2003 SSANGYONG MUSSO battery

TRANSFER CASE (TOD) 5D2-25
Error in electro - magnetic clutch : fault code “1721 ”, “1722 ”
Phenomenon
1. Upon diagnosis by SCAN-100, it displays on fault
codes “1721,1722 ”.
Cause
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 sNo
C1
Ye sNo
Ye s
No
11-15Vdc Ye s
No
C2
Ye sNo
Test Stage / ContentsResult
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
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 withScan - 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

Charging/ Replace battery
Replace fuse
Repair wires

TRANSFER CASE (TOD) 5D2-29
Shift motor malfunction : Fault code ® 1741,
1742, 1743
Phenomenon
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.
Cause
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 sNo
Ye sNo
E2
Ye sNo
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
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 locatedbetween 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 stagePerform E2 stage Perform E4 stage Perform E2 stage Perform E3 stage Perform E2-2 stage Perform E3 stage Normal system

TRANSFER CASE (TOD) 5D2-35
Removal & Installation Procedure1. Disconnect (-) cable from battery.
2. Lift on vehicle and make sure on safety. NoticeBe 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. NoticeOil 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.

TRANSFER CASE (TOD) 5D2-37
Replacement of Shift Motor
1. Disconnect (-) cable from battery.
2. Disconnect shift motor/clutch coil connector (black pin7)upper backside.
3. Unscrew 3 units of shift motor mounting bolts (M10).
4. Unscrew 1unit of bracket mounting bolt (M10). Installation Notice
Tightening Torque 9 - 11 Nm
Notice When disconnecting shift motor and mounting bracket, it is required to unscrew 2 units of adjusting bolts (M10) formmotor and bracket.
5. Keep shift motor even then pull rearward.
6. Clean connection surface of transfer case and shift motor.
7. If necessary, make a test by SCANNER with shift motor assembly.Notice
Do not disassemble shift motor. If necessary, replace by shift motor assembly unit.
8. Applying sealant into connecting surface for new shift motor.
9. Installation should follow the removal procedure in the reverse order. Before installation, make sure that motor position match with mode of 4H/4L switch. ReferenceWhen accord position of motor with 4H/4L switch and transfer case match position of the disconnected motor and newone.

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 3pin) 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.

7D-12 FATC-HAVC Pin Number and Connection Circuit
Pin No.1 Connection circuit
2 3456789
10 11
1213141516
Rheostat Tail lamp
Battery (+)
Power TR (B) Power TR (C)
Temperature actuator (CCW) IG2
Ground
Airconditioner switch ground HI speed relay
Photo sensor (+)
Photo sensor (-)
Temperature actuator F/B
Temperature actuator (CW) IG2
Ground
Connector A
Pin No.
1 Connection circuit
2 345 6 789
101112131415
Incar sensor (+)
Ambient sensor (+) Coolant sensor (+)
Sensor voltage 5V Sensor ground
Intake (ambient) Intake (incar)
- --
VENT
B/L
FLR MIX
DEF
--- - -
Connector B
17 18
19
20
16

FATC-HAVC 7D-19
Fault : intake (recirculation/fresh air) door inoperative
Remove the glove box.
Measure voltage between 6c terminal positive pole (+)
and bo dy (-).
Measured voltage is 12V.Check No. 24 fuse (15A) in the box.
Turn the ignitin switch OFF and disconnect harness of
the intake actuator.
Ye s No
Disconnect 3-pin connector of the intake mode actuator and turn the ignition switch to ON position.
6A
6B 6C
Check that it operates toward each direction after connecting the battery to the 6C terminal of intake
actuator and ground 6A & 6B to the body.6C 6B 6A
Wiring side connector
Actuator connector
Intake actuator is normal.
Ye s
Repair and replace the intake actuator.
No
Check intake actuator linkage and door for
proper operation and repair if necessary.Disconnect 20-pin connector from the airconditioner control unit.
Check current between the intake actuator (6A, 6B) and the airconditioner control unit (6,7).
Is there current?
Ye s
Repair open wire between the intake actuator and the control unit.
No
Replace the good control unit and re-check. If no fault, replace the control panel.
67

0.5YB

0.5LgR
+
-

SECTION 8A
SEAT BELTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 8A-1
Fastener Tightening Specifications . . . . . . . . . 8A-1
Component Locator . . . . . . . . . . . . . . . . . . . 8A-2
Front Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . 8A-2
Rear Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . 8A-3 TABLE OF CONTENTS
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 otherwisenoted.
General Description and System
Operation . . . . . . . . . . . . . . . . . . . . . . . . . 8A-4
Driver Seat Belt Warning . . . . . . . . . . . . . . . . 8A-4
Operation and Functional Checks . . . . . . . . . 8A-4
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Anchor Bolt N
m
35 - 55