1998 SSANGYONG MUSSO sensor

TRANSFER CASE (TOD) 5D2-27
Defect in speed sensor : fault code 1731, 1732,
1733, 1734, 1735,1736
lPhenomenon
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”.
lCause
1. Defect of speed sensor (front, rear).
2. Defect of power supply.
4.75-5.25Vdc
Ye s
No D1
Ye s
No
D2
Ye s
Ye s
Ye s
No D3Test Stage / Contents
Result
Stage Test Contents and ProcedureSpecified Value
/Yes/NoCountermeasure
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 to
1736.
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 stage
Perform 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 s
No D4Test Stage / Contents
Result
Stage Test Contents and ProcedureSpecified Value
/Yes/NoCountermeasure
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 within
specified 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 of
control 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 " ¥ W " ?Repair wire Perform
D5-4 stge
Ye s
NoWiring short, repair
Perform D3 stage,
then delete fault
codes with
rediagnosis

TRANSFER CASE (TOD) 5D2-35
Removal & Installation Procedure
1. Disconnect (-) cable from battery.
2. Lift on vehicle and make sure on safety.
Notice
Be careful for catalytic converter due to high temperature
after driving or engine running.
3. Prepare a vessel to drain transfer case and manual
transmission oil.
4. Release drain plug and drain transfer case and manual
transmission oil.
If planar damper is installed, unscrew 4 bolts and remove
the planar damper.
Notice
Oil drain should be along with whole transfer case
disassembly and assembly.
5. Disconnect transmission extension wiring connector back
side transfer case.
Notice
When disconnect connector, make sure on direction of
locking tab towards inside.
6. Disconnect shift motor/clutch coil connect (Black 7 pin)
connector upper backside.
7. Disconnect front and rear speed sensor connector (white
7 pin).
8. Disconnect speedometer sensor connector right upper
side.
9. Disconnect breather tube front upper side transfer case
(upper connecting point of transfer case and front
propeller).
10. Prepare hydraulic jack and support transfer case assembly.

5D2-38 TRANSFER CASE (TOD)
SPEED SENSOR IN FRONT AND
REAR PROPELLER SHAFT
Replacement Procedure
1. Disconnect (-) cable from battery.
2. Detach shift motor assembly.
3. Disconnect front and rear speed sensor connector (white 3
pin) upper backside transfer case.
4. Disconnect speed sensor connect from locking sleeve by
pushing.
5. Disconnect wire stick cap from the detached connector.
6. Unscrew rear speed sensor mounting bolt (M10) from upper
side of rear case flange.
7. Detach sensor from transfer case by lifting up using tool.
Notice
When disconnect sensor, make sure on adequate pressure
due to sensitiveness with shock.
8. Disconnect taping from both protection tube ends that wrap
3 wires of speed sensor and 1 wire of clutch coil.
9. Disconnect tube.

TRANSFER CASE (TOD) 5D2-39
10. Disconnect pin and wire from speed sensor connector by
pulling sticking long-nose plier into “L” pin in connector.
11. On the same way, disconnect pin and wire “M” and “N”
from connector.
Notice
Do not touch the wires related with EMC.
12. Prepare new speed sensor.
13. Connect 3 pins with wires of speed sensor to coincide with
each connection position.
14. Using long-nose plier, connect tightly by pulling pins.
15. Apply rubber cap into connector using long-nose plier not
to detach.
16. Connect protection tube with wire.
17. Tape both ends of tube.
18. Putting rear speed sensor into hole, connect exactly
pushing both ends.
19. Screw 1 unit of bolt (M10).
Installation Notice
Tightening Torque 9 - 11 Nm
20. Connect speed sensor connector, then locking sleeve.
Reference
Front propeller shaft should be premised by removal of
shift motor.
After disconnecting shift motor, procedure of replacement
on sensor assembly of accords with one of rear speed
sensor.

