2003 SSANGYONG MUSSO Service Manual

TRANSFER CASE (PART TIME 4408) 5D1-37
Inspection and Repair
1. 4H and 4L indicator light inspection When turn the ignition switch to "ON" position, 4H and
4L indicator light will turn on for 0.6 second and will turn
off immediately.
Notice
If indicator light does not turn on, check bulb, wiring harness and TCCU.
2. TCCU inspection
Pin No. Operation Condition
4H or 4L
2H
4H indicator light ON
4H indicator light OFF 2H or 4H4L
Clutch pedal applied
Clutch pedal released 4L indicator light ON
4L indicator light OFF Motor OFF
Motor ON
Motor OFF Motor ON
Auto locking hub ON
Auto locking hub OFF Voltage(V)
4.75 - 5.35
0 - 0.50< 1.00
> 11.00
4.75 - 5.35 0 - 0.50
< 0.50
> 11.00
< 1.00
> 11.00 < 1.00
> 11.00 < 1.00
> 11.00
> 11.00 < 1.00
J1 - 7
J1 - 8
J1 - 13 J1 - 14 J1 - 15 J1 - 16 J1 - 17 J1 - 23
Notice DC 12V for the TCCU operation should be maintained.
In case of J1-8 and J1-15, indicator light will turn on for 0.6
second when turn the ignition switch ON.
If 4H and 4L indicator lights remain turned on when turn the
ignition switch on or during driving, perform the TCCUdiagnosis.

SECTION 5D2
TRANSFER CASE (TOD)
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D2-1General Specifications . . . . . . . . . . . . . . . . . 5D2-1
Schematic and Routing Diagrams . . . . . . . 5D2-2 TOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-2
T.C.C.U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-3
Function Description . . . . . . . . . . . . . . . . . 5D2-4
TOD Control Unit . . . . . . . . . . . . . . . . . . . 5D2-12
Control Unit Diagram . . . . . . . . . . . . . . . . 5D2-14
TOD Control Unit . . . . . . . . . . . . . . . . . . . . 5D2-14
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-15 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . 5D2-15
Diagnostic Trouble Codes (DTC's) . . . . . . . 5D2-17
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
ModelLength (mm)Weight (kg)Shift ModeGear Ratio Oil
Max. Torque
High Low SpecificationCapacityInterval TOD(Torque On Demand) Transfer Case (4423E)
343.036.6
4H and 4L
1 : 1
2.48 : 1
ATF S-3, S-4 or Dexron II, III 1.4 L
Inspect Every 15,000km, Replace Every 50,000km 550 lbft ( 76kg m)
.
= .
.
= .
Application Description
Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-18
Eliminate the Memorized Fault Code . . . . .
5D2-20
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-21
Maintenance and Repair . . . . . . . . . . . . . 5D2-33
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D2-33
TOD Control Unit . . . . . . . . . . . . . . . . . . . . 5D2-33
Transfer Case (TOD) . . . . . . . . . . . . . . . . . 5D2-34
Speed Sensor in Front and Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . . 5D2-38
Replacement of Oil . . . . . . . . . . . . . . . . . . . 5D2-40
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D2-41 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D2-41

5D2-2 TRANSFER CASE (TOD)SCHEMATIC AND ROUTING DIAGRAMS
TOD

TRANSFER CASE (TOD) 5D2-3
T.C.C.U

5D2-4 TRANSFER CASE (TOD)FUNCTION DESCRIPTION
TOD System Select Mode (4H and 4L) 4H is the mode when drive normally of which gear ratio is 1:1 and 4L mode distributes power to front and rear wheels 50:50 of which gear ratio is 2.48:1.
TOD System Function (select 4H mode) TOD system controls clutch mechanism to comply with rotation in front and rear propeller shaft and if its difference exceeds the permissible range, corresponding power is distributed into front wheel through EMC (Electro-MagneticClutch). Hall effect sensor signals speed on front and rear propeller shafts going through with TOD control unit.
Transfercase clutch coil is activated by variable current on exceeding difference of speed in front and rear propeller shafts.
Function of 4L Mode When select 4L mode, EMC is locked to apply maximum torque into front and rear propeller shafts. Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1:1 to 2.48:1 by planetarygear set.
Shift Motor It locates backside transfer case, which drives rotary helical cam. When mode select switch changes to 4L, shift fork is on position for 2.48:1 by rotation of helical cam.
Transfer Case
TOD transfer case distributes power into front and rear axle by operation of 4H/4L switch and shift motor. Shifting 4H to 4L, is performed towards reducing HI-LO collar by means for connection HI-LO shift fork with
output shaft in order to join with planetary gear. Torque transmits input shaft then sun gear rotating front planetary
gear. Front planetary gear join with output shaft and drives LO position.

