1998 SSANGYONG MUSSO battery

AUTOMATIC TRANSMISSION 5A-67
Table 6.1.3 - Diagnostic Trouble Messages
Description / Cause
There have been no faults recorded since the TCU was last cleared. If
the fault history has never been cleared, then there have been no
faults recorded since the TCU was originally powered up.
There is an internal fault within the TCU.
The voltage measured by the TCU corresponding to the battery sup-
ply voltage has been outside the range of the maximum operating
voltage of 16.5 volts.
The minimum operating voltage depends on the transmission tem-
perature but is typically between 8-9 V for a warm transmission.
The voltage measured by the TCU from the throttle potentiometer has
been outside acceptable levels.
This would typically indicate a loose connection in the wiring to, or
within, the throttle sensor which has caused the signal at the TCU to
read 0V or 5V.
The voltage measured by the TCU across the temperature Input ter-
minals has been outside acceptable levels.
This would typically be caused by a loose connection or short to ground
in the wiring to, or within, the temperature sensor which has caused
the signal at the TCU to read 0V or 5V.
The voltage measured by the TCU across the shift lever input termi-
nals has been outside acceptable levels for a significant length of
time. This would typically be caused by a loose connection or short to
ground in the wiring to, or within, the inhibitor switch which has caused
the signal at the TCU to read 0V or 5V.
The signal from the ignition, of ignition pulses, has either been non-
existent or has been unreliable.
There are two reasons this fault could occur. The first is due to a lack
of ignition pulses when other TCU inputs would indicate that the en-
gine is running, that is the gear lever is in a driving position, the throttle
is applied and vehicle speed increasing.
The second cause of this (aunt is the frequency of the pulses of the
ignition pulse input to the TCU indicate an unachievable engine speed.
The pulses from the shaft speed sensor have either been non-exis-
tent or have been unreliable.
There are three reasons this fault could occur. The first is due to a
sudden loss of speedometer pulses at a time when they were fre quent,
thus indicating an unachievable degree of deceleration of the drive
line. The second cause of this fault is that the frequency of the pulses
on the shaft speed sensor input to the TCU indicate an unachievable
propeller shaft speed. The third is the presence of a high engine speed
in a driving gear with no speedometer pulses. Condition
Test Pass
Transmission Control
Module Fault
Battery Voltage Input
Fault
Throttle Input Fault
Temperature Input Fault
Shift Lever Position
Input Fault
(Inhibitor/PRNDL Switch)
Engine Speed Sensor
Fault
Shaft Speed Sensor
Fault
(Speedo Sensor)Solenoid
1
2
3
4
5
6
7
8

AUTOMATIC TRANSMISSION 5A-69
MECHANICAL TESTS
In Vehicle Transmission Checks
Carry out the following tests before removing the transmission.
lSee Checking Transmission Fluid Level, Section 7.2.1.
lCheck that the transmission oil is not burnt (colour and smell are correct).
lEnsure that the transmission is not in limp home mode (LHM).
lCheck that the battery terminals and the earth connections are not corroded or loose.
lCheck the engine stall speed is within the handbook value.
lCheck that the cooler flow is not restricted.
lCheck that all electrical plug connections are tight.
lCarry out a road test to confirm the symptoms, if necessary.
lInspect the oil, ensure that there are no metal or other contaminants in the oil pan.
Diagnosing Oil Leaks
Determine the source of oil leaks by firstly cleaning down the affected area, then driving the vehicle.
Inspect the seals to confirm the source of the leak.
lTo determine the source of a rear servo oil leak, raise the vehicle on a hoist, then carry out a reverse stall.
lTo determine the source of a front servo leak, raise the vehicle on a hoist, then run the vehicle in second gear.
Troubleshooting Charts
The troubleshooting charts are set out as follows:
lTable 6.2.1 Drive Faults,
lTable 6.2.2 Faulty Shift Patterns.
lTable 6.2.3 Shift Quality Faults.
lTable 6.2.4 After Teardown Faults.
Table 6.2.1 - Drive Faults
Action
Check the fluid level. Top up as necessary.
Inspect and clean C1/C2 feed.
Reinstall/renew the ‘z’ link.
Remove, clean and re-install the PRV.
Inspect and replace as necessary.
Inspect and replace as necessary.
Inspect and replace as necessary.
Check servo adjustment or replace rear band
as necessary.
Check for failure in C3, C3 hub or C1/C2 cylin-
der. Repair as necessary.
Inspect and clean PRV.
Inspect and replace pump gears as necessary.
Inspect and repair as necessary. Possible Cause
Insufficient auto transmission fluid.
Blocked feed in C1/C2 cylinder.
‘Z’ link displaced.
Primal regulator valve (PRV) jammed open.
Overdrive shaft or input shaft seal rings
failed.
3-4 or 1-2 one way clutch (OWC) installed
backwards or failed.
C2 piston broken or cracked.
Rear band or servo faulty.
Failure in C3, C3 hub or C1/C2 cylinder.
Jammed primary regulator valve (PRV).
Damaged/broken pump gears.
Dislodged output shaft snap ring.Symptom
No Drive in D
No Drive in
Reverse
No engine braking
in Manual 1
Engine braking in
Manual 1 is OK
No drive in Drive
and Reverse

