lever Position
Manual 1 Manual 2Manual 3Drive Netural ReverseParkResistance (OHMS) 1k - 1.4k
1.8k - 2.2k
3k - 3.4k
4.5k - 4.9k 6.8k - 7.2k
10.8k - 11.2k 18.6k - 19k
Table 3.3 - Readings for Resistance/Shift Lever Positions Diagnostics Inputs
The diagnostics control input or K-line is used to initiate the outputting of diagnostics data from the TCU to a diagnostic
test instrument. This input may also be used to clear the stored fault history data from the TCU’s
retentive memory. Connection to the diagnostics input of the TCU is via a connector included in the vehicle’s wiring
harness or computer interface. Refer to the vehicle manufacturer’ s manual for the location of the self test connectors.
Battery Voltage Monitoring Input
The battery voltage monitoring input connects to the positive side of the battery. The signal is taken from the main supply to the TCU.
If operating conditions are such that the battery voltage at the TCU falls below 11.3V the transmission will adopt a ‘low
voltage’ mode of operating in which shifts into first gear are inhibited. All other shifts are allowed but may not occur
because of the reduced voltage. This condition normally occurs only when the battery is in poor condition.
When system voltage recovers, the TCU will resume normal operation after a 3 second delay period. TCU Outputs
The outputs from the TCU are supplied to the components described below: Solenoids
The TCU controls seven solenoids. Solenoids 1 to 6 (S1 to S6) are mounted in the valve body, while Solenoid 7 (S7)
is mounted in the pump cover. The normal state (OPEN/CLOSED) and the functions associated with the solenoids
are detailed in table 3.4. Table 3.5 details the S1 and S2 logic for static gear states. The logic during gear changes for
S1 to S4 and S7 is detailed in table 3.6.

5A-86 AUTOMATIC TRANSMISSION
9. Remove the pump to case bolts using a multi-hex 8 mmspanner.
10. Using the pump puller No. 0555-332941, remove the pump.
11. Remove the input shaft, forward clutch cylinder, and the overdrive shaft as an assembly, withdrawing them through the front of the case.
12. Remove the C3 clutch cylinder and sun gears.
13. Remove the fronts band struts. Remove the front band.
14. Remove the two centre support retaining bolts using a T50 Torx bit.
15. Remove the centre support retaining circlip. Notice
Do not hammer the output shaft to remove the centre
support as this will cause permanent damage to the thrust bearing surfaces.
16. Remove the centre support, 1-2 one way clutch, planetary gear set and output shaft as an assembly.
17. Remove the parking rod cam plate. (T40 Torx bit).
18. Remove the rear band struts and remove the band. 4. Detach each end of the filter retaining clip from the valve
body and remove the filter.
5. Detach the wires from each solenoid and lay the wiring to one side.
6. Remove the valve body securing screws and remove the valve body from the case.
7. Remove the front servo cover circlip. Remove the cover and piston.Notice
The plastic servo block is retained by the piston return
spring only.
8. Where fitted, remove the flange yoke, and then remove the extension housing (RWD model).
Remove the adaptor housing (4WD model).

5A-92 AUTOMATIC TRANSMISSION
Planet Carrier and Centre Support
To remove the planet carrier and centre support, proceed as follows.1. Separate the planet carrier and centre support from the output shaft. Remove the thrust bearings from the output
shaft and the planet carrier.
2. Separate the centre support from the planet carrier by rotating it anti-clockwise.
3. Lift the one way clutch from the planet carrier.
4. Remove the circlip retaining the one way clutch outer race in the planet carrier and remove the race.
5. Remove the one way clutch retainer from the planet carrier.
Pump
Note that the following valves are housed in the pump cover:
Solenoid 7
C1 bias valve
Converter clutch control valve
Converter clutch regulator valve
Primary regulator valve
To remove the pump, proceed as follows. 1. Remove the wiring loom retainer plate and remove solenoid 7 with a T30 Torx bit.
2. Remove the five washer head bolts from the cover plate using a multi-point 8 mm socket.
3. Remove the five Torx head screws from the cover plate (Torx bit No. 30). Note that the odd screw holds the pump
body to the pump body cover. Notice
Do not strike the converter support tube to loosen the
pump body.
4. Separate the pump body from the pump cover.
5. Lift the cover plate from the cover.
6. Remove the two ball check valves and one spring from the pump cover.Notice
Some of the valves and plugs are preloaded by springs
and may unexpectedly fall out of the cover when the pinsare removed.
7. Depress the plug inward and remove the retaining pin for each of the four valves.
8. Remove the four valves, plugs and springs.
9. Remove the pump gears from the pump body.
10. Remove the lip seal from the front of the pump body.

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

5A-124 AUTOMATIC TRANSMISSION
27. Install the line pressure plug and tighten to specification.Refer to figure 8.62.
28. Install the detent spring assembly (spring, support plate and screw), ensuring that the screw is tightened to
specification. Check the spring for wear or damage.
29. Install the manual shift valve. Refer to figure 8.60. Notice Be aware that the manual valve will fall out of the valve
body.
Figure 8.62 - Wiring Installation
Figure 8.60 - Manual Shift 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

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

TRANSFER CASE (TOD) 5D2-29
Shift motor malfunction : Fault code ® 1741,
1742, 1743
Phenomenon
1. When change the 4H/4L switch from 4H to 4L, ‘4L ’
indicator lamp turn off after blinking for a time and then ‘ 4WD CHECK ’ indicator lamp turn on.
2. Fault codes display by diagnosis of SCAN-100 : 1741, 1742, 1743
3. The shifting operation is not occurred when 4H / 4L switch, is operating.
Cause
Defect in shift motor, improper voltage provided, incorrect
connection in connector, short of wiring.
11-14 V
(Battery voltage) Ye s
No
E1
11-14 V
(Battery voltage)
Ye sNo
Ye sNo
E2
Ye sNo
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check the input voltage of shift motor.
1. Turn the ignition switch to
“ON ” position.
2. Measure the Hi/Low voltage of motor which is located between No.1/No.14 and No.2/No.15 connector of TOD control unit with digital Multi-tester or which is locatedbetween No.G connector and body after detaching T/C
motor connector.
- The specified value (When operates 4H/4L switch)
- Measured value is within specified range ?
3. Measure the Hi/Low voltage of motor which is located between No.2/No.5 and No.1/No.14 connector or which is located No.B connector and body after detaching T/C motor connector
- The specified value (When operates 4H/4L switch)
- Measured value is within specified range ?
Check the fault condition of the relevant connector.
1. Check the installation condition of TOD control unit 30pin connector and T/C shift motor connector.
- Is it installed properly ?
2. If the connector installation is improper, install properly and then perform follows :
a. Delete the fault code of control unit by scan scope
b. Turn off the ignition switch
c. Turn on the ignition switch
d. Re-diagnosis of system
It displays one or more fault code among 1741 to 1743. Perform E1-3 stagePerform E2 stage Perform E4 stage Perform E2 stage Perform E3 stage Perform E2-2 stage Perform E3 stage Normal system

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.