TRANSFER CASE (TOD) 5D2-5
Definitions
Rear Speed Sensor A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal inresponse to a rotating 30 tooth wheel coupled to the rear propshaft inside the
Transfer Case. Each rotation of the rear propshaft will result in 30 speed sensor pulse.
Front Speed Sensor A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal in response to a rotating 30 tooth wheel coupled to the front propshaft inside the
Transfer Case. Each rotation of the front propshaft will result in 30 speed sensor pulse.
EMC An Electromagnetic clutch used to control the amount of torque applied to the front propshaft.
TOD TM
Torque on DemandTM
.
Duty Cycle Duty Cycle is the time the EMC is on divided by the period in which it is being modulated.
Touch-off A minimum amount of duty cycle applied to the EMC.
Front OverrunA condition where the front propshaft is turning at a rate which is faster than the rear propshaft.
Rear Overrun A condition where the rear propshaft is turning at a rate which is faster than the
front propshaft.
High Range The highest (numerically lowest = 1 :1) gear ratio between the input and outputsof the Transfer Case.
Low Range The lowest (numerically highest = 2.48:1) gear ratio between the input and outputs
of the Transfer Case.
4H/4L Switch A switch which selects the desired gear ratio.
Shift Motor Electric motor which changes the Transfer Case range.
Position Encoder A set of 4 Gray code switches which provide feedback to the TCCU indicating theposition of the Shift Motor.
Clutch Interlock Switch A switch on vehicles equipped with a manual transmission which indicates that the clutch pedal is depressed.
Neutral Safety Switch A switch on vehicles equipped with an automatic transmission which indicatesthat the transmission is in neutral.
Shift Inhibit Speed The vehicle speed above which Transfer Case shifts are disallowed. Vehicle speedis indicated by propshaft speed measurement.

5D2-6 TRANSFER CASE (TOD) Input/Output diagram TOD control unit and main wiring harness is linked by 30 pin
connector. Each pin joins with switche and actuator whosedetails refer to the below diagram.
Battery Power
Ignition ON/OFF
Position Encoder 1
Position Encoder 2
Position Encoder 3
Position Encoder 4
4H / 4L Switch Signal
A/T “N” Position Signal
Speed / TPS Supply
Front Speed Sensor Input
Rear Speed Sensor Input
ABS Operation Signal
Brake Switch Signal
4 5271028309241611292526
19 CAN H
CAN L
Shift Motor output port (LO-HI)
Shift Motor output port (HI-LO)
EMC
'4L' Indicator
Position Return
'4WD CHECK' IND
TPS/speed Sensor Ground (Speed / TPS Return)
2 13216713
1514
K-Line
20
22
23
17 18

TRANSFER CASE (TOD) 5D2-7
1. K-LINE : Communication line for coding and diagnosis with SCANNER.
Classification of Pin No.
Classification
Pin No. Pin Name Description
Power Supply 17,18
Ground
TOD control unit ground
4,19 Battery TOD control unit battery supply : (Fuse No 13,20A)
5 Ignition Ignition ON / OFF
27 Position 1
Position encoder 1 : check of shift motor position
10 Position 2 Position encoder 2 : check of shift motor position
28 Position 3
Position encoder 3 : check of shift motor position
30 Position 4
Position encoder 4 : check of shift motor position
9 4H/4L Switch Transfer case mode input
24 Auto T/M Neutral Check of neutral gear position in Auto T/M 16 Speed 5V supply (TPS / speed sensor)
11 Front Speed
Front speed sensor signal input
Signal Input
29 Rear Speed Rear speed sensor signal input
25 ABS Operation
ABS ON / OFF
6 Position Return
Position encoder ground
13 Speed / TPS Return Ground for speed sensor / TPS
2 2 CAN-L CAN bus low line
23 CAN-H
CAN bus high line
2,15 Motor LO-HI Motor output port
- LO to HI : join with battery
- HI to LO (or motor brake) : join with ground
1,14 Motor HI-LO Motor output port
- HI to LO : join with battery
- LO to HI (or motor brake) : join with ground
3 EMC TOD output
Signal Output
21 4L Illumination Illuminates
“4L ” indicator
7 Diagnosis Display
4WD check lamp illuminator
- Upon defect ; Ground circuit
20K-LINE1)
Diagnosis