2003 SSANGYONG MUSSO gas type

Diesel Gasoline (M161) Gasoline (M162)
Diesel Gasoline
Application
Joint Type Number of Spider Front FrontRear Front Rear
Front (Full-Time)
Front (Part-Time)Rear Front Rear
SECTION 3C
PROPELLER SHAFT
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 General Specifications . . . . . . . . . . . . . . . . . . 3C-1
Component Locator . . . . . . . . . . . . . . . . . . . 3C-2 M/T & A/T (Part-time T/C) . . . . . . . . . . . . . . . . 3C-2 Maintenance and Repair . . . . . . . . . . . . . . . 3C-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . .
3C-3
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . 3C-3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Description
Single or Single & Double Cardan Single Cardan
Constant Velocity(CV) & Double Carden Single Cardan
3 22
CV Joint : 1, Double Spiders : 1 2
Diesel Gasoline
Shaft Dimensions (L×O.D ×I.D)
When CompressedFully FrontRearFrontRear Front Rear- --M/T & MB A/T
BTRA A/T (2p-Type) TONGIL KSC-
576
×59.5 ×63.5
973 ×
63.5 ×659.5
583.5 ×
44.7×50.8
973 ×
63.5 ×459.5
380.8 ×
63.5×59.5
591.5 ×
63.5×59.5
601.6 ×
50.8×44.7
579.6 ×
50.8×44.7
776.8 ×
63.5×59.5

5A-24 AUTOMATIC TRANSMISSION
Transmission Control Unit(TCU)
The TCU is an in-vehicle micro-processor based transmission management system. It is usually mounted in the
vehicle cabin, under the instrument panel, under the seat, behind the side kick panels or under the floor in the
footwell on the passenger side. Different control units are supplied for different vehicle applications.The TCU contains:
Processing logic circuits which include a central microcontroller and a back-up memory system.
Input circuits.
Output circuits which control external devices such as the variable pressure solenoid (VPS), on/off solenoid
drivers, a diagnostics output and the driving mode indicator light.
The various items which make up the TCU are discussed below.
Processing Logic
Shift schedule and calibration information is stored in an erasable programmable read only memory (EEPROM).
Throttle input calibration constants and the diagnostics information are stored in electrically erasable programmable
read only memory (EEPROM) that retains the memory even when power to the TCU is disconnected. In operation the software continuously monitors the input values and uses these, via the shift schedule, to determine the required gear state, At the same time it monitors, via the solenoid outputs, the current gear state. Whenever the
input conditions change such that the required gear state is different to the current gear state, the TCU initiates a
gear shift to bring the two states back into line.
Once the TCU has determined the type of gear shift required the software accesses the shift logic, estimates the
engine torque output, adjusts the variable pressure solenoid ramp pressure then executes the shift.
The TCU continuously monitors every input and output circuit for short or open circuits and operating range. When
a failure or abnormal operation is detected the TCU records the condition code in the diagnostics memory and
implements a limp mode, The actual limp mode used depends upon the failure detected with the object to maintain
maximum driveability without damaging the transmission. In general input failures are handled by providing a default
value. Output failures, which are capable of damaging the transmission, result in full limp mode giving only third or
fourth gear and reverse. For further details of limp modes and memory retention refer to the Diagnostic Section.
The TCU is designed to operate at ambient temperatures between -40 and 85°C . It is also protected against
electrical noise and voltage spikes, however all the usual precautions should be observed, for example when arc welding or jump starting. TCU Inputs
To function correctly, the TCU requires engine speed, road speed, transmission sump temperature, throttle position
and gear position inputs to determine the variable pressure solenoid current ramp and on/off solenoid states. This
ensures the correct gear selection and shift feel for all driving conditions. The inputs required by the TCU are as follows: Engine Speed
The engine speed signal is derived from the tachometer signal line, a dedicated sensor or a Controlled Area Network (CAN).
Road Speed
4WD (Diesel) - The shaft speed signal is derived from the speedo sensor located on the transfer case. This signal is transmitted directly to the TCU.
4WD (Gasoline) - The speedo sensor sends the shaft speed signal to the engine control module (ECM). The
information is then transferred to the TCU via the CAN.
Transmission Sump Temperature
The transmission sump temperature sensor is a thermistor located in the solenoid wiring loom within the transmission.
This sensor is a typical NTC resistor with low temperatures producing a high resistance and high temperatures

