2003 SSANGYONG MUSSO Service Manual

5D2-24 TRANSFER CASE (TOD)
Ye sNo
B4
B5
Ye s
No
B6 4.75-5.25Vdc
Ye s
No
B7 0.3-0.9Vdc 4.6-4.9Vdc
Ye s
No
4.6-4.9Vdc0.3-0.9Vdc Ye s
No
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Check CAN communication line by diagnosis of E/G ECU.
1. Diagnose E/G ECU with SCANNER.
2. Does it display on fault code
“27 ” ?
Check power supply and signal output on throttle valve position sensor (potentiometer) 1,2.
1. Diagnose E/G ECU with SCANNER. - Fault codes : 104, 105, 108, 109, 119, 185 Does it display on above code ?
Check power supply (5V) of throttle valve position sensor.
1. Ignition “ON ”
2. Measure voltage between pin 112(+) and 84(-) keeping coupling connection status using multi - tester.
- Specified value
- Measured value is within specified range ?
Check output signal from throttle position sensor 1 and 2.
1. Keep E/G idle status.
2. Measure output voltage between pin 87 (+) and 84 (-) keeping E/G ECU coupling connection status using multi-
tester. (potentiometer 1)
- Specified value min. acc. Pedal max. acc. Pedal
- Measured value is within specified range ?
3. Measure output voltage between pin 85 (+) and 84 (-) keeping E/G ECU coupling connection status using multi-
tester. (potentiometer 2)
- Specified value min. acc. Pedal
max. acc. Pedal
- Measured value is within specified range ? Replace TOD control unit Replace throttle bodyactuator or check cable
Perform B1, B2, B3 stagesPerform B5 stage Perform B6 stage Replace TOD control unit or perform A1- A5 stages Perform B7 stage Replace E/G ECU or perform B1-2 stage after checking cable. Perform B7-3 stage Replace throttle body actuator or check cable.

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

5D2-26 TRANSFER CASE (TOD)0Vdc
11 - 15Vdc
Ye s
No
2.5
Ye s No
C3 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
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

0 : short
: open
C4 Check 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 TODcontrol unit Replace wire

TRANSFER CASE (TOD) 5D2-27
Defect in speed sensor : fault code 1731, 1732, 1733, 1734, 1735,1736
Phenomenon
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 ”.
Cause
1. Defect of speed sensor (front, rear).
2. Defect of power supply.
4.75-5.25Vdc
Ye sNo
D1
Ye s
No
D2
Ye s
Ye s
Ye sNo
D3 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
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 to1736.
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 stagePerform 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 sNo
D4 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
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 withinspecified 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 ofcontrol 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 " " ? Repair wire Perform D5-4 stge
Ye s No Wiring short, repairPerform D3 stage, then delete fault codes with rediagnosis

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

5D2-30 TRANSFER CASE (TOD)
Ye sNo
Ye s No
Ye s No
E3
Ye s
No
E4
Ye s
No
E5 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
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 0 ?
4. Perform the short test between No.1/No.14 Connector and body, No2/No.15 connector and body.
- Is there resistance of 0 ?
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 andNo.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 faultis 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 motoror delete fault codeand rediagnosis system.

TRANSFER CASE (TOD) 5D2-31
Position incoder and position 1,2,3,4 malfunction :Fault code®1750,1751,1752,1753, 1754
Phenomenon 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.
Cause The portion of position incoder malfunction, each wiring is shorted with ground.
Ye s
No
F1
Ye s No
Ye s
No
F2 Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
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 0 ? Perform F2 stagePerform F1-2 stage Perform F2 stage Normal system Repair or replace due to wiring short
1. Replace the
motor Ass ’y due
the defectiveposition incoder portion.
2. And then, perform F1-2 stage.