TRANSFER CASE (TOD)212.113.105.12/library/BOOKS/CAR/SsangYong/Korando/Koran...TRANSFER CASE 5D1-3 SSANGYONG MY2002 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 B1 B2 B3 B4 B5 B6 B7 B8 B9

SECTION 5D1

TRANSFER CASE (TOD)CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when atool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cablewill help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unlessother-wise noted.

TABLE OF CONTENTS

Description and Operation ................................. 5D1-2

Torque on Demand (TOD) SystemTransfer Case ................................................. 5D1-2

Transfer Case Control Unit (TCCU) ..................... 5D1-2

TCCU Coding .................................................... 5D1-2

Pin Description .................................................. 5D1-3

Components of the TOD Transfer Case System .. 5D1-4

Definition of Terminology .................................... 5D1-4

Operation of the TOD Transfer Case System ...... 5D1-4

Component Locator ........................................... 5D1-7

Torque on Demand (TOD) Type Transfer Case .... 5D1-7

Transfer Case Disassembled View ..................... 5D1-8

TOD Control Unit .............................................. 5D1-10

Diagnosis .......................................................... 5D1-11

Self-Diagnostic Tests ....................................... 5D1-11

Diagnostic Trouble Codes (DTCs) .................... 5D1-12

Clearing Diagnostic Trouble Codes .................. 5D1-12

4WD Check Indicator Stays on with IgnitionSwitch ON .................................................... 5D1-14

4WD Low Indicator Stays on with IgnitionSwitch ON .................................................... 5D1-16

No 4WD Check or 4WD Low Indicator withIgnition Switch ON ........................................ 5D1-18

4WD Low Indicator Blink Steadily ..................... 5D1-20

TCCU Diagnostic System Check ...................... 5D1-21

DTC 1714 Eeprom Checksum Fault .................. 5D1-22

DTC 1715 Tp Sensor Loss of Signal ................. 5D1-24

DTC 1716 Tp Sensor Out of Range ................... 5D1-26

DTC 1721 Electromagnetic Clutch Open / Shortto Battery ..................................................... 5D1-28

DTC 1722 Electromagnetic Clutch Short toGround ......................................................... 5D1-32

DTC 1731 Front Speed Sensor Voltage Low ...... 5D1-36

DTC 1732 Front Speed Sensor Voltage High ..... 5D1-38

DTC 1733 Rear Speed Sensor Voltage Low ...... 5D1-40

DTC 1734 Rear Speed Sensor Voltage High ..... 5D1-42

DTC 1735 Speed Sensor Reference VoltageLow .............................................................. 5D1-44

DTC 1736 Speed Sensor Reference VoltageHigh ............................................................. 5D1-46

DTC 1741 Motor Output Open / Shortedto Battery ..................................................... 5D1-48

DTC 1742 Motor Output Shorted to Ground ...... 5D1-52

DTC 1743 Shift System Timeout ....................... 5D1-55

DTC 1750 General Position Encoder Fault(Invalid Code) ............................................... 5D1-56

DTC 1751 Position 1 Shorted to Ground ............ 5D1-58




Repair Instructions ............................................ 5D1-66

On-Vehicle Service ............................................. 5D1-66

Oil Replacement .............................................. 5D1-66

Transfer Case Control Unit (TCCU) ................... 5D1-67

Transfer Case .................................................. 5D1-67

Shift Motor ....................................................... 5D1-69

Front and Rear Propeller Shaft Speed Sensor ... 5D1-70

Unit Repair ........................................................ 5D1-71

Transfer Case Overhaul ................................... 5D1-71

Specifications ................................................... 5D1-79

General Specification ....................................... 5D1-79

TCCU Electric Characteristics .......................... 5D1-79

Fastener Tightening Specifications ................... 5D1-79

Schematic and Routing Diagram .................... 5D1-80

TOD Transfer Case Control Unit (TCCU) ............ 5D1-80

Special Tools and Equipment .......................... 5D1-82

Special Tool Table ........................................... 5D1-82

TR

AN

SF

ER

CA

SE

5D

1-8

1

SS

AN

GY

ON

G M

Y2002

KA

A5D

620

TOD TRANSFER CASE CONTROL UNIT (TCCU) - 2 OF 2

SSANGYONG MY2002

5D1-2 TRANSFER CASE

DESCRIPTION AND OPERATIONTORQUE ON DEMAND (TOD)SYSTEM TRANSFER CASETransfer case is designed to distribute the power tofront and rear axle by operation of 4H/4L switch andshift motor. Shifting 4 wheel drive high (4H) to 4 wheeldrive low (4L) is performed towards reducing high-lowcollar by means for connection high-low shift fork withoutput shaft in order to join with planetary gear. Torquetransmits input shaft then sun gear rotating frontplanetary gear. Front planetary gear joins with outputshaft and drives at low position.

The Torque On Demand (TOD) system has 2 selectablemode, 4H and 4L. 4H is the normal operating modewhen drive of which gear ratio is 1 : 1 and 4L modedis-tributes power to front and rear wheels 50 : 50 ofwhich gear ratio is 2.48 : 1.

4H ModeThe TOD system transfer case controls the clutchmechanism to comply with rotation in front and rearpropeller shaft and if its difference exceeds thepermissible range, corresponding power is distributedinto front wheel through electromagnetic clutch (EMC).

Hall effect speed sensors are located front and rearpropeller shafts, send signals to TOD transfer casecontrol unit (TCCU). The EMC coil is activated byvariable current on exceeding difference of speed infront and rear propeller shafts.

4L ModeWhen select 4L mode, EMC is locked to applymaximum torque into front and rear propeller shafts.Shift motor rotates also 4L position by rotation of camthus propeller shaft torque changes from 1 : 1 to 2.48: 1 by planetary gear set.

TRANSFER CASE CONTROL UNIT(TCCU)Transfer case control unit (TCCU) receives, front andrear propeller shaft speed, shift motor position, and4H/4L switch signals and controls electromagneticclutch (EMC), shift motor. TCCU communicates withscan tool with K-line for diagnosis. It located underthe front Left Handed seat.

TCCU CODINGAn input activity of data is required for the properperformance by matching specification, devices andsystem with control unit using a scan tool.

Coding is required for following case:

• Replacement of transfer case control unit (TCCU).

• Adjustment by input error.

• Change of tire specification.

Coding Item• Engine type

• Transmission and vehicle type

• Axle ratio

• Tire size

Coding Method1. Check and record engine type, axle ratio and tire

size.

2. Turn the ignition switch to OFF.

3. Connect scan tool with data link connector (DLC) inpassenger room near left side of instrument panelcenter.

4. Turn the ignition switch to ON.

5. Read the current memorized specification in transfercase control unit (TCCU).

6. Compare memorized specification with the checkedrecord. If not matched, perform a coding.

7. Read again memorized coding specification inTCCU for confirmation of coding.

8. Check coding specification whether it matches withvehicle or not. If not, perform a coding again.

TRANSFER CASE 5D1-3

SSANGYONG MY2002

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

A12

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

B12

B13

B14

B15

B16

B17

B18

Shift motor output (- High to low: Battery voltage/ - Low to high or motor brake : Ground)

Shift motor output (- Low to high: Battery voltage/ - High to Low or motor brake : Ground)

TOD output: Electromagnetic clutch control

B (+) : Fuse F17

Ignition Voltage: Fuse F23

Shift motor output (- High to low: Battery voltage/ - Low to high or motor brake : Ground)

Shift motor output (- Low to high: Battery voltage/ - High to Low or motor brake : Ground)

Reference voltage (5V) supply to Throttle Position (TP) sensor and speed sensor

Ground

Ground

B (+) : Fuse F17

Diagnosis (K-line)

Position encoder ground

Illuminate 4WD CHECK lamp

Not in used

Mode (4H/4L) input

Position encoder 2 input

Front propeller shaft speed sensor input

Not in used

Speed sensor ground. Throttle position (TP) sensor return

Illuminate 4WD LOW indicator

CAN bus high line

CAN bus low line

Neutral position sensor signal input (A/T only)

ABS operation signal (ON/OFF)

Brake switch signal input



Rear propeller shaft speed sensor signal input


PIN DESCRIPTION

Pin No. Description

SSANGYONG MY2002

5D1-4 TRANSFER CASE

COMPONENTS OF THE TODTRANSFER CASE SYSTEMShift MotorIt locates backside transfer case, which drives rotaryhelical cam. When mode select switch changes to 4L,shift fork is on position for 2.48 : 1 by rotation of helicalcam.

