1997 SSANGYONG KORANDO engine

ABS AND TCS 4F-85
SSANGYONG MY2002
Step
4
5
6
7
8
9
10
11
12
13
DTC 28 - Low Voltage Fault (Cont’d)
Action
Go to Step 5
System OK
System OK
Go to Step 8
Go to Step 9
System OK
System OK
Go to Step 12
Go to Step 13
System OKGo to Step 6
-
-
Go to Step 11
Go to Step 10
-
-
Go to Step 15
Go to Step 14
- -
-
-
-
-
-
-
-
-
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1. Replace fuse EF11.
2. Turn the ignition to ON.
Does the fuse blow again?
1. Turn the ignition to OFF.
2. Trace the BLK/WHT wires in the ABS wiring
harness from terminal 8 of C104 at the engine fuse
block to F19 in the I/P fuse block.
3. Repair any short circuit found along this path.
Is the repair complete?
1. Turn the ignition to OFF.
2. Install the scan tool.
3. Clear all DTCs.
4. Road test the vehicle.
Does DTC 28 reset?
Check fuse F19 in the I/P fuse block.
Is the fuse blown?
1. Replace fuse F19.
2. Turn the ignition to ON.
Does the fuse blow again?
1. Turn the ignition to OFF.
2. Trace the WHT/RED wires in the ABS Wiring
harness from fuse F19 to terminal 50 of the EBCM
connector.
3. Repair any short circuit found along this path.
Is the repair complete?
1. Turn the ignition to OFF.
2. Install the scan tool.
3. Clear all DTCs.
4. Rood test the vehicle.
Does DTC 28 reset?
Check fuse F29 in the I/P fuse block.
Is fuse F29 blown?
1. Replace fuse F29.
2. Turn the ignition to ON.
Does fuse F29 blow again?
1. Turn the ignition to OFF.
2. Trace the WHT/RED wire from fuse F19 to terminal
1 of the EBCM connector.
3. Repair any short circuit found along this path.
Is the repair complete?
Value(s) Yes No

SSANGYONG MY2002
4F-102 ABS AND TCS
ACCELERATION SENSOR
Removal and Installation Procedure
1. Disconnect the negative battery cable.
2. Disconnect the acceleration sensor connector. It
is located at the rear of audio system.
3. Remove the acceleration sensor mounting bolts.
Installation Notice
SYSTEM FUSE
Removal and Installation Procedure
The ABS/TCS system fuse, EF11, is located in the
engine fuse block. Counting from the battery toward
the surge tank, it is the first system fuse in the row.
KAA4F410
KAA4F420
Tightening Torque 7 Nm (62 lb-in)
4. Installation should follow the removal procedure in
the reverse order.
INDICATORS
The indicator lamps ABS and EBD and TCS are part of
the instrument cluster. Refer to Section 9E, instrumenta-
tion/ Driver information, for removal and replacement
details.

SSANGYONG MY2002
4G-2 PARKING BRAKE
DESCRIPTION AND OPERATION
BRAKE CALIPER
This braking system uses a BRAKE warning light lo-
cated in the instrument panel cluster.
The following conditions will activate the BRAKE lamp:
•The parking brake is applied when the ignition is
ON. The lamp will turn off when the parking brake
is released.
The fluid level is below the minimum mark in the
master cylinder reservoir. The lamp will turn off when
the fluid level is above the minimum.
As a test of the lamp circuit, the BRAKE lamp will
glow dimly when the ignition is ON, even if the
parking brake is off and fluid level is above the
minimum. The lamp will turn off when the engine is
started. When the brake is firmly applied, the parking
brake should hold the vehicle with ample pedal
travel remaining.
Check for frayed cables, rust, etc. or any condition
that may inhibit present (or future) free movement of
the parking brake lever assembly.

