1997 SSANGYONG KORANDO Service Repair Manual

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Page 1377 of 2053

SSANGYONG KORANDO 1997 Service Repair Manual TRANSFER CASE 5D1-7
SSANGYONG MY2002
COMPONENT LOCATOR
TORQUE ON DEMAND (TOD) TYPE TRANSFER CASE
KAA5D010
1 Transmission
2 Transfer Case
3 Rear Propeller Shaft
4 Bolt5 Bolt
6 Front Propeller Shaft
7

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SSANGYONG KORANDO 1997 Service Repair Manual SSANGYONG MY2002
5D1-8 TRANSFER CASE
TRANSFER CASE DISASSEMBLED VIEW
KAA5D020

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SSANGYONG KORANDO 1997 Service Repair Manual TRANSFER CASE 5D1-9
SSANGYONG MY2002
1 Bearing
2 Bushing
3 Carrier Assembly
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Output Shaft Thrust Washer
8 Bearing
9 Snap Ring
10 High-Low Collar
11 Rear Outpu

Page 1380 of 2053

SSANGYONG KORANDO 1997 Service Repair Manual SSANGYONG MY2002
5D1-10 TRANSFER CASE
TOD CONTROL UNIT
KAA5D030
1 Transfer Case Control Unit (TCCU)

Page 1381 of 2053

SSANGYONG KORANDO 1997 Service Repair Manual TRANSFER CASE 5D1-11
SSANGYONG MY2002
DIAGNOSIS
While the transfer case control unit (TCCU) is active it
periodically monitors its inputs and outputs. If a fault
is detected the 4WD CHECK lamp is ill

TRANSFER CASE 5D1-11
SSANGYONG MY2002
DIAGNOSIS
While the transfer case control unit (TCCU) is active it
periodically monitors its inputs and outputs. If a fault
is detected the 4WD CHECK lamp is illuminated and a
fault code is stored in the TCCU memory.
When requested, fault codes are downloaded to scan
tool through a diagnostic connector (K-line) serial com
munication.
SELF-DIAGNOSTIC TESTS
TCCU Internal Function
When the ignition is turned on the TCCU tests its read
only memory (ROM) and random access memory
(RAM). If there is a fault, the TCCU immediately resets
itself and re-tests the ROM and RAM. If the fault
persists the TCCU continues to reset and re-test until
the fault is corrected or the ignition is turned off. All
TCCU functions are inhibited until the fault is corrected.
The 4WD CHECK lamp is not illuminated if there is a
ROM or RAM fault.
If the ROM/RAM passes the electronically erasable
programmable read only memory (EEPROM) is tested.
If there is a fault the 4WD CHECK lamp is illuminated
and the TCCU continues to operate using the default
calibration data stored in ROM. Fault codes are not
stored when there is an EEPROM fault.
An EEPROM fault can only be cleared by cycling
ignition OFF-ON.
Shift Motor Assembly Test
If the TCCU detects a shift motor or position encoder
fault continuously for one second the 4WD CHECK
lamp is turned on and the appropriate fault code is
stored in memory.
1. A shift motor fault when the motor is off is defined
as follows:
Motor HI-LO circuits are shorted to ground.
Motor LO-HI circuits are shorted to ground.
Motor circuits are open.
2. A shift motor fault when the motor is energized is
defined as follows:
Motor HI-LO circuits are shorted to ground.
Motor LO-HI circuits are shorted to ground.
Motor HI-LO circuits are shorted to motor LO
HI circuits.
Motor circuits are open.
3. A position encoder fault is defined as follows:
Any position code which does not correspond
to the valid 9 codes.
A short to ground on any of the encoder lines.
4. If no shifts are in progress when a failure occurs
the TCCU will not respond to any shift commands.5. If a shift command has been received but not
acted upon when a failure occurred the TCCU
would cancel the command and not respond to
any subsequent shift commands.
6. If a shift command is in progress when an invalid
position code is confirmed it will be halted and
the TCCU will turn the motor toward the high
position. Afterwards the TCCU will not respond to
any shift commands.
7. If the shift motor or position encoder assembly
failures, other than a motor failure which occurs
when the motor is energized, recovers continuously
for one second the TCCU will function normally.
The 4WD CHECK lamp is turned off but the fault
code will remain in memory.
8. A motor failure (i.e. open or short circuit) which
occurs when the motor is energized can only be
cleared by cycling the ignition OFF-ON.
Front Speed Sensor Test
If a front speed sensor fault is detected continuously
for 0.5 second the 4WD CHECK lamp is illuminated.
The TCCU then responds as follows:
1. If the system is in high range the TCCU uses the
rear speed sensor to determine the EMC touch off
level and wheel slip control is suspended.
2. If the system is in low range, the EMC duty cycle
is set to maximum, independent of vehicle speed,
until the system is shifted out of low range.
3. All electric shift activity is halted until the Ignition
is cycled. If a shift is in progress it will be
completed.
If the front speed sensor recovers continuously for O.5
second the TCCU will function normally. The 4WD
CHECK lamp is turned off but the fault code will remain
in memory.
Rear Speed Sensor Test
If a rear speed sensor fault is detected continuously
for 0.5 second the 4WD CHECK lamp is illuminated.
The TCCU then responds as follows:
1. If the system is in high range the TCCU uses the
front speed sensor to determine the EMC touch
off level and wheel slip control is suspended.
2. If the system is in low range, the EMC duty cycle
is set to maximum independent of vehicle speed
until the system is shifted out of low range.
3. All electric shift activity is halted until the Ignition
is cycled. If a shift is in progress it will be
completed.
4. If the rear speed sensor recovers continuously for
0.5 second the TCCU will function normally. The
4WD CHECK lamp is turned off but the fault code
will remain in memory.