Rear Speed SensorA hall effect speed sensor which produces a squarewave. 0 to 5 volts direct current signal in response toa rotating 30-tooth wheel coupled to the rear propellershaft inside the transfer case. Each rotation of the rearpropeller shaft will result in 30 speed sensor pulse.

Front Speed SensorA hall effect speed sensor which produces a squarewave. 0 to 5 volts direct current signal in response toa rotating 30-tooth wheel coupled to the front propellershaft inside the transfer case. Each rotation of the frontpropeller shaft will result in 30 speed sensor pulse.

Electro-Magnetic ClutchAn electromagnetic clutch used to control the amountof torque applied to the front propeller shaft.

Position EncoderA set of 4 gray code switches which provide feedbackto the TCCU indicating the position of the shift motor.

Clutch Pedal Position SwitchA switch on vehicles equipped with a manual transmis-sion which indicates that the clutch pedal is depressed

Park/Neutral Position SwitchA switch on vehicles equipped with an automatic trans-mission which indicates that the transmission is in neu-tral.

4H/4L SwitchA switch selects the desired gear ratio.

DEFINITION OF TERMINOLOGYShift Inhibit SpeedThe vehicle speed limit, which transfer case shifts, isdisallowed. Vehicle speed is indicated by propellershaft speed measurement.

Duty CycleDuty cycle is the time the electromagnetic clutch is ondivided by the period in which it is being modulated.

Touch-offA minimum amount of duty cycle applied to the electromagnetic clutch.

Front OverrunA condition where the front propeller shaft is turning ata rate which is faster than the rear propeller shaft.

Rear OverrunA condition where the rear propeller shaft is turning ata rate which is faster than the front propeller shaft.

High RangeThe highest (numerically lowest = 1 : 1) gear ratio be-tween the input and outputs of the transfer case.

Low RangeThe lowest (numerically highest = 2.48 : 1) gear ratiobetween the input and outputs of the transfer case.

OPERATION OF THE TODTRANSFER CASE SYSTEMInitial Operation of TOD Control UnitWhen ignition switch is turned to ON, 4WD LOW and4WD CHECK lamp illuminates for 0.6 second to checkbulb in instrument panel, then perform diagnosis ofsystem. Refer to “Self-Diagnosis Test” in this section.

Electric Shift System OperationThe electric shift system is responsible for changingthe transfer case gear ratio by controlling the electricshift motor. The TCCU monitors the 4H/4L switch, park/neutral position switch, speed sensors, positionencoder, and ignition switch.

A range change is initiated when:

• The 4H/4L switch is changed from 4H to 4L or from4L to 4H.

• The motor position (as indicated by the positionencoder) does not match the 4H/4L switchimmediately after the ignition is turned on.

Shift CriteriaWhen a range change is initiated a diagnostic test willbe completed on the motor, speed sensors, andposition encoder. If the diagnostic test fails, the shiftwill not be attempted. If all components are operatingproperly, the TCCU will attempt a range change afterthe following shift criteria are met:

• The transmission is in neutral for 2 seconds afterthe shift is requested.

• Both propeller shaft speeds are below 87 rpm (2580pulses/minute). If the transmission is taken out ofneutral before 2 seconds has passed, or eitherpropeller shaft speed increases above the limit, theshift will be suspended and the 4L indicator willcontinue to blink until the criteria are met again orthe 4H/4L switch is returned to the original position.

Range Change

When the shift criteria are met, the motor is rotated inthe appropriate direction (as determined by the selectorswitch) until one of the following occurs:

TRANSFER CASE 5D1-5

SSANGYONG MY2002

• The motor reaches its destination.

• The motor is on for 5 seconds without reaching itsdestination. The shift has failed and the TCCU willrespond as default mode.

• A fault occurs with either the motor or positionencoder. Refer to the diagnosis requirement.

When the motor is energized, the Ignition, 4H/4Lswitch, propeller shaft speeds, and transmissionneutral inputs are ignored.

Indicator FunctionOnce a range change has been initiated the 4WD LOWindicator will begin to blink at a rate of 0.3 secondson, 0.3 seconds off until the shift is completed orcanceled. If a successful shift has been completed,the 4WD LOW indicator will be illuminated if the motoris in low range and it will be turned off if the motor is inhigh range.

4WD LOW indicator illuminates as below figure.

KAA5D000

TODTM System OperationThe TODTM System is responsible for distributing torquebetween the front and rear axles. The TCCU monitorsthe propeller shaft speeds, operating range (high/low),and ABS activity and then applies a calculated amountof torque to the front axle by pulse width modulating(PWM) the current applied to the electromagnetic clutch(EMC).

Touch-off Torque

The minimum EMC duty cycle is based on the vehiclespeed and throttle position. The TCCU receives thethrottle position (TP) sensor signal from the engine control module (ECM) through CAN bus line.

Wheel Slip Detection and Control

The TCCU continuously monitors the front and rear pro-peller shaft speeds to detect wheel slip.

When wheel slip is detected the TCCU controls theEMC duty cycles as necessary until the wheel slip isreduced below the allowable limit. The EMC duty cyclewill then be reduced to the touch-off value.

Brake/ABS Strategy

When the ABS System is active, the EMC duty cycleis set to a fixed duty cycle (30%) to aid in brakingwithout counteracting the ABS System.

4L Strategy

When the system is operating in 4WD low range, theTCCU continues TODTM operation provided that the propeller shaft speed is below 175 rpm (5220 pulses/min-ute). When the speed increases above 175 rpm, theEMC duty cycle is set to the maximum value (88 %)which applies the maximum available torque to the frontaxle.

Position EncoderThe position encoder is used by the TCCU to determinethe position of the shift motor. Each motor position isidentified by a position code as shown.

Motor Position

Left Stop

Left of High

High

Right of High

Zone 1

Neutral

Zone 2

Low

Right Stop

Position code 1/2/3/4

1111

1010

0010

0000

1110

1001

0001

0101

0100

Notice:

• All other position codes are invalid

• Position input : open circuit (> 4.5V) = 1

• Position input : Shorted to speed/position return(< 0.5V) = 0

Position Sensor Interpretation1. When the module powers up, it will read the position

sensor and the 4H/4L switch input and respond tothe possible codes as following tables.

2. A command to shift will only be acted upon if theTCCU is reading a valid code at the time the com-mand to shift is made.

3. After a shift has started, the TCCU will power theshift motor until the code for the requested positionis read. If an invalid code is read, the TCCU will gointo a default mode.

4. During a shift attempt, the shift motor will be ener-gized for a maximum of 5 second

SSANGYONG MY2002

5D1-6 TRANSFER CASE

4H

4H

4H

4H

4H

4H

4H

4H

4H

4H

4H

4H

4H

4H

4H

4H

4H

4H

Left Stop

Left of High

High

Right of High

Zone 1

Neutral

Zone 2

Low

Right Stop

Left Stop

Left of High

High

Right to High

Zone 1

Neutral

Zone 2

Low

Right stop

No action required. 4WD LOW indicator off.

Blink 4WD LOW indicator.After the shift conditions are input, attempt a shift to 4H mode if follow-ing conditions are maintained for 2 seconds conditions are maintainedfor 2 seconds.

• Shift lever position is in neutral.

• The speed of front and rear propeller shaft is below 87 rpm.After successfully shifting into 4L mode, stop blinking 4WD LOW indicator.

Blink 4WD LOW indicator.

After the shift conditions are input, attempt a shift to 4L mode if followingconditions are maintained for 2 conditions are maintained for 2 seconds.

• Shift lever position is in neutral.

• The speed of front and rear propeller shaft is below 87 rpm.After successfully shifting into 4L mode, stop blinking 4WD LOW indicator.

No action required. 4WD LOW indicator on.