5A-60 AUTOMATIC TRANSMISSIONDIAGNOSIS
DIAGNOSTIC SYSTEM Recommended T est Equipment and Procedure
The test equipment is designed to be used with the control modules in all vehicles. The components used in the transmission application are: Multi Function Tester, and
Appropriate vehicle for testing.
Multi Function Tester (MFT)
The MFT is programmed with the special vehicle diagnostic software that allows selection of the unit under test.
The program allows the proper communication to the Transmission Control Unit (TCU).
It then requests information from the user via a menu system to select the required set up.
Examples are viewing codes, clearing error codes, and real-time operation. Set up and operation instructions are detailed in the user manual.
This equipment can be used by trained personnel such as technicians and mechanics to diagnose electronic and
wiring problems relating to the vehicle transmission. Information that is available includes engine and road (shaft)
speed, transmission oil temperature, throttle position, solenoid/gear status and gear lever position. Current andstored faults detected by the electronics are also available.
TCU Pin Description The TCU pin descriptions are listed in table 6.1.1. The wiring loom pins are shown in figure 6.1.1
Pin
No. 1 2 3 4 5 6 7 8Identification
Common Ground Do not use Mode Indicator Lamp -‘ Winter ’
Gear Position ‘Park ’
LampGear Position ‘Reverse ’
LampGear Position ‘Neutral ’
LampDo not useEngine Speed Input
Sensor (-Ve) Type
GND -
OP OP OP OP
-
IP Description
Main power ground (or the module. Connects
directly to the battery negative terminal. Indicates ‘WINTER ’ mode shift schedule is se-
lected.
Drives the jewel in the instrument cluster to in-dicate ‘PARK ’ gear lever position.
Drives the jewel in the instrument cluster to in- dicate ‘REVERSE ’ gear lever position.
Drives the jewel in the instrument cluster to in- dicate ‘NEUTRAL ’ gear lever position.
Flywheel/Ring gear pulses to indicate engine speed.
4WD
(Diesel)
O O




4WD
(Gas)
O O O






Table 6.1.1 - TCU Pin Description

AUTOMATIC TRANSMISSION 5A-61
Pin
No. 9 10
11
12 13 14 1516 17 1819 20 21 22 2324 25 26 27 28 29 30Identification
Mode Indicator Lamp - ‘ Power ’
Throttle Position Sensor Output as Pulse Width Modulation for TODAir Conditioner Input SignalKickdown Switch Mode Switch
Transfer Case Input (High) -4WD Lamp High Ignition Switch Do not use Gear Position ‘1’ Lamp/
Gear Position Code 1
*Gear Position ‘2’ Lamp/
Gear Position Code 2* Gear Position ‘3’ Lamp/
Gear Position Code 3* Gear Position ‘Drive ’
Lamp/ Gear Position Code 4*CAN (-ve)CAN (+ve) K-line Communication Link Engine Speed InputSensor (+ve)Road Speed Pulses Shaft Speed Sensor SignalThrottle Position Sensor -GroundThrottle Position Sensor - Reference Throttle Position Sensor -Input Signal
Transfer(or Case Input
(Low) - 4WD Lamp Low Type
OP OP
-
IP IP IP IP
-
OPOPOP OP
I/O
I/O
I/O IP
OP
IP
GND
REF IP IP Description
Indicates ‘POWER ’ mode shift schedule is se-
lected.
Provides an analogue signal of the throttle po- sition for the T orque on Demand (T OD) Con-
trol Module. Input
Switch to indicate when a kickdown is required
at high throttle position. Switch to select ‘NORMAL ’, ‘POWER ’ or ‘WIN-
TER ’ shift schedule.
Voltage varies from OV to 12V. Switch to indicate 4WD ’HIGH RANGE ’ is se-
lected.
Ignition power is used as the main power source
to drive the unit and the solenoids.
Drives jewel in the instrument cluster to indi- cate gear leverposition ’1'. Drives jewel in the instru-
ment cluster to indicate gear lever position ’2'. Drives jewel in the instru-
ment cluster to indicate gear lever position’3'.
Drives jewel in the instrument cluster to indi- cate ‘ DRIVE ’. gear lever position.
CAN low side bus communication (CANL).
CAN high side bus communication (CANH).
Diagnostic information and vehicle coding.
Flywheel/Ring gear pulses to indicate engine speed.
Road speed signals derived from shaft speedsensors.
This sensor transmit shaft speed signal to the TCU. Throttle position sensor ground. This is the 5V reference voltage supply gener-
ated by the unit for the throttle position sensor.
This sensor is a resistance potentiometer indi-
cating throttle position.
Voltage varies 0V to 5V.Switch to indicate 4WD ’LOW RANGE ’ is se-
lected.
4WD
(Diesel)
O O O O