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SSANGYONG KORANDO 1997 Service Repair Manual SSANGYONG MY2002
5D1-12 TRANSFER CASE
Both Speed Sensor Faulty
If both the front and rear speed sensors are faulty con
tinuously for 0.5 seconds the 4WD CHECK lamp is
illuminated. The TCCU then respo

SSANGYONG MY2002
5D1-12 TRANSFER CASE
Both Speed Sensor Faulty
If both the front and rear speed sensors are faulty con
tinuously for 0.5 seconds the 4WD CHECK lamp is
illuminated. The TCCU then responds as follows:
1. If the system is in high range the TCCU sets the
EMC touch off level based on a vehicle speed of
0 and wheel slip control is suspended.
2. If the system is in low range, the EMC duty cycle
is set to maximum until the system is shifted out
of low range.
3. All electric shift activity is halted until the Ignition
is cycled. If a shift is in progress it will be
completed.
If both speed sensors recover continuously for 0.5 sec-
ond the TCCU will function normally. The 4WD CHECK
lamp is turned off but the fault code will remain in
memory.
Electro-Magnetic Clutch Test
The electromagnetic clutch (EMC) is tested for open
circuit or short circuit to ground. If a fault is detected
continuously for 0.8 second the 4WD CHECK lamp is
turned on and all TODTM activity is halted.
If the EMC recovers continuously for 0.8 second the
TCCU will function normally. The 4WD CHECK lamp is
turned off but the fault code will remain in memory.
DIAGNOSTIC TROUBLE CODES
(DTCS)
When a fault is detected a diagnostic trouble code
(DTC) is stored in the TCCU and illuminates the 4WD
CHECK indicator. This DTC will remain in memory until
the TCCU is instructed to erase DTCs by scan tool.
Notice: DTCs can not be erased by disconnecting of
power supply to the TCCU.
Diagnostic Trouble Codes Table
CLEARING DIAGNOSTIC
TROUBLE CODES
When diagnose by scan tool, it is required that you
make adequate service on defects against all fault
codes. And then you should delete the memorized fault
codes in transfer case control unit (TCCU) using scan
tool as follows;
1. Connect a scan tool with dada link connector
(DLC).
2. Select TROUBLE CODE CLEAR in scan tool.
3. In TROUBLE CODE CLEAR screen, press ENTER
key to erase the fault code.
Description
EEPROM Checksum Fault
TP Sensor Loss of Signal
TP Sensor Out of Range
Electro-Magnetic Clutch Open / Short
to Battery
Electro-Magnetic Clutch Short to
Ground
Front Speed Sensor Voltage Low
Front Speed Sensor Voltage High
Rear Speed Sensor Voltage Low
Rear Speed Sensor Voltage High
Speed Sensor Reference Voltage Low
Speed Sensor Reference Voltage
High DTC
1714
1715
1716
1721
1722
1731
1732
1733
1735
1736
1741
Description
Motor Open / Shorted to Battery
Motor Output Shorted to Ground
Shift System Timeout
General Position Encoder Fault (In-
validCode)
Position 1 Shorted to Ground
Position 2 Shorted to Ground
Position 3 Shorted to Ground
Position 4 Shorted to Ground DTC
1742
1714
1743
1750
1751
1752
1753
1754

Page 1383 of 2053

SSANGYONG KORANDO 1997 Service Repair Manual TRANSFER CASE 5D1-13
SSANGYONG MY2002
BLANK

Page 1384 of 2053

SSANGYONG KORANDO 1997 Service Repair Manual SSANGYONG MY2002
5D1-14 TRANSFER CASE
4WD CHECK INDICATOR STAYS ON WITH IGNITION SWITCH ON
KAA5D040
Circuit Description
When the ignition switch turns to ON the transfer case
control unit (TCCU) illu

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