4H/4L SwitchInput ActionMotor Position

TRANSFER CASE 5D1-7

SSANGYONG MY2002

COMPONENT LOCATORTORQUE ON DEMAND (TOD) TYPE TRANSFER CASE

KAA5D010

1 Transmission2 Transfer Case3 Rear Propeller Shaft4 Bolt

5 Bolt6 Front Propeller Shaft7 Bolt

SSANGYONG MY2002

5D1-8 TRANSFER CASE

TRANSFER CASE DISASSEMBLED VIEW

KAA5D020

TRANSFER CASE 5D1-9

SSANGYONG MY2002

1 Bearing2 Bushing3 Carrier Assembly4 Sun Gear5 Thrust Plate6 Input Shaft7 Output Shaft Thrust Washer8 Bearing9 Snap Ring

10 High-Low Collar11 Rear Output Shaft12 Oil Strainer13 Coupling Hose14 Hose Clamp15 Pump Assembly16 Thrust Washer17 Sprocket, Drive (214t)18 lutch Pack Assembly19 Insulator Washer20 Armature21 Snap Ring22 Wave Washer23 Apply Cam24 Ball25 Cam And Coil Assembly26 Nut, Metric (2)27 Output Shaft Yoke Washer28 Oil Seal29 Case Flange30 Bolt31 Upper Speed Sensor (Rear)32 Nut33 Washer34 Bolt (M10 X 1.5 X 30)35 Tag, Identification36 Thrust Bearing37 Clutch Coil Assembly38 Fork, Reduction Shift

39 Shift Rail40 Shaft, Shift41 Spacer42 Torsion Spring43 Spring, Electric Shift44 Transfer Case Shift Motor45 Bolt46 J-Clip47 Connector Retainer48 Bolt49 Support Stud50 Lower Speed Sensor (Front)51 Plug52 Identification Decal53 Case54 Tone Wheel, Lower55 Chain, Drive56 Sprocket, Driven (24t)57 Oil Pan Magnet58 Case Flange And Output Shaft59 Case Assembly60 Barb, Breather61 Spirol Pin62 Oil Seal63 Pin, Dowel64 Ring Gear65 Retaining Ring66 Snap Ring67 Bearing68 Snap Ring69 Bearing70 Speedometer Drive Gear71 Facing, Shift Fork72 Upper Tone Wheel73 Oil Seal74 Bearing Sleeve75 Bearing

SSANGYONG MY2002

5D1-10 TRANSFER CASE

TOD CONTROL UNIT

KAA5D030

1 Transfer Case Control Unit (TCCU)

TRANSFER CASE 5D1-11

SSANGYONG MY2002

DIAGNOSISWhile the transfer case control unit (TCCU) is active itperiodically monitors its inputs and outputs. If a faultis detected the 4WD CHECK lamp is illuminated and afault code is stored in the TCCU memory.

When requested, fault codes are downloaded to scantool through a diagnostic connector (K-line) serial communication.

SELF-DIAGNOSTIC TESTSTCCU Internal FunctionWhen the ignition is turned on the TCCU tests its readonly memory (ROM) and random access memory(RAM). If there is a fault, the TCCU immediately resetsitself and re-tests the ROM and RAM. If the faultpersists the TCCU continues to reset and re-test untilthe fault is corrected or the ignition is turned off. AllTCCU functions are inhibited until the fault is corrected.The 4WD CHECK lamp is not illuminated if there is aROM or RAM fault.

If the ROM/RAM passes the electronically erasableprogrammable read only memory (EEPROM) is tested.If there is a fault the 4WD CHECK lamp is illuminatedand the TCCU continues to operate using the defaultcalibration data stored in ROM. Fault codes are notstored when there is an EEPROM fault.

An EEPROM fault can only be cleared by cyclingignition OFF-ON.

Shift Motor Assembly Test

If the TCCU detects a shift motor or position encoderfault continuously for one second the 4WD CHECKlamp is turned on and the appropriate fault code isstored in memory.

1. A shift motor fault when the motor is off is definedas follows:

• Motor HI-LO circuits are shorted to ground.

• Motor LO-HI circuits are shorted to ground.

• Motor circuits are open.

2. A shift motor fault when the motor is energized isdefined as follows:



• Motor HI-LO circuits are shorted to motor LOHI circuits.


3. A position encoder fault is defined as follows:

• Any position code which does not correspondto the valid 9 codes.

• A short to ground on any of the encoder lines.

4. If no shifts are in progress when a failure occursthe TCCU will not respond to any shift commands.

5. If a shift command has been received but notacted upon when a failure occurred the TCCUwould cancel the command and not respond toany subsequent shift commands.

6. If a shift command is in progress when an invalidposition code is confirmed it will be halted andthe TCCU will turn the motor toward the highposition. Afterwards the TCCU will not respond toany shift commands.

7. If the shift motor or position encoder assemblyfailures, other than a motor failure which occurswhen the motor is energized, recovers continuouslyfor one second the TCCU will function normally.The 4WD CHECK lamp is turned off but the faultcode will remain in memory.

8. A motor failure (i.e. open or short circuit) whichoccurs when the motor is energized can only becleared by cycling the ignition OFF-ON.

Front Speed Sensor TestIf a front speed sensor fault is detected continuouslyfor 0.5 second the 4WD CHECK lamp is illuminated.The TCCU then responds as follows:

1. If the system is in high range the TCCU uses therear speed sensor to determine the EMC touch offlevel and wheel slip control is suspended.

2. If the system is in low range, the EMC duty cycleis set to maximum, independent of vehicle speed,until the system is shifted out of low range.

3. All electric shift activity is halted until the Ignitionis cycled. If a shift is in progress it will becompleted.

If the front speed sensor recovers continuously for O.5second the TCCU will function normally. The 4WDCHECK lamp is turned off but the fault code will remainin memory.

Rear Speed Sensor TestIf a rear speed sensor fault is detected continuouslyfor 0.5 second the 4WD CHECK lamp is illuminated.The TCCU then responds as follows:

1. If the system is in high range the TCCU uses thefront speed sensor to determine the EMC touchoff level and wheel slip control is suspended.

2. If the system is in low range, the EMC duty cycleis set to maximum independent of vehicle speeduntil the system is shifted out of low range.


4. If the rear speed sensor recovers continuously for0.5 second the TCCU will function normally. The4WD CHECK lamp is turned off but the fault codewill remain in memory.

SSANGYONG MY2002


Both Speed Sensor FaultyIf both the front and rear speed sensors are faulty continuously for 0.5 seconds the 4WD CHECK lamp isilluminated. The TCCU then responds as follows:

1. If the system is in high range the TCCU sets theEMC touch off level based on a vehicle speed of0 and wheel slip control is suspended.

2. If the system is in low range, the EMC duty cycleis set to maximum until the system is shifted outof low range.


If both speed sensors recover continuously for 0.5 sec-ond the TCCU will function normally. The 4WD CHECKlamp is turned off but the fault code will remain inmemory.

Electro-Magnetic Clutch TestThe electromagnetic clutch (EMC) is tested for opencircuit or short circuit to ground. If a fault is detectedcontinuously for 0.8 second the 4WD CHECK lamp isturned on and al l TODTM act ivi ty is halted.If the EMC recovers continuously for 0.8 second theTCCU will function normally. The 4WD CHECK lamp isturned off but the fault code will remain in memory.

DIAGNOSTIC TROUBLE CODES(DTCS)When a fault is detected a diagnostic trouble code(DTC) is stored in the TCCU and illuminates the 4WDCHECK indicator. This DTC will remain in memory untilthe TCCU is instructed to erase DTCs by scan tool.

Notice: DTCs can not be erased by disconnecting ofpower supply to the TCCU.