5A-76 AUTOMATIC TRANSMISSION
Action
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck voltage between terminal 27 and 29 of TCU,
- Standard value : 0.2 - 4.7V
lCheck TPS.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck engine speed sensor.
lCheck resistance between terminal 8 and 24 of TCU (when the
connector is disconnected).
- Standard value : 1 .9 - 0.2 k
W
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck vehicle speed sensor.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck engine speed sensor.
lCheck inhibitor switch resistance between terminal 34 and 37 of
TCU(when the connector is disconnected).
- Standard value : 1st gear - 4 - 4.4 k
W
2nd gear - 4,8 - 2.2 kW
3rd gear - 3 - 3.4 kW
D gear - 4.5 - 4.g kW
N gear - 6.8 - 7.2 kW
R gear - 10.8 -11.2 kW
P gear - 18.6 - 19 kW
lCheck voltage between terminal 31 and 37 of TCU.
- Standard value : 0-5V(P,R,N,D,L)
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck mode switch.
lCheck condition between terminal 1 and 13 of TCU.
Winter mode :12V, Normal mode : Open status, Power mode : 0V
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck voltage between terminal 32 and 38 of TCU.
- Standard value : 0-5V
lCheck oil temperature sensor.
lCheck cable for open / short.
lCheck connection of other connectors.
lCheck battery condition.
lCheck alternator. Possible Cause
Throttle position sensor
Engine RPM
Vehicle speed
Shift lever
W, E, P mode switch
T/M oil temperature
Battery voltage Symptom
P1702
P1703
P1704
P4705
P1706
P1707
P1708
Self-diagnosis List

5A-82 AUTOMATIC TRANSMISSION
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
Tightening Torque 70 - 80 Nm
5. Remove the rear propeller shaft .
Installation Notice
REMOVAL & INSTALLATION OF
TRANSMISSION
1. Disconnect the negative battery cable.
2. Disconnect the connectors from transfer case.
3. Disconnect the speedometer connector from transfer
case.
4. Disconnect the inhibitor and Sear position sensor
connector.
6. Unscrew the eight bolts and two nuts, and remove the
cross member.

AUTOMATIC TRANSMISSION 5A-85
UNIT REPAIR
REBUILD WARNINGS
Prior to rebuilding a transmission system, the following warnings
are to be noted.
lEnsure that, before replacing a transmission the cooler
lines are flushed out to remove any debris. This can be
done by applying compressed air to the rear cooler line
forcing oil and any contaminants out of the front cooler
line.
lThe cooler flow should be checked after the transmission
has been fitted. With the front cooler line connected
and the rear line run into a suitable container, measure
the flow over 15 seconds with the vehicle idling in park.
lThe flow rate should exceed 1 liter in 15 seconds.
lBe wary of any situation where water enters the
transmission. This may result in fluid foaming and leaking
through the breather.
lEnsure that both earth straps (one at the batted terminal
and one on the vehicle body) are connected in the
vehicle before connecting the positive side of the
battery.
lFollow the throttle position calibration procedure in
section 7 of this manual if the powertrain control module
transmission control unit (PCM/TCU) is swapped.
DISASSEMBLY PROCEDURE
Transmission
Notice
Remove the inhibitor switch before washing the transmission
in solvent or hot wash.
It is assumed that the transmission fluid has been drained
when the transmission was removed from the
vehicle and that the ‘special tools’ quoted are available.
The transmission is dismantled in a modular fashion, and the
details of disassembly for each module are given under the
appropriate subject. Refer to table 9.10 in section 9.6 for details
of all special tools required when performing disassembly
procedures.
Technicians overhauling these transmissions will also require
a selection of good quality Torx bit sockets, in particular
numbers 30, 40 and 50, and an 8 mm,10 mm and 12 mm
double hex socket.
To disassemble the transmission, proceed as follows:
1. Remove the converter and the converter housing.
2. Mount the transmission on the bench cradle
No.0555-331895.
3. Remove the sump and the sump seal.

