1998 SSANGYONG MUSSO wiring

TRANSFER CASE (TOD) 5D2-25
Error in electro - magnetic clutch : fault code
“1721”, “1722”
lPhenomenon
1. Upon diagnosis by SCAN-100, it displays on fault
codes “1721,1722”.
lCause
1. Defect in electro - magnetic clutch
2. Defect in connector or wiring
- Open or short from EMC to the supply : 1721
- Short EMC to ground : 1722
Ye s
No
C1
Ye s
No Ye s
No
11-15Vdc
Ye s
No
C2
Ye s
No
Test Stage / ContentsResult
Stage Test Contents and ProcedureSpecified Value
/Yes/NoCountermeasure
Check relevant connector connection status.
1. Check relevant connector connection status with TOD
control unit.
- Does it connect correctly ?
2. Check connection status of speed sensor and clutch
coil connector (7 pin) in transfer case.
- Does it connect correctly ?
3. In case of bad connection, connect it correctly then
perform the follows :
a. Delete the memorized fault code in control unit with
Scan - 100.
b. Ignition “OFF”.
c. Ignition “ON”.
d. Diagnose by SCAN-100
- Does it display on fault codes “1721,1722” ?
Check supply voltage into electro-magnetic clutch.
1. Ignition “ON”
2. Measure voltage between pin 4/19(+) and 17/18(-) in
TOD control unit connector.
- Specified value
- Measured value is within specified range ?
3. If the specified value would not be measured, perform
the follows :
a. Check battery voltage (charging condition)
b. Check open circuit on No.13 fuse (20A)
c. Check relevant wires.
- Is the above 3a, 3b, 3c normal ?Perform C1-2 stage
Perform C1-3 stage
Perform C2 stage
Normal system Perform C2 stage
Perform C1-3 stage
Perform C3 stage
Perform C2-3 stage
Perform C3 stage
lCharging/
Replace battery
lReplace fuse
lRepair wires

5D2-26 TRANSFER CASE (TOD)
0Vdc
11 - 15Vdc
Ye s
No
2.5W
Ye s
No C3Test Stage / Contents
Result
Stage Test Contents and ProcedureSpecified Value
/Yes/NoCountermeasure
Check resistance of electro-magnetic clutch.
1. Disconnect 30 pin connector from TOD control unit.
2. Measure resistance between pin 3 and 7 in wiring
connector using multi-tester.
- Specified value
- Measured value is within specified range?Perform C4 stage
l0W : short
l¥W : open
C4Check operational voltage of elector-magnetic clutch.
1. Ignition "ON"
2. Measure voltge between pin 3(+) and 17(-)in TOD
control unit connector.
- Specified value 4WD high
4WD low
- Measure value is within specified range ?Replace TOD
control unit
Replace wire

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) 5D2-29
Shift motor malfunction : Fault code ® 1741,
1742, 1743
lPhenomenon
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.
lCause
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 s
No
Ye s
No
E2
Ye s
No Test Stage / Contents
Result
Stage Test Contents and ProcedureSpecified Value
/Yes/NoCountermeasure
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 located
between 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 stage
Perform 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 s
No
Ye s
No
Ye s
No E3
Ye s
No E4
Ye s
No E5Test Stage / Contents
Result
Stage Test Contents and ProcedureSpecified Value
/Yes/NoCountermeasure
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 0W ?
4. Perform the short test between No.1/No.14 Connector
and body, No2/No.15 connector and body.
- Is there resistance of 0W ?
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 and
No.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 fault
is 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 motor
or delete fault code
and rediagnosis
system.

TRANSFER CASE (TOD) 5D2-31
Position incoder and position 1,2,3,4 malfunction
:Fault code®1750,1751,1752,1753, 1754
lPhenomenon
The ‘4WD check’ lamp can not go out when the ignition
switch positioned to ‘ON’.
The fault code display 1750, 1751, 1752, 1753, 1754 by
diagnosis of SCAN-100.
lCause
The portion of position incoder malfunction, each wiring is
shorted with ground.
Ye s
No
F1
Ye s
No
Ye s
No F2Test Stage / Contents
Result
Stage Test Contents and ProcedureSpecified Value
/Yes/NoCountermeasure
Check the installation condition of connector.
1. Check the installation condition between 30 pin connector
of TOD control unit and motor connector of T/C portion.
- Is it installed properly ?
2. If the connector installation is improper, install properly
and then execute follow procedure.
a. Delete the all fault code from memory by scan scope.
b. Turn off ignition switch.
c.Turn on ignition switch.
d. Rediagnosis the system.
- Does the fault codes display one or more among
1750 ~ 1754.
Check the each wiring whether it is shorted or not.
1. Turn off the ignition switch
2. Detach the 30 pin connector of TOD control unit.
3. Perform short test each connector, No.27 (Position 1),
No.10 (Position 2), No.28 (Position 3),No.30 (Position
4), No.6 with body.
- Is there resistance of 0W?Perform F2 stage
Perform F1-2 stage
Perform F2 stage
Normal system
Repair or replace
due to wiring short
1. Replace the
motor Ass’y due
the defective
position incoder
portion.
2. And then, perform
F1-2 stage.

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.

MANUAL & SEMIAUTO-HVAC 7B/C-5
Action
Clean oily plate using cleaning agent.
Charge battery or check for cause.
Check wire continuity
Check A/C switch and fan switch for continuity and ground.
DEFECTIVES IN FAN MOTOR CIRCUIT
Fan Motor Does Not Run
Checks
Blown fuse
Battery voltage is low
Faulty wiring
Faulty groundAction
Check for short and replace fuse.
Check battery voltage.
Check connectors’ connection.
Do not apply grease. This can cause voltage down.
Remove body painting and completely ground,
Tighten ground bolts and make sure body ground connection.
Checks
Blown resister temperature fuse
Air leakage in parts connection
Action
Replace resistor.
Check heater, cooling unit and blower for proper connection.
Fan Motor Runs in ‘4’position Only (‘3’, ‘2’, ‘1’ : Does Not Run)
Frosted Evaporator
DEFECTIVES IN COMPRESSOR CIRCUIT
Compressor Does Not Run
Checks
Faulty thermo ampAction
Frosted evaporator reduces cooling capacity.
Off compressor and maximize blowing capacity
Checks
Faulty high/low pressure
Faulty A/C relayAction
Check compressor magnet voltage supply.
A/C relay.
Checks
Oily clutch plate
Low voltage
Faulty electric connection or operation
Magnetic Clutch Slips /Idles
Checks
Clogged or blocked intake grilleAction
Clogged or blocked intake grille reduces blowing capacity.
Motor Runs With Poor Blowing
Checks
Excessive clearance between
Clutch plate and clutch coilAction
Adjust clutch clearance (0.2-0.6mm).
Magnetic Clutch Plays By Hand Only