Diagnostic Trouble Codes Table

CLEARING DIAGNOSTICTROUBLE CODESWhen diagnose by scan tool, it is required that youmake adequate service on defects against all faultcodes. And then you should delete the memorized faultcodes in transfer case control unit (TCCU) using scantool as follows;

1. Connect a scan tool with dada link connector(DLC).

2. Select TROUBLE CODE CLEAR in scan tool.

3. In TROUBLE CODE CLEAR screen, press ENTERkey to erase the fault code.

Description

EEPROM Checksum Fault

TP Sensor Loss of Signal

TP Sensor Out of Range

Electro-Magnetic Clutch Open / Short

to Battery

Electro-Magnetic Clutch Short to

Ground

Front Speed Sensor Voltage Low

Front Speed Sensor Voltage High

Rear Speed Sensor Voltage Low

Rear Speed Sensor Voltage High

Speed Sensor Reference Voltage Low

Speed Sensor Reference Voltage

High

DTC

1714

1715

1716

1721

1722

1731

1732

1733

1735

1736

1741

Description

Motor Open / Shorted to Battery

Motor Output Shorted to Ground

Shift System Timeout

General Position Encoder Fault (In-

validCode)

Position 1 Shorted to Ground




DTC

1742

1714

1743

1750

1751

1752

1753

1754


SSANGYONG MY2002

BLANK

SSANGYONG MY2002


4WD CHECK INDICATOR STAYS ON WITH IGNITION SWITCH ON

KAA5D040

Circuit Description

When the ignition switch turns to ON the transfer casecontrol unit (TCCU) illuminates 4WD CHECK and 4WDLOWindicator to check bulb operation and turns offafter 0.6 seconds. Then TCCU starts self-diagnosisand illuminate 4WD CHECK indicator when TCCUdetects any fault.

Diagnostic Aids

• If the 4WD CHECK indicator illuminates steadily theTCCU may detect some fault. TCCU should bechecked by scan tool to solve the problem.

• The 4WD CHECK indicator also illuminates steadilyif the terminal B2 of TCCU connector is shorted toground. The shorted wire or terminals should be re-paired.

Test Description

The number(s) below refer to step(s) on the diagnostictable.

2. This step, along with step 4, checks the short toground condition of the wire or terminals

Step

1

ABS INDICATOR LAMP ILLUMINATED CONTINUOUSLY, NO DTCs STORED

Action Yes

Go to thespecific DTC

diagnostic table

No

Go to Step 2

Value(s)

1. Turn the ignition switch to OFF.2. Connect the scan tool to the data link connector

(DLC).3. Turn the ignition switch to ON and request the DTC.Does the scan tool display any DTC?


SSANGYONG MY2002

Step

2

3

4

5

Action Yes

Go to Step 3

System OK

Go to Step 5

System OK

No

Go to Step 4

-

System OK

-

Value(s)1. Turn the ignition switch to OFF.2. Disconnect the 18-pin connector from transfer case

control unit (TCCU).3. Turn the ignition switch to ON and check the 4WD

CHECK bulb operation.Does the 4WD CHECK indicator come on steadily?Repair any short to ground circuit between terminalB2 of TCCU connector and terminal A4 of cluster.Is the repair complete?1. Turn the ignition OFF.2. Check the pin or terminals for damage or improper

connection.3. Reconnect all the connectors.4. Turn the ignition ON.Does the 4WD CHECK indicator come on steadily?Replace the TCCU.Is the repair complete?

SSANGYONG MY2002


KAA5D040

NO 4WD LOW INDICATOR STAYS ON WITH IGNITION SWITCH ON

Circuit Description


Diagnostic Aids

• If the 4WD LOW indicator illuminates steadily thetransfer case in 4 wheel drive low range and 4H/4Lswitch set to 4L. It is normal condition.

• The 4WD LOW indicator also illuminates steadily ifthe terminal B9 of TCCU connector is shorted toground. The shorted wire or terminals should be re-paired.

Test Description


2. This step checks for the normal bulb operation.

Step

1

2

Action Yes

Go to Step 2

System OK

No

Go to Step 3

-

Value(s)

Check the position of 4H/4L switch.Does the 4H/4L switch set on 4L.1. Turn the ignition switch to ON.2. Set the shift lever to N (neutral).3. Turn the 4H/4L switch to 4H.Does the 4WD LOWindicator go off?


SSANGYONG MY2002

Step

3

4

5

6

7

Action Yes

Go to Step 4

System OK

Go to Step 6

System OK

System OK

No

Go to Step 5

-

System OK

Go to Step-7

-

Value(s)1. Turn the ignition switch to ON.2. Set the shift lever to N (neutral).3. Turn the 4H/4L switch to 4L.Does the 4WD LOWindicator go off?The wiring of 4H/4L switch is reversed. Repair thewiring.Is the repair complete?1. Turn the ignition OFF.2. Check the pin or terminals for damage or improper

connection.3. Reconnect all the connectors.4. Turn the ignition ON.Does the 4WD LOW indicator come on steadily?Repair any short to ground circuit between terminal B9of TCCU connector and terminal A8 of cluster.Is the repair complete?Replace the TCCU.Is the repair complete?

SSANGYONG MY2002


KAA5D040

NO 4WD CHECK OR 4WD LOW INDICATOR WITH IGNITION SWITCH ON

Circuit Description


Diagnostic Aids

• If the both of the 4WD CHECK and 4WD LOWindica-tor were not illuminating there would be some prob-lems with fuse, power supply line, improperconnection of connector or transfer case control unit(TCCU).

• If one of the indicators illuminates, the fuse andpower supply line is good and the connector orTCCU may be the cause of problems.

Test Description


1. This step checks for the normal bulb operation.

5. This step checks voltage supply condition.

Step

1

ActionCheck the bulb operation when the ignition switchturns to ON.Does the only 4WD LOWindicator come on and goesafter 0.6 seconds?

Yes

Go to Step 2

No

Go to Step 5

Value(s)


SSANGYONG MY2002

Step

2

3

4

5

6

7

Action

Go to Step 3

System OK

System OK

Go to Step 6

System OK

System OK

Go to Step 4

Go to Step 7

Go to Step 7

Go to Step 7

Go to Step 7

-

Value (s)

1. Turn the ignition switch to OFF.2. Disconnect 18-pin connector from the transfer case

control unit (TCCU).3. Using test lamp check the continuity between

terminal B2 of TCCU and ground.Does the test lamp come on?1. Turn the ignition OFF.2. Check the pin or terminals for damage or improper

connection.3. Reconnect all the connectors.4. Turn the ignition ON.Do the two indicators come on go after 0.6 seconds?Repair or replace of following components:

• Open circuit between terminal A1 to A3 of cluster.

• 4WD CHECK indicator bulb.

• Open circuit between terminal A4 of cluster andterminal B2 of TCCU connector.Is the repair complete?1. Check the fuse F30 and indicator bulbs.2. Check the continuity for following terminals:

• FuseF30 to A1 (Cluster)

• A1 (Cluster) to A3 (Cluster)

• A4 (Cluster) to B2 (TCCU)

• A8 (Cluster) to B9 (TCCU)Are there any problems?Repair open circuit or replace damaged parts.Is the repair complete?Replace the TCCU.Is the repair complete?

NoYes

SSANGYONG MY2002


4WD LOW INDICATOR BLINK STEADILY

Circuit Description

When the 4H/4L switch turned from 4H (4L) to 4L (4H)electric shift starts and 4WD LOW indicator begin toblink until the shifting is completed or canceled. If 4Hto 4L shifting is completed the 4WD LOW indicatorwill illuminated and 4L to 4H shifting is completed itwill be turned off.

If shifting fails the 4WD LOW indicator will blinksteadily until the shifting is completed or canceled.

Diagnostic Aids

The 4WD LOW indicator shows that the transfer caseis operating in low range. And the indicator will blinkwhile shifting from low to high range or high to lowrange. If the indicator blinks steadily it warns theshifting command and real position of the shift motoror position encoder are not matched.

Step

1

2

3

Action1. Stop the vehicle.2. Turn the 4H/4L switch to original position.Does the 4WD LOW indicator stop blinking?1. Make sure the vehicle stopped completely.2. Set the shift lever to N (neutral) and wait more than

2 seconds.3. Turn the 4H/4L switch.Does the 4WD LOW indicator blink and stop aftercomplete shifting.

• 4H → 4L: 4WD LOW indicator illuminates• 4L → 4H: 4WD LOW Indicator turns off.