4WD
(Gas)
O O O O O O OO

5A-62 AUTOMATIC TRANSMISSION
Identification
Gear Lever Position
Transmission Oil
Temperature Solenoid 4 Solenoid 1 Do not use Solenoid 5Return (-ve) Gear Lever Position - Ground
Transmission Oil
Temperature - Ground Solenoid 6 Solenoid 2 Solenoid 3 Solenoid 7 Do not use Solenoid 5 (+ve) Type
IP IP
OPOP -
IP
GND GND OPOP OP OP -
OP Description
This switch has discreet values indicating the
positions selected by the gear shift lever
(PRNDL). Voltage varies 0V to 5V.
Resistive sensor indicates transmission tem-perature .High R = low temp Low R = high temp
Voltage varies 0V to 5V.
On/Off solenoid normally open, combines with
other On/off solenoid 3 for shift quality and se-quencing.
On/off solenoid normally open, combines with
other On/off solenoid to set the selected gear.
This ensures the earth path for the VPS and
the current in this line is monitored to give feed-
back control of the VPS. PRNDL switch ground. Ground reference for temperature sensor in-
put.
On/Off solenoid normally open, sets low/high line pressure.
On/off solenoid normally open, combines with
other On/off solenoid to set the selected gear.
On/off solenoid normally open, combines with
On/off solenoid 4 for shift quality and sequenc- ing.
On/off solenoid normally open, locks up the
torque converter to Increase cruising efficiency. This is the variable force solenoid which ramps the pressure during gear changes and solenoid
switching, to enhance transmission shift quality.
4WD
(Diesel)
O O

4WD
(Gas)
O O






Pin
No. 31 32 33 34 35 36 37 38 39 40 41 42 43 44






= circuit connected
O = circuit not connected
* = unique
OP = Output
IP = Input
I/O = Input/output
GND = Ground
REF = Reference
Notice :

TRANSFER CASE (TOD) 5D2-19
ClassificationEngine Type
Transmission/Vehicle Type Axle Ratio
Tire Size
Coding Required
1. Replacement of TOD control unit.
2. Adjustment by input error.
3. Change of tire specification.
Items
Gasoline Engine (E32) 661 Diesel Engine
661LA Diesel Turbo Engine
662 Diesel Engine
662LA Diesel Turbo Engine Manual Transmission
Automatic Transmission MUSSO
KORANDO 3.734.554.895.38 5.86
P215 P235P255P275
Coding Method
1. Check and record engine type, axle ratio and tire size.
2. Ignition “OFF ”.
3. Connect SCANNER with diagnosis connector in engine room.
4. Ignition “ON ”.
5. Read the current memorized specification in TOD control unit.
6. Compare memorized specification with the checked record. If not matched, perform a coding.
7. Read again memorized coding specification in TOD control unit for confirmation of coding.
8. Check coding specification whether it matches with vehicle or not. If not, perform a coding again.
Coding items

9A-8 BODY WIRING SYSTEM1 Fuse Box
2 Door Lock Relay
3 Relay Box
3.1 Front Wiper Relay
3.2 ABS Warning Lamp Relay ....................................ABD 5.0
3.3 Flasher Unit
3.4 Fuel Pump Relay ................................................. Gasoline E/G
3.5 Shift Lock Relay ................................................... Automatic Transmission
3.6 Clutch Interlock & Neutral Relay ...........................Manual Transmission or Automatic Transmission
3.7 Sun Roof Relay
3.8 Automatic T ransmission ‘B’ Switch Interlock ....... Automatic Transmission
3.9 Power Window Relay
3.10 Rear Fog Lamp Relay .......................................... Rear Fog Lamp
3.11 ECS Relay 4 Defogger Relay
5 Ground 1
6 Roof Wiring Connector
7 Diode 1
8 Front Door Wiring Connector
9 Front Door Wiring Connector
10 Front Door Wiring Connector 11 Front Door Wiring Connector
12 Kick Down Relay .................................................. Automatic Transmission
13 Floor Wiring Connector
14 Floor Wiring Connector
15 Floor Wiring Connector
16 ABD Floor Wiring Connector ................................ABD 5.0
17 ECS Floor Wiring Connector
18 Rear Iper & Washer Switch
19 Clutch Switch ........................................................ Manual Transmission
19-1 Clutch Switch ........................................................ E32 Gasoline E/G with Manual Transmission
20 Stop Lamp Switch
21 Outside Mirror Switch
22 Ignition Switch
23 Multi Function Switch
24 Multi Function Switch
25 Black Out Switch .................................................. Black Out Lamp
26 Black out switch ................................................... Black Out Lamp
27 Joint Connector (Tail)
28 Joint Connector (Ignition)
29 Cluster
30 Cluster ................................................................. Automatic Transmission
31 Cluster
32 Cluster
33 4WD Switch .......................................................... Except TOD
33-1 4WD Switch .......................................................... TOD
3 4 Hazard Switch
35 Ground 2
36 Pedal Module ....................................................... Gasoline E/G with MSE ECU
37 Audio Switch
3 8 Immobilizer ........................................................... Crypto Type, Gasoline E/G with MSE ECU or Diesel E/G
39 Ignition Switch
40 Multi Function Switch
4 1 STICS
4 2 STICS
4 3 REKES ................................................................. Remote Keyless