SECTION 5A
AUTOMATIC TRANSMISSION
CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
otherwise noted.
TABLE OF CONTENTS
Description and Operation . . . . . . . . . . . . . . . . . 5A-2
BTRA M74 4WD Automatic Transmission . . . . . . 5A-2
Operators Interfaces . . . . . . . . . . . . . . . . . . . . . 5A-2
Control Systems . . . . . . . . . . . . . . . . . . . . . . . . 5A-3
Electronic Control System . . . . . . . . . . . . . . . . . 5A-3
Hydraulic Control System . . . . . . . . . . . . . . . . . . 5A-9
Hydraulic Control Circuit . . . . . . . . . . . . . . . . . . 5A-10
Power Train System . . . . . . . . . . . . . . . . . . . . . 5A-14
Power Flows . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-18
Park and Neutral . . . . . . . . . . . . . . . . . . . . . . . 5A-20
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-22
Manual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-24
Drive 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-26
Drive 2 and Manual 2 . . . . . . . . . . . . . . . . . . . . 5A-28
Drive 3 and Manual 3 . . . . . . . . . . . . . . . . . . . . 5A-30
Drive 3 Lock Up and Manual 3 Lock Up . . . . . . 5A-32
Drive 4 (Overdrive) . . . . . . . . . . . . . . . . . . . . . 5A-34
Drive 4 Lock Up . . . . . . . . . . . . . . . . . . . . . . . . 5A-36
Diagnostic Information and Procedures . . . . . 5A-38
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-38
Basic Knowledge Required . . . . . . . . . . . . . . . 5A-38
Functional Check Procedure . . . . . . . . . . . . . . . 5A-38
Transmission Fluid Level Service Procedure . . . 5A-38
Fluid Leak Diagnosis and Repair . . . . . . . . . . . 5A-39
Electrical / Garage Shift Test . . . . . . . . . . . . . . 5A-40
Road Test Procedure . . . . . . . . . . . . . . . . . . . . 5A-40
Electronic Adjustments . . . . . . . . . . . . . . . . . . 5A-40
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . 5A-41
Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-41
Faulty Shift Pattern . . . . . . . . . . . . . . . . . . . . . . 5A-42Shift Quality Faults . . . . . . . . . . . . . . . . . . . . . . 5A-44
After Teardown Faults . . . . . . . . . . . . . . . . . . . 5A-46
Trouble Code Diagnosis - Gasoline Vehicle . . 5A-48
TCM Diagnostic System Overview . . . . . . . . . . 5A-48
Clearing Trouble Codes . . . . . . . . . . . . . . . . . . 5A-48
Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 5A-48
Trouble Code Diagnosis - Diesel Vehicle . . . . . 5A-50
TCM Diagnostic System Overview . . . . . . . . . . 5A-50
Clearing Trouble Codes . . . . . . . . . . . . . . . . . . 5A-50
Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 5A-50
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . 5A-157
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 5A-157
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-157
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-160
Rebuild Warnings . . . . . . . . . . . . . . . . . . . . . . 5A-160
Disassembly Procedure . . . . . . . . . . . . . . . . . . 5A-161
Assembly Procedure . . . . . . . . . . . . . . . . . . . . 5A-171
Front and Rear Band Adjustment . . . . . . . . . . . 5A-199
Gear Shift Control Lever . . . . . . . . . . . . . . . . . . 5A-202
Kickdown Switch . . . . . . . . . . . . . . . . . . . . . . . 5A-202
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-203
General Specification . . . . . . . . . . . . . . . . . . . . 5A-203
Fastener Tightening Specifications . . . . . . . . . . 5A-205
Schematic and Routing Diagrams . . . . . . . . . . 5A-206
TCM Wiring Diagrams (Gasoline Engine) . . . . . 5A-206
TCM Wiring Diagrams (Diesel Engine) . . . . . . . 5A-208
Connector End View . . . . . . . . . . . . . . . . . . . . . 5A-210
Special Tools and Equipment . . . . . . . . . . . . . 5A-211
Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5A-211

5A-2 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
OPERATORS INTERFACES
There are three operator interfaces as the following;
•Gear Shift Control Lever
Driving Mode Selector
Indicator Light
Gear Shift Control lever
The transmission uses a conventional shift control lever.
The gear shift control lever can be moved from one
position to another within the staggered configuration
of the shift control lever gate to positively indicate the
gear selection.
DESCRIPTION AND OPERATION
BTRA M74 4WD AUTOMATIC
TRANSMISSION
The BTR Automotive Model 74 Four Speed Automatic
Transmission is an electronically controlled overdrive
four speed unit with a lock-up torque converter. The
lock-up torque converter results in lower engine speeds
at cruise and eliminates unnecessary slippage. These
features benefit the customer through improved fuel
economy and noise reduction.Of primary significance is the Transmission Control Mo-
dule (TCM) which is a microprocessor based control
system.
The TCM utilizes throttle position, rate of throttle open-
ing, engine speed, vehicle speed, transmission fluid
temperature, gear selector position and mode selector
inputs, and in some applications a Kickdown Switch
to control all shift feel and shift schedule aspects.
The TCM drives a single proportional solenoid multi-
plexed to three regulator valves to control all shift feel
aspects. The output pressure of this solenoid is con-
trolled as a function of transmission fluid temperature
to maintain consistent shift feel throughout the
operating range.
Shift scheduling is highly flexible, and several indepen-
dent schedules are programmed depending on the ve-
hicle.
Typically the NORMAL schedule is used to maximize
fuel economy and driveability, and a POWER schedule
is used to maximize performance. WINTER schedule
is used to facilitate starting in second gear. Configuration Max.
Power
(kW)
320 160260 mm Torque
Converter-Wide
Ratio Gear Set
Splined Output for Transfer
Case
P - Park position prevents the vehicle from rolling
either forward or backward by locking the
transmission output shaft. The inhibitor switch
allows the engine to be started. For safety reasons,
the parking should be used in addition to the park
position. Do not select the Park position until the
vehicle comes to a complete stop because it
mechanically locks the output shaft.
R - Reverse allows the vehicle to be operated in a
rearward direction. The inhibitor switch enables re-
verse lamp operation.
KAA5A010