5D2-42 TRANSFER CASE (TOD)
1 Bearing
2 Bushing
3 Carrier Assembly
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Output Shaft Thrust Washer
8 Bearing
9 Retaining Ring
10 Snap Ring
11 High-low Collar
12 Rear Output Shaft
13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Assembly
17 Thrust Washer
18 Sprocket, Drive (24T)
19 Clutch Pack Assembly
20 Insulator Washer
21 Armature
22 Snap Ring
23 Wave Washer
24 Apply Cam
2 5 Ball
26 Cam and Coil Assembly
27 Nut, Metric
28 Output Shaft Yoke Washer
29 Oil Seal
30 Case Flange
3 1 Bolt
32 Upper Speed Sensor (Rear)
3 3 Nut
34 Washer
3 7 Bolt
38 Tag, Identification
39 Thrust Bearing
40 Clutch Coil Assembly
41 Fork, Reduction Shift42 Shift Rail
43 Shaft, Shift
44 Spacer
45 Torsion Spring
46 Shift Cam
47 Transfer Case Shift Motor
4 8 Bolt
4 9 J-clip
50 Connector Retainer
5 1 Bolt
52 Support Stud
53 Lower Speed Sensor (Front)
5 4 Plug
55 Identification Decal
56 Cover
57 Tone Wheel, Lower
58 Chain, Drive
59 Sprocket, Driven (24T)
61 Magnet
62 Case
63 Case Flange and Output Shaft
64 Barb, Breather
68 Spiral Pin
69 Oil Seal
70 Pin, Dowel
71 Ring Gear
72 Retaining Ring
73 Snap Ring
74 Bearing
75 Snap Ring
76 Bearing
77 Speedometer Drive Gear
78 Facing, Shift Fork
79 Upper Tone Wheel
80 Oil Seal
81 Bearing Sleeve
82 Bearing

TRANSFER CASE (TOD) 5D2-43
Disassembly Procedure
1. Disconnect transfer case from vehicle
2. Using a 30mm thin-wall socket, first remove the rear output
nut, output shaft yoke washer, oil seal then the case flange.
Installation Notice
27 Nut
28 Washer
30 Case Flange
Tightening Torque 137 - 196 Nm
3. Disconnect shift motor/clutch coil connector and speed
sensor connector from upper bracket of transfer case.
Notice
When disconnect connector, pull forwards grasping
connector housing.
4. Remove outer tube on speed sensor connector.
5. Remove wire supporting cape back side of speed sensor
connector.
6. Disconnect pin of clutch coil wire (yellow) from speed sensor
connector (white 7 pin) using long-nose plier.
7. Remove shift motor.
Notice
When remove shift motor, pay attention to the location of
triangular slot and shaft in transfer case inside motor.
8. Disconnect front and rear speed sensor.

TRANSFER CASE (TOD) 5D2-51
25. Install the pin on the tang end of the helical cam into the
hole in the front case. Position the torsion spring tangs so
that they are pointing toward the top side of the transfer
case and just touching the high-low shift fork.
CAUTION
Do not bend the helical cam during installation to the front
case because of possible damage to the pin at the tang
end of the motor shaft.
26. Install the shift rail through the high-low shift fork and make
sure that the reverse gear shift rail is seated in the front
case bore.
27. Install upper and lower speed sensors into the cover. Feed
the coil wire through the upper speed sensor wire shield.
28. Install upper tone wheel, speedometer gear and rear output
seal. Use Output Shaft Seal Replacer and Driver or
equivalent to install seal.
29. Coat the mating surface of the front case with a bead of
Black Non-Acid Cure Silicone Rubber or equivalent.
30. The following procedure must be followed prior to installing
the rear case onto the front case half:
a. Align the output shaft with the rear case output shaft bore.
b. Align the helical cam with the rear case motor bore.
If difficulty is encountered with seating the rear case, tap
the rear output shaft with a sharp blow using a rubber
mallet in a direction away from the triangular shaft while
pushing down on the rear case.
Tightening Torque 25 - 37 Nm 31. Install the bolts retaining the case halves and tighten.