1. Starts TCCU Diagnostic System Check.2. If there were no trouble code, replace TCCU.Is the repair complete?

Yes

Go to Step 2

System OK

System OK

No

Go to Step 3

Go to Step 3

-

Value(s)


SSANGYONG MY2002

TCCU DIAGNOSTIC SYSTEM CHECK

Circuit Description

The diagnostic system check is an organized approachto identifying a problem created by a transfer casecontrol unit (TCCU) malfunction. It must be startingpoint for any derivability complaint diagnosis because

it directs the technician to the next logical step indiagnosing the complaint. Understanding the table andusing it correctly will reduce diagnostic time andprevent the unnecessary replacement of parts.

Step

1

2

3

4

5

6

7

8

9

10

11

ActionVerify the customer complaint(s).Are the customer’s complaint(s) verified.Turn the ignition ON.Is the 4WD CHECK indicator come on steadily?Jumper the terminal B2 of the transfer case controlunit (TCCU) and ground.Does the 4WD CHECK indicator comes on.

1. Turn the ignition OFF.2. Connect the scan tool to the data link connector

(DLC) and follow the directions given in the scantool manual.

3. Turn the ignition ON.Does the scan tool communicate with TCCU?Check the scan tool communication with other controlunit.Does the scan tool communicate with other controlunit?Repair diagnostic line between terminal A12 of TCCUand terminal 13 of DLC.Is the repair complete?Change the scan tool.Does the scan tool communicate with other controlunit?1. Replace TCCU.2. Connect the scan tool to DLC.3. Request the DTC.Are any DTCs displayed?Request DTC with the scan tool.Are any DTCs displayed?1. Road tests the vehicle.2. Recheck for the presence of the any DTCs.Are any DTCs displayed?Refer to the applicable DTC table. Start with the DTCwith the lowest numerical value and move up.Are the DTC(s) identified as valid trouble code(s) ?

Yes

Go to Step 2

Go to Step 4

Go to Step 4

Go to Step 9

Go to Step 6

Go to Step 4

Go to Step 4

Go to Step

Go to Step 11

Go to Step 11

Go to applicableDTC table

No

-

Go to Step 3

Repair 4WDCHECK

indicator bulbor wiring circuit

Go to Step 5

Go to Step 7

-

Go to Step 8

Go to Step 10

Go to Step 10

System OK

-

Value(s)

SSANGYONG MY2002


DIAGNOSTIC TROUBLE CODE (DTC) 1714EEPROM CHECKSUM FAULT

Circuit Description

When the ignition is turned on the transfer case controlunit (TCCU) receives battery voltage and ignition volt-age and illuminates the 4WD CHECK and 4WD LOWindicators for 0.6 seconds. Then it starts self diagnosisto check itself.

Conditions for Setting the DTCDTC 1714 is an indication of a potential internal transfercase control unit (TCCU) malfunction. It will set if anyof following conditions is detected.

• The calculated checksum for internal memory doesnot match the stored value.

• The permanent memory storage area is malfunction-ing.

Action Taken When the DTC Sets

The TCCU will illuminates 4WD CHECK indicator andDTC is stored in TCCU.

Diagnostic Aids• Check for poor connections, fuse and power supply

wiring.

• Check for ground condition.

Test DescriptionThe number(s) below refer to step(s) on the diagnostictable.

2. This step checks the battery supply voltage.4. This step checks the ground condition.6. This step checks the connection status.

Step

1

2

3

4

5

ActionWas the TCCU Diagnostic System Check performed?

1. Turn the ignition switch to OFF.2. Disconnect the 12-pin connector from transfer case

control unit (TCCU).3. Turn the ignition switch to ON.4. Connect a digital voltmeter between each of the

following TCCU connector terminal and ground.

• A4 (Battery supply).

• A11 (Battery supply).

• A5 (Battery supply).Does the voltage of the all circuits measure within thevalue specified?1. Check the fuse EF11, F17, F23 and voltage supply

circuit.2. Repair or replace any open or damaged circuit or

fuse.Is the repair complete?Connect a digital ohmmeter between each of thefollowing TCCU connector terminal and ground.

• A9 (Ground).

• A10 (Ground).Does the resistance of the all circuits measure withinthe value specified?Repair or replace any open or damaged circuit.Is the repair complete?

No

Go to “TCCUDiagnostic

System Check”

Go to Step 3

-

Go to Step 5

-

Value(s)

11 - 14v

≈ 0 v

Yes

Go to Step 2

Go to Step 4

Go to Step 4

Go to Step 6

Go to Step 6


SSANGYONG MY2002

Step

6

7

Action1. Check the terminals for damages and loose

connection.2. Replace or repair the faulty connector, wire, or

terminals.3. Connect the TCCU connector.4. Connect the scan tool to data link connector (DLC)

and follow the directions given in the scan toolmanual.

5. Turn the ignition switch to ON.6. Delete and request DTC with scan tool.Is DTC 1714 still present?1. Replace the TCCU.2. Turn the ignition switch to OFF.3. Connect the scan tool to data link connector (DLC)


4. Turn the ignition switch to ON.5. Delete DTC with scan tool.Is the repair complete?

No

System OK

-

Value(s) No

Go to Step 7

System OK

SSANGYONG MY2002


KAA5D070

DIAGNOSTIC TROUBLE CODE (DTC) 1715TP SENSOR LOSS OF SIGNAL

Circuit Description

The transfer case control unit (TCCU) receives throttleposition (TP) sensor signals from engine control module(ECM) through CAN bus line.

Conditions for Setting the DTC

• The transfer case control unit (TCCU) can notreceive throttle position (TP) sensor signal fromengine control module (ECM). There is a badcommunication between TCCU and ECM.

• TCCU is malfunction.

• ECM is malfunction.



Diagnostic Aids

• Check for poor connections of CAN bus line.

• Check for ECM and TP sensor.

Test Description


2. This step decides the causal parts of the problem.

4. This step checks the ground condition.

6. This step checks the connection status.

Step

1

2


1. Turn the ignition switch to OFF.2. Connect the scan tool to data link connector (DLC)


3. Turn the ignition switch to ON and request engineDTC.

Are there any engine DTC related throttle position (TP)sensor?

Yes

Go to Step 2

Go to specificengine DTCdiagnosis.

Refer toSection

1F, EngineControl

NoGo to “TCCU

DiagnosticSystem Check”

Go to Step 3

Value(s)


SSANGYONG MY2002

Step

3

4

5

6

Action1. Turn the ignition switch to OFF.2. Disconnect the 18-pin connector from the transfer

case control unit (TCCU).3. Disconnect the gray connector from engine control

module (ECM).4. Connect a digital ohmmeter between the following

TCCU connector terminal and gray ECM connectorterminal.

• B11 (TCCU) and 37 (ECM)• B10 (TCCU) and 38 (ECM)Does the resistance of the all circuits measure withinthe value specified?Repair or replace any open wires, faulty connector, orterminal.Is the repair complete?1. Replace the TCCU.2. Connect all connectors.3. Request DTC with scan tool.Is the repair complete?Replace the ECM.Is the repair complete?

Yes

Go to Step

System OK

System OK

System OK

No

Go to Step 4

-

Go to Step 6

-

Value(s)

≈ 0 v

SSANGYONG MY2002


KAA5D070

DIAGNOSTIC TROUBLE CODE (DTC) 1716TP SENSOR OUT OF RANGE

Circuit Description

The transfer case control unit (TCCU) receives throttleposition (TP) sensor signals from engine control module(ECM) through CAN bus line.


• The transfer case control unit (TCCU) receivesthrottle position (TP) sensor signal from engine con-trol module (ECM), but the signal is out of the range.There is a bad communication between TCCU andECM.

• TCCU is malfunction.

• ECM is malfunction.



Diagnostic Aids

• Check for poor connections of CAN bus line.

• Check for ECM and TP sensor.

Test Description


2. This step decides the causal parts of the problem.


6. This step checks the connection status.

Step

1

2

ActionWas the TCCU Diagnostic System Checkperformed?



3. Turn the ignition switch to ON and request engineDTC.

Are there any engine DTC related throttle position (TP)sensor?

Yes

Go to Step 2

Go to specificengine DTCdiagnosis.

Refer toSection

1F, EngineControl

NoGo to “TCCU


Go to Step 3

Value(s)


SSANGYONG MY2002

Step

3

4

5

6

Action1. Turn the ignition switch to OFF.2. Disconnect the 18-pin connector from the transfer

case control unit (TCCU).3. Disconnect the gray connector from engine control

module (ECM).4. Connect a digital ohmmeter between the following

TCCU connector terminal and gray ECM connectorterminal.