AUTOMATIC TRANSMISSION 5A-3
SSANGYONG MY2002
N - Neutral allows the engine to be started and oper-
ated while driving the vehicle. The inhibitor switch
allows the engine to be started. There is no power
transferred through the transmission in Neutral. But
the final drive is not locked by the parking pawl, so
thewheels are free to rotate.
D - Overdrive range is used for all normal driving
conditions. 4th gear (overdrive gear) reduces the
fuel consumption and the engine noise. Engine
braking is applied with reduced throttle.
First to second (1 → 2), first to third (1 → 3), second
to third (2 → 3), second to fourth (2 → 4), third to
fourth (3 → 4), fourth to third (4 → 3), fourth to
second (4 → 2), third to second (3 → 2), third to
first (3 → 1) and second to first (2 → 1) shifts are
all available as a function of vehicle speed, throttle
position and the time change rate of the throttle
position.
Downshifts are available for safe passing by
depress-ing the accelerator. Lockup clutch may be
enabled in 3rd and 4th gears depending on vehicle
type.
3 - Manual 3 provides three gear ratios (first through
third) and prevents the transmission from operating
in 4th gear. 3rd gear is used when driving on long
hill roads or in heavy city traffic. Downshifts are
available by depressing the accelerator.
2 - Manual 2 provides two gear ratios (first and
second). It is used to provide more power when
climbing hills or engine braking when driving down
a steep hill or starting off on slippery roads.
1 - Manual 1 is used to provide the maximum engine
braking when driving down the severe gradients.When NORMAL mode is selected upshifts will occur
to maximize fuel economy. When POWER mode is se-
lected, upshifts will occur to give maximum
performance and the POWER mode indicator light is
switched ON.
When WINTER mode is selected, starting in second
gear is facilitated, the WINTER mode indicator light is
switched ON and the POWER mode indicator light is
switched OFF.
Indicator Light
The indicator light is located on the instrument panel.
Auto shift indicator light comes ON when the ignition
switch ON and shows the gear shift control lever
position.
POWER mode indicator light comes ON when the
POWER mode is selected and when the kickdown
switch is depressed.
WINTER mode indicator light comes ON when the
WINTER mode is selected.
CONTROL SYSTEMS
BTRA M74 4WD automatic transmission consists of
two control systems. One is the electronic control
system that monitors vehicle parameters and adjusts
the transmission performance. Another is the hydraulic
control system that implements the commands of the
electronic control system commands.
ELECTRONIC CONTROL SYSTEM
The electronic control system comprises of sensors, a
TCM and seven solenoids. The TCM reads the inputs
and activates the outputs according to values stored
in Read Only Memory (ROM).
The TCM controls the hydraulic control system. This
control is via the hydraulic valve body, which contains
seven electromagnetic solenoids. Six of the seven
solenoids are used to control the line pressure, operate
the shift valves and the torque converter lock-up clutch,
and to turn ON and OFF the two regulator valves that
control the shift feel.
The seventh solenoid is the proportional or Variable
Pressure Solenoid (VPS) which works with the two regu-
lator valves to control shift feel.
Transmission Control Module (TCM)
The TCM is an in-vehicle micro-processor based trans-
mission management system. It is mounted under the
driver’s side front seat in the vehicle cabin.
The TCM contains:
Processing logic circuits which include a central mi-
croprocessor controller and a back-up memory
system.
Input circuits.
Driving Mode Selector
The driving mode selector consists of a driving mode
selector switch and indicator light. The driving mode
selector is located on the center console and allows
the driver to select the driving mode.
The driving modes available to be selected vary with
vehicle types. Typically the driver should have the
option to select among NORMAL, POWER and
WINTER modes.
KAA5A020