9A-10 BODY WIRING SYSTEM94 Seat Belt Switch (Driver)
95 Seat Belt Switch (Dirver)
96 Parking Brake Switch
97 Rear Cigarette Lighter
9 8 OVPR ................................................................. Gasoline E/G
99 LH Side Repeater ............................................... Rear Fog Lamp
100 Engine Wiring Connector
101 Engine Joint Connector
102 Engine Joint Connector ......................................Gasoline E/G
103 ECS Engine Wiring Connector ...........................Diesel E/G & Gasoline E/G with HFM ECU
104 ABD Engine Wiring Connector ...........................ABD 5.0
105 ABD Engine Wiring Connector ...........................ABD 5.0
105-1 ABS Engine Wiring Connector ............................ABS 5.0
106 Canister Purge Solenoid Valve ...........................Gasoline E/G with MSE ECU
106-1 Canister Purge Solenoid Valve ...........................E20 & E23 Gasoline E/G with FHM ECU
107 Econo/Standard Solenoid Valve .........................Gasoline E/G with Automatic Transmission
108 CO Potentio Meter .............................................. Gasoline E/G with HFM ECU & CO Potentio Meter
109 Front Wiper Motor 11 0 O 2 Sensor
........................................................... E20 or E23 Gasoline E/G
111 RH Side Repeater
112 Engine Wiring Connector
113 Vertical Sensor
114 Lateral Sensor
115 Diagnosis
11 6 Joint Box ............................................................. Gasoline E/G (E32)
117 Canister Purge Solenoid Valve ...........................E32 Gasoline E/G with HFM ECU
118 Led Antenna ...................................................... Rolling code type Immobilizer
119 E-key Connector ................................................ Gasoline E/G with Rolling Code Type Immobilizer
120 Receiver Unit ...................................................... Gasoline E/G with Rolling Code Type Immobilizer
121 Receiver Unit ...................................................... Gasoline E/G with Rolling Code Type Immobilizer
122 Receiver Antenna .............................................. Gasoline E/G with Rolling Code Type Immobilizer
123 Receiver Connector ........................................... Gasoline E/G with Rolling Code Type Immobilizer
124 ICU Connector .................................................... Gasoline E/G with Rolling Code Type Immobilizer
125 ICU ..................................................................... Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
126 CAN Line ............................................................ Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
127 TOD ................................................................... Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
128 TOD ................................................................... Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
129 Transfer Case Speed Sensor .............................Gasoline E/G with TOD (MSE ECU 3.2 Engine Only)
130 Engine Main Wiring Connector ...........................Gasoline E/G with MSE ECU
131 Remote Engine Start .......................................... Diesel E/G with A/T & Black Out Lamp
132 Remote Engine Start .......................................... Diesel E/G with A/T & Black Out Lamp
133 TCU .................................................................... Diesel E/G with BTRE A/T
134 TCU .................................................................... Diesel E/G with BTRE A/T
135 Ground 5 ............................................................ Diesel E/G
136 Start Protection Relay .........................................Diesel E/G with Rolling Code Type Immobilizer
137 EGR control unit ................................................. Diesel E/G
1 3 8 ICU 1 .................................................................. Diesel E/G with Rolling Code Type Immobilizer
1 3 9 ICU 2 .................................................................. Diesel E/G with Rolling Code Type Immobilizer
140 Injection Pump Valve Extension ..........................Diesel E/G with Rolling Code Type Immobilizer
141 Injection Pump Valve Extension ..........................Diesel E/G with Rolling Code Type Immobilizer
142 EGR Solenoid .................................................... Diesel E/G
143 ICU led ................................................................ Diesel E/G with Rolling Code Type Immobilizer
144 Immobilizer Solenoid Valve ..................................Diesel E/G with Crypto Type Immobilizer
147 Immobilizer Unit ................................................... Diesel E/G with Crypto Type Immobilizer