• B11 (TCCU) and 38 (ECM)• B10 (TCCU) and 37 (ECM)• B11 (TCCU) and ground• B10 (TCCU) and groundDoes the resistance of the all circuits measure withinthe value specified?Repair or replace any short wires, faulty connector, orterminal.Is the repair complete?1. Replace the TCCU.2. Connect all connectors.3. Request DTC with scan tool.Is the repair complete?Replace the ECM.Is the repair complete?

Yes

Go to Step 4

System OK

System OK

System OK

No

Go to Step 5

-

Go to Step 6

-

Value(s)

≈ 0 v

SSANGYONG MY2002


KAA5D090

DIAGNOSTIC TROUBLE CODE (DTC) 1721ELECTROMAGNETIC CLUTCH OPEN / SHORT TO BATTERY

Circuit Description

To control the distribution of the torque to front propellershaft, the transfer case control unit (TCCU) sends asignal to the electromagnetic clutch (EMC). Then theclutch disc is compressed or released by the EMC.

Conditions for Setting the DTCEven the TCCU send signal for controlling the EMC, itreceives uncontrolled propeller shaft speed signal..

• The wiring circuit to EMC opened.

• The wiring circuit is shorted to battery.



Diagnostic Aids

• Check for poor connections of the circuit.

• Check for EMC.


2. This step checks poor connection or damage onthe pin.

3. This step, along with step4, checks the voltagesupply condition.


7. This step checks the continuity of the wire andshort to battery condition.

Step

1


Yes

Go to Step 2

NoGo to “TCCU


Value(s)


SSANGYONG MY2002

Step

2

3

4

5

6

7

8

9

Action1. Turn the ignition switch to OFF.2. Disconnect two connectors of the transfer case

control unit (TCCU) and white 7-pin connector, forpropeller shaft speed sensor and clutch coil,located under the body.

3. Inspect the terminals for damage or improperconnection.

4. Repair any damaged pins or terminals on thewiring harness and TCCU.

5. Reconnect the connectors and make sure it isseated properly.

6. Connect a scan tool to the data link connector(DLC).

7. Turn the ignition ON.8. Request the DTC with scan tool.Is the DTC still current?1. Turn the ignition switch to OFF.2. Disconnect the 12-pin connector from transfer case


following TCCU connector terminal and ground.• A4 (Battery supply).• A11 (Battery supply).Does the voltage of the all circuits measure within thevalue specified?1. Check the fuse EF11, F17 and voltage supply


fuse.Is the repair complete?Connect a digital ohmmeter between each of thefollowing TCCU connector terminal and ground.• A9 (Ground).• A10 (Ground).Does the resistance of the all circuits measure withinthe value specified?Repair or replace any open or damaged circuit.Is the repair complete?1. Disconnect the white 7-pin connector under the

body.2. Measure the resistance between terminal A3 (DK

GRN) of TCCU and terminal A (DK GRN) of thewhite connector.

Is the resistance within the value specified?3. Measure the voltage between terminal A3 (DK

GRN) of TCCU and ground.Is the voltage within the value specified?Repair open or short to battery circuit.Is the repair complete?Measure the resistance between terminal A (DK GRN)of clutch coil and ground.

Is the measurement within the value specified?

Yes

Go to Step 3

Go to Step 5

Go to Step 5

Go to Step 7

Go to Step 7

Go to Step 9

System OK

Go to Step 11

No

System OK

Go to Step 4

-

Go to Step 6

-

Go to Step 8

-

Go to Step 10

Value(s)

11 - 14 v

≈ 0 v

0 Ω

≈ 0 v

2.2 - 2.8 Ω

SSANGYONG MY2002


Step

10

11

Action1. Replace electromagnetic clutch (EMC) coil.2. Connect all the connectors.3. Connect a scan tool to the DLC.4. Turn the ignition switch to ON.5. Delete and request DTC.Is the repair complete?Replace the TCCU.Is the repair complete?

Yes

System OK

System OK

No

-

-

Value(s)


SSANGYONG MY2002

BLANK

SSANGYONG MY2002


KAA5D090

DIAGNOSTIC TROUBLE CODE (DTC) 1722ELECTROMAGNETIC CLUTCH SHORT TO GROUND

Circuit Description

To control the distribution of the torque to front propellershaft, the transfer case control unit (TCCU) sends asignal to the electromagnetic clutch (EMC). Then theclutch disc is compressed or released by the EMC.

Conditions for Setting the DTCEven the TCCU send signal for controlling the EMC, itreceives uncontrolled propeller shaft speed signal.

• The wiring circuit to EMC is shorted to ground.



Diagnostic Aids

• Check for poor connections of the circuit.

• Check for EMC.


2. This step checks poor connection or damage onthe pin.

3. This step, along with step 4, checks the voltagesupply condition.


7. This step checks the continuity of the wire andshort to battery condition.

Step

1


Yes

Go to Step 2

NoGo to “TCCU


Value(s)


SSANGYONG MY2002

Step

2

3

4

5

6

7

8

9







7. Turn the ignition ON.8. Request the DTC with scan tool.Is the DTC still current?1. Turn the ignition switch to OFF.2. Disconnect the 12-pin connector from transfer case


following TCCU connector terminal and ground.• A4 (Battery supply).• A11 (Battery supply).Does the voltage of the all circuits measure within thevalue specified?1. Check the fuse EF11, F17 and voltage supply


fuse.Is the repair complete?Connect a digital ohmmeter between each of thefollowing TCCU connector terminal and ground.• A9 (Ground).• A10 (Ground).Does the resistance of the all circuits measure withinthe value specified?Repair or replace any open or damaged circuit.Is the repair complete?1. Disconnect the white 7-pin connector under the

body.2. Measure the resistance between terminal A3 (DK

GRN) of TCCU and terminal A (DK GRN) of thewhite connector.

Is the resistance within the value specified?3. Measure the voltage between terminal A3 (DK

GRN) of TCCU and ground.Is the voltage within the value specified?Repair open or short to battery circuit.Is the repair complete?Measure the resistance between terminal A (DK GRN)of clutch coil and ground.

Is the measurement within the value specified?

Yes

Go to Step 3

Go to Step 5

Go to Step 5

Go to Step 7

Go to Step 7

Go to Step 9

System OK

Go to Step 11

No

System OK

Go to Step 4

-

Go to Step 6

-

Go to Step 8

-

Go to Step 10

Value(s)

11 - 14 v

≈ 0 v

0 Ω

≈ 0 v

2.2 - 2.8 Ω

SSANGYONG MY2002


Step

10

11

Action1. Replace electromagnetic clutch (EMC) coil.2. Connect all the connectors.3. Connect a scan tool to the DLC.4. Turn the ignition switch to ON.5. Delete and request DTC.Is the repair complete?Replace the TCCU.Is the repair complete?

Yes

System OK

System OK

No

-

-

Value(s)


SSANGYONG MY2002

BLANK

SSANGYONG MY2002


KAA5D110

DIAGNOSTIC TROUBLE CODE (DTC) 1731FRONT SPEED SENSOR VOLTAGE LOW

Circuit Description

The transfer case control unit (TCCU) supplies 5 voltsreference voltage to the front speed sensor andreceives speed signals generated by Hall effect speedsensor.


• The wiring circuit for speed sensor shorted to groundor opened.

• The reference voltage circuit is shorted to groundor opened.


The TCCU will illuminates 4WD CHECK indicator andDTC is stored in TCCU. The TCCU then responds asfollows:

• If the system is in high range the TCCU uses therear speed sensor to determine the EMC touch offlevel and wheel slip control is suspended.

• If the system is in low range, the EMC duty cycle isset to maximum, independent of vehicle speed, untilthe system is shifted out of low range.

• All electric shift activity is halted until the Ignitionis cycled. If a shift is in progress it wil l becompleted.

Diagnostic Aids

• Check for short to ground or open circuit.

• Check for front propeller speed sensor..

