2003 SSANGYONG MUSSO sensor

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) 5D2-27
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) 5D2-35
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.

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.

TRANSFER CASE (TOD) 5D2-39
10. Disconnect pin and wire from speed sensor connector bypulling 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
31 Bolt
32 Upper Speed Sensor (Rear)
33 Nut
34 Washer
37 Bolt
38 Tag, Identification
39 Thrust Bearing
40 Clutch Coil Assembly
41 Fork, Reduction Shift 42 Shift Rail
43 Shaft, Shift
44 Spacer
45 Torsion Spring
46 Shift Cam
47 Transfer Case Shift Motor
48 Bolt
49 J-clip
50 Connector Retainer
51 Bolt
52 Support Stud
53 Lower Speed Sensor (Front)
54 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 outputnut, 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.