MANUAL TRANSMISSION 5B-15
Removal & Installation Procedure
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug from the transmission housing and
drain the oil. Reinstall the drain plug.
Installation Notice
Tightening Torque
25 Nm
4. Disconnect the back-up switch connector.
5. Remove the breather hose.
6. Remove the speedometer connector and other wiring
harnesses and connectors.

Type
Clutch Pedal
Clutch Disc
Clutch Master Cylinder
Clutch Release Cylinder
Clutch FluidDescription
Hydraulic
Suspended
158 mm
5 - 10 mm
Single Dry Diaphragm
9.85 - 10.2 mm
9.2 mm
19.8 mm
f15.87 mm
14.0 mm
f17.46 mm
SAE J1703 / DOT3
SECTION 5C
CLUTCH
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5C-1
General Specifications . . . . . . . . . . . . . . . . . . 5C-1
Fastener Tightening Specifications . . . . . . . . . 5C-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5C-3
Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5C-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Clutch Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Poor Disengagement . . . . . . . . . . . . . . . . . . . 5C-4
Hard to Shift or Will not Shift . . . . . . . . . . . . . . 5C-4
Clutch Chatters When Starting . . . . . . . . . . . . 5C-4
Difficult Pedal Operation . . . . . . . . . . . . . . . . . 5C-5
SPECIFICATIONS
GENERAL SPECIFICATIONS
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.
Application
Type
Max. Pedal Stroke
Pedal Free Play
Type
Thickness of Disc
Stroke
Inner Diameter
Stroke
Inner DiameterFree
With Load
Clutch Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5
Component Locator . . . . . . . . . . . . . . . . . . . 5C-6
Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . 5C-6
Pedal and Master Cylinder . . . . . . . . . . . . . . . 5C-7
Maintenance and Repair . . . . . . . . . . . . . . . 5C-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 5C-8
Bleeding of Clutch System . . . . . . . . . . . . . . . 5C-8
Clutch Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 5C-13
Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Clutch Oil Chamber . . . . . . . . . . . . . . . . . . . 5C-17

Model
Type
Gear Ratio
Oil
Manufacturer
WeightPart-Time 4408 (E)
E.S.O.F. Type
1 : 1
2.48 : 1
ATF S-3, S-4 or DEXRON II, III
1.2 L
Check : Every 15,000 km
Replace : Every 50,000 km
Borg Warner
30 kg
SECTION 5D1
TRANSFER CASE (PART TIME 4408)
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
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.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D1-1
General Specifications . . . . . . . . . . . . . . . . . 5D1-1
Schematic and Routing Diagram . . . . . . . . 5D1-2
Part Time Transfer Case - 4408 . . . . . . . . . . 5D1-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D1-3
Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . 5D1-4
System Description . . . . . . . . . . . . . . . . . . . . 5D1-4
Self-Diagnosis Test . . . . . . . . . . . . . . . . . . . . 5D1-8Diagnostic Diagram . . . . . . . . . . . . . . . . . . . 5D1-9
Maintenance and Repair . . . . . . . . . . . . . 5D1-10
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D1-10
Maintenance of Transfer Case Lubricant . . 5D1-10
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-11
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case Control Unit (TCCU) . . . . . . 5D1-36
High
Low
Specification
Capacity
Lubrication ApplicationDescription