Test Description


3. This step checks the continuity.

5. This step checks the speed sensor.

Step

1

2




3. Turn the ignition switch to ON4. Request DTC with scan tool.Is the DRC 1735 slso shown?

Yes

Go to Step 2

Go to “DTC1735 - Speed

SensorReference

Voltage Low”

NoGo to “TCCU


Go to Step 3

Value(s)


SSANGYONG MY2002

Step

3

4

5

6

7

Action1. Turn the ignition switch to OFF.2. Disconnect 18-pin connectors of the transfer case


3. Measure the resistance between terminals B6 (YEL)of TCCU and terminals C (YEL) in female white 7-pin connector.

Is measured value equal to specified range?4. Measure the resistance between terminals B6 (YEL)

of TCCU and ground.Is measured value equal to specified range?1. Repair any damaged pins, terminals, open or short

to ground circuit.2. Reconnect the connectors and make sure it is

seated properly.3. Connect a scan tool to the data link connector

(DLC).4. Turn the ignition ON.5. Request the DTC with scan tool.Is the DTC still current?Measure the resistance between terminals of the malewhite 7-pin connector.Is the measurement within specified range?• Terminal B and terminal C• Terminal B and terminal D• Terminal C and terminal DReplace front propeller shaft speed sensor.Is the repair complete?1. Replace the TCCU.2. Turn the ignition switch to OFF.3. Connect the scan tool to data link connector (DLC)


4. Turn the ignition switch to ON.5. Delete and request DTC with scan tool.

Yes

Go to Step 5

Go to Step 5

Go to Step 7

System OK

System OK

No

Go to Step 4

System OK

Go to Step 6

-

Value(s)

0 Ω

∞

5 - 6 MΩ

5 - 6 MΩ

9 - 10 kΩ

SSANGYONG MY2002


KAA5D110

DIAGNOSTIC TROUBLE CODE (DTC) 1732FRONT SPEED SENSOR VOLTAGE HIGH

Circuit Description



• The wiring circuit for speed sensor shorted tovoltage.

• The reference voltage circuit is shorted to voltage.



• If the system is in high range the TCCU uses therear speed sensor to determine the EMC touch offlevel and wheel slip control is suspended.

• If the system is in low range, the EMC duty cycle isset to maximum, independent of vehicle speed, untilthe system is shifted out of low range.


Diagnostic Aids



Test Description




Step

1

2





Yes

Go to Step 2


SensorReference

Voltage High”

NoGo to “TCCU


Go to Step 3

Value(s)


SSANGYONG MY2002

Step

3

4

5

6

7



3. Measure the voltage between terminals B6 (YEL) ofTCCU and ground.

Is measured value below the specified value?1. Repair any damaged pins, terminals, short to

battery circuit.2. Reconnect the connectors and make sure it is


(DLC).4. Turn the ignition ON.5. Request the DTC with scan tool.Is the DTC still current?Measure the resistance between terminals of the malewhite 7-pin connector.Is the measurement within specified range?• Terminal B and terminal C• Terminal B and terminal D• Terminal C and terminal DReplace front propeller shaft speed sensor.Is the repair complete?1. Replace the TCCU.2. Turn the ignition switch to OFF.3. Connect the scan tool to data link connector (DLC)


4. Turn the ignition switch to ON.5. Delete and request DTC with scan tool.Is the repair complete?

Yes

Go to Step 5

Go to Step 5

Go to Step 7

System OK

System OK

No

Go to Step 4

System OK

Go to Step 6

-

Value(s)

1 v

5 - 6 MΩ

5 - 6 MΩ

9 - 10 kΩ

SSANGYONG MY2002


KAA5D110

DIAGNOSTIC TROUBLE CODE (DTC) 1733REAR SPEED SENSOR VOLTAGE LOW

Circuit Description

The transfer case control unit (TCCU) supplies 5 voltsreference voltage to the front and rear speed sensorand receives speed signals generated by Hall effectspeed sensor.


• The wiring circuit for speed sensor shorted to groundor opened.

• The reference voltage circuit is shorted to groundor opened.



• If the system is in high range the TCCU uses thefront speed sensor to determine the EMC touch offlevel and wheel slip control is suspended.

• If the system is in low range, the EMC duty cycle isset to maximum independent of vehicle speed untilthe system is shifted out of low range.


Diagnostic Aids



Test Description




Step

1

2





Yes

Go to Step 2


SensorReference

Voltage Low”

NoGo to “TCCU


Go to Step 3

Value(s)


SSANGYONG MY2002

Step

3

4

5

6

7



3. Measure the resistance between terminals B17 (DKGRN/BLK) of TCCU and terminals F (DK GRN/BLK)in female white 7-pin connector.

Is measured value equal to specified range?4. Measure the resistance between terminals B17 (DK

GRN/BLK) of TCCU and ground.Is measured value equal to specified range?1. Repair any damaged pins, terminals, open or short



(DLC).4. Turn the ignition ON.5. Request the DTC with scan tool.Is the DTC still current?Measure the resistance between terminals of the malewhite 7-pin connector.Is the measurement within specified range?• Terminal G and terminal F• Terminal G and terminal E• Terminal F and terminal EReplace rear propeller shaft speed sensor.Is the repair complete?1. Replace the TCCU.2. Turn the ignition switch to OFF.3. Connect the scan tool to data link connector (DLC)



Yes

Go to Step 5

Go to Step 5

Go to Step 7

System OK

System OK

No

Go to Step 4

System OK

Go to Step 6

-

Value(s)

0 Ω

∞

5 - 6 MΩ

5 - 6 MΩ

9 - 10 kΩ

SSANGYONG MY2002


KAA5D110

DIAGNOSTIC TROUBLE CODE (DTC) 1734REAR SPEED SENSOR VOLTAGE HIGH

Circuit Description



• The wiring circuit for speed sensor shorted tovoltage.

• The reference voltage circuit is shorted to voltage.



• If the system is in high range the TCCU uses thefront speed sensor to determine the EMC touch offlevel and wheel slip control is suspended.

• If the system is in low range, the EMC duty cycle isset to maximum independent of vehicle speed untilthe system is shifted out of low range.


Diagnostic Aids


• Check for front propeller speed sensor.

Test Description




Step

1

2





Yes

Go to Step 2


SensorReference

Voltage High”

NoGo to “TCCU


Go to Step 3

Value(s)


SSANGYONG MY2002

Step

3

4

5

6

7



3. Measure the voltage between terminals B17 (DKGRN/BLK) of TCCU and ground.

Is measured value below the specified value?1. Repair any damaged pins, terminals, open or short






Yes

Go to Step 5

Go to Step 5

Go to Step 7

System OK

System OK

No

Go to Step 4

System OK

Go to Step 6

-

Value(s)

1 v

5 - 6 MΩ

5 - 6 MΩ

9 - 10 kΩ


SSANGYONG MY2002

Step

3

4

5

6

7



3. Measure the voltage between terminals B17 (DKGRN/BLK) of TCCU and ground.

Is measured value below the specified value?1. Repair any damaged pins, terminals, open or short






Yes

Go to Step 5

Go to Step 5

Go to Step 7

System OK

System OK

No

Go to Step 4

System OK

Go to Step 6

-

Value(s)

1 v

5 - 6 MΩ

5 - 6 MΩ

9 - 10 kΩ

SSANGYONG MY2002


KAA5D110

DIAGNOSTIC TROUBLE CODE (DTC) 1735SPEED SENSOR REFERENCE VOLTAGE LOW

Circuit Description

The transfer case control unit (TCCU) provides reference voltage to front and rear propeller-shaft speedsensor.

Conditions for Setting the DTCIf the reference voltage supply line is open or shortedto ground, then the 4WD CHECK indicator willilluminated and the diagnostic trouble code (DTC) willstored to the TCCU.

• If the system is in high range the TCCU sets theEMC touch off level based on a vehicle speed of 0and wheel slip control is suspended.

• If the system is in low range, the EMC duty cycle isset to maximum until the system is shifted out oflow range.


Diagnostic Aids


Test Description



5. This step checks the continuity of ground line.

7. This step checks the speed sensors.

Step

1

2


1. Disconnect white 7-pin connector, for propellershaft speed sensor and clutch coil, located underthe body.

2. Turn the ignition switch to ON.3. Measure the voltage between following terminals of

male white 7-pin connector:• Terminal D/E and terminal B/GIs measured value within the specified range?