5A-4 AUTOMATIC TRANSMISSION
SSANGYONG MY2002
Output circuits which control external devices such
as the Variable Pressure Solenoid (VPS) driver, On/
Off solenoid drivers, a diagnostics output and the
driving mode indicator light.
Processing Logic
Shift schedule and calibration information is stored in
an Erasable Programmable Read Only Memory (EPROM).
Throttle input calibration constants and the diagnostics
information are stored in Electrically Erasable Program-
mable Read Only Memory (EEPROM) that retains the
memory even when power to the TCM is disconnected.
TCM continuously monitors the input values and uses
these, via the shift schedule, to determine the required
gear state. At the same time it monitors, via the solenoid
outputs, the current gear state, whenever the input
conditions change such that the required gear state is
different to the current gear state, the TCM initiates a
gear shift to bring the two states back into line.
Once the TCM has determined the type of gearshift
required the TCM accesses the shift logic, estimates
the engine torque output, adjusts the variable pressure
solenoid ramp pressure then executes the shift.The TCM continuously monitors every input and output
circuit for short or open circuits and operating range.
When a failure or abnormal operation is detected the
TCM records the condition code in the diagnostics
memory and implements a Limp Home Mode (LHM).
The actual limp home mode used depends upon the
failure detected with the object to maintain maximum
drive-ability without damaging the transmission. In
general input failures are handled by providing a default
value. Output failures, which are capable of damaging
the transmission, result in full limp mode giving only
third or fourth gear and reverse. For further details of
limp modes and memory retention refer to the
Diagnostic Trouble Code Diagnosis Section.
The TCM is designed to operate at ambient
temperatures between - 40 and 85 °C (- 40 and 185 °F).
It is also protected against electrical noise and voltage
spikes, however all the usual precautions should be
observed, for example when arc welding or jump
starting.
TCM Inputs
To function correctly, the TCM requires engine speed,
vehicle speed, transmission fluid temperature, throttle
position, gear position and Kickdown Switch inputs to
determine the variable pressure solenoid current ramp
and on/off solenoid states.
KAA5A030
This ensures the correct gear selection and shift feel
for all driving conditions.
The inputs required by the TCM are as follows;

AUTOMATIC TRANSMISSION 5A-5
SSANGYONG MY2002
Engine Speed
The engine speed signal is derived from the Control-
ler Area Network (CAN) via Engine Control Module
(ECM).
Vehicle Speed
The vehicle speed sensor, which is located in the
transfer case, sends the output shaft speed signal
to the Engine Control Module (ECM). The information
is then transferred to the TCM via the CAN.
Transmission Fluid Temperature
The transmission fluid temperature sensor is a
thermistor located in the solenoid wiring loom within
the valve body of the transmission. This sensor is
a typical Negative Temperature Coefficient (NTC)
resistor with low temperatures producing a high
resistance and high temperatures producing a low
resistance.
If the transmission fluid temperature exceeds 135
°C (275 °F), the TCM will impose converter lock-up
at lower vehicle speeds and in some vehicles
flashes the mode indicator light. This results in
maximum oil flow through the external oil cooler and
eliminates slippage in the torque converter. Both
these actions combine to reduce the oil temperature
in the transmission.
Minimum Temperature
(°C)Resistance (Ohms)
-20
0
20
100
135 (Overheat
Mode Threshold)13,638
5,177
2,278
117
75
Maximum
17,287
6,616
2, 723
196
85
Pin No. Wire ColorConnects to
1 Red Solenoid 1
2 BlueSolenoid 2
3 YellowSolenoid 3
4 OrangeSolenoid 4
5 GreenSolenoid 5
6 VioletSolenoid 6
7 BrownSolenoid 7
8 GreenSolenoid 5
9 White Temperature Sensor
10 Red Temperature Sensor
Pin No. Codes and colors in Solenoid Loom
KAA5A040KAA5A050
Gear Position Sensor
The gear position sensor is incorporated in the inhibitor
switch mounted on the side of the transmission case.
Inhibit starting of the vehicle when the shift lever is
in a position other than Park or Neutral
Illuminate the reverse lamps when Reverse is se-
lected
Indicate to the TCM which lever position has been
selected by way of a varying resistance. The gear position sensor is a multi-function switch pro-
viding three functions;
KAA5A060