Yes

Go to Step 2

Go to Step 7

NoGo to “TCCU


Go to Step 3

Value(s)

4.5 - 5.5 v


SSANGYONG MY2002

Step

3

4

5

6

7

8

9

ActionMeasure the resistance between terminal A8 (DKBLU/YEL) and terminals B8 (BLK/YEL) of transfercase control unit (TCCU).Is measured value within the specified range?1. Turn the ignition switch to OFF.2. Check two connectors of the TCCU and white 7-

pin connector.3. Repair any damaged pins, connector or wires.4. Reconnect all the connectors and make sure it is


(DLC).6. Turn the ignition switch to ON.7. Request DTCIs the DTC still current?1. Turn the ignition switch to OFF.2. Disconnect two connectors of the TCCU and white

7-pin connector under the body.3. Measure the resistance between following termi-

nals:

• A8 (TCCU) and D/E (white 7-pin connector)

• B8 (TCCU) and B/G (white 7-pin connector)the resistance equal to specified value?

4. Measure the resistance between A8 and B8 ofTCCU connector and ground

Is the resistance equal to specified value?Repair any open or short to ground circuit.Is the repair complete?Measure the resistance between terminals of the malewhite 7-pin connector.Is the measurement within specified range?• Terminal B and terminal C• Terminal B and terminal D• Terminal C and terminal D• Terminal G and terminal F• Terminal G and terminal E• Terminal F and terminal EReplace front or rear propeller shaft speed sensor.Is the repair complete?1. Replace the TCCU.2. Turn the ignition switch to OFF.3. Connect the scan tool to data link connector (DLC)



Yes

Go to Step 5

Go to Step 7

Go to Step 7

System OK

Go to Step 9

System OK

System OK

No

Go to Step 4

System OK

Go to Step 6

Go to Step 7

Go to Step 8

-

Value(s)

4.5 - 5.5 v

0 Ω

∞

5 - 6 MΩ

5 - 6 MΩ

9 - 10 kΩ

5 - 6 MΩ

5 - 6 MΩ

9 - 10 kΩ

SSANGYONG MY2002


KAA5D110

DIAGNOSTIC TROUBLE CODE (DTC) 1736SPEED SENSOR REFERENCE VOLTAGE HIGH

Circuit Description

The transfer case control unit (TCCU) provides refer-ence voltage to front and rear propeller-shaft speedsensor.

Conditions for Setting the DTCIf the reference voltage supply line is shorted tobattery, then the 4WD CHECK indicator will illuminatedand the diagnostic trouble code (DTC) will stored tothe TCCU.

• If the system is in high range the TCCU sets theEMC touch off level based on a vehicle speed of 0and wheel slip control is suspended.

• If the system is in low range, the EMC duty cycle isset to maximum until the system is shifted out oflow range.


Diagnostic Aids


Test Description




7. This step checks the speed sensors.

Step

1

2

3

ActionWas the TCCU Diagnostic System Checkperformed?1. Disconnect white 7-pin connector, for propeller

shaft speed sensor and clutch coil, located underthe body.

2. Turn the ignition switch to ON.3. Measure the voltage between following terminals of

male white 7-pin connector:• Terminal D/E and terminal B/G

Is measured value within the specified range?Measure the resistance between terminal A8 (DK BLU/YEL) and terminals B8 (BLK/YEL) of transfer casecontrol unit (TCCU).Is measured value within the specified range?

Yes

Go to Step 2

Go to Step 7

Go to Step 5

NoGo to “TCCU


Go to Step 3

Go to Step 4

Value(s)

4.5 - 5.5 v

4.5 - 5.5 v


SSANGYONG MY2002

Step

4

5

6

7

8

9

Action1. Turn the ignition switch to OFF.2. Check two connectors of the TCCU and white 7-pin

connector.3. Repair any damaged pins, connector or wires.4. Reconnect all the connectors and make sure it is


(DLC).6. Turn the ignition switch to ON.7. Request DTCIs the DTC still current?1. Turn the ignition switch to OFF.2. Disconnect two connectors of the TCCU and white

7-pin connector under the body.3. Measure the resistance between following termi-

nals:• A8 (TCCU) and D/E (white 7-pin connector)• B8 (TCCU) and B/G (white 7-pin connector)Is the resistance equal to specified value?4. Measure the voltage between A8 and B8 of TCCU

connector and groundIs the resistance below the specified value?Repair any short to battery circuit.Is the repair complete?Measure the resistance between terminals of the malewhite 7-pin connector.Is the measurement within specified range?• Terminal B and terminal C• Terminal B and terminal D• Terminal C and terminal D• Terminal G and terminal F• Terminal G and terminal E• Terminal F and terminal EReplace front or rear propeller shaft speed sensor.Is the repair complete?1. Replace the TCCU.2. Turn the ignition switch to OFF.3. Connect the scan tool to data link connector (DLC)



Yes

Go to Step 5

Go to Step 7

System OK

Go to Step 9

System OK

System OK

No

System OK

Go to Step 6

Go to Step 7

Go to Step 8

-

Value(s)

0 Ω

1 v

5 - 6 MΩ

5 - 6 MΩ

9 - 10 kΩ

5 - 6 MΩ

5 - 6 MΩ

9 - 10 kΩ

SSANGYONG MY2002


KAA5D170

DIAGNOSTIC TROUBLE CODE (DTC) 1741MOTOR OUTPUT OPEN / SHORTED TO BATTERY

Circuit Description

The transfer case control unit (TCCU) sends current tomove the shift motor upon the position of the 4H/4Lswitch.

Conditions for Setting the DTCIf the TCCU detects a shift motor fault continuously forone seconds, the 4WD CHECK indicator will illuminatedand the diagnostic trouble code (DTC) will stored tothe TCCU.

• Motor HI-LO circuits are shorted to battery.

• Motor LO-HI circuits are shorted to battery.

• Motor HI-LO circuits are shorted to motor LO-HI cir-cuits.


Diagnostic Aids

• Check for short to battery or open circuit.

• Check for the shift motor.


2. This step checks the connector and connectionstatus.



7. This step checks the shift motor.

Step

1


Yes

Go to Step 2

NoGo to “TCCU


Value(s)


SSANGYONG MY2002

Step

2

3

4

5

6


control unit (TCCU) and black 7-pin connectorunder the body.





7. Turn the ignition ON.8. Request the DTC with scan tool.Is the DTC still current?1. Disconnect the black 7-pin connector for shift

motor under the body.2. Turn the ignition switch to ON.3. Position shift lever to N (neutral).4. Connect the voltmeter between terminal G of

female black 7-pin connector and ground.5. Measure the voltage while switching the 4L/4H

switch from 4H to 4L.Is the voltage within the specified value?6. Connect the voltmeter between terminal B of


switch from 4L to 4H.Is the voltage within the specified value?1. Connect terminal A1/A6 (RED/YEL) and terminal

A9/A10 (BLK) with digital voltmeter.2. Measure the voltage while switching the 4L/4H

switch from 4H to 4L.Is the voltage within the specified value?3. Connect terminal A2/A7 (YEL) between terminals


switch from 4L to 4H.Is the voltage within specified range?1. Disconnect 12-pin connector from transfer case

control unit (TCCU) and black 7-pin connector.2. Measure the resistance between following termi-

nals.• A2 (TCCU) and B (black 7-pin connector)• A7 (TCCU) and B (black 7-pin connector)• A1 (TCCU) and G (black 7-pin connector)• A6 (TCCU) and G (black 7-pin connector)Is the resistance equal to specified value?3. Measure the voltage between following terminals:• A2/A7 (TCCU) and ground• A1/A6 (TCCU) and groundRepair any open or short to battery circuit.Is the resistance equal to specified value?

Yes

Go to Step 3

Go to Step 7

Go to Step 5

Go to Step 7

System OK

No

System OK

Go to Step 4

Go to Step 9

Go to Step 6

Go to Step 7

Value(s)

11 - 14 v

11 - 14 v

11 - 14 v

11 - 14 v

0 Ω

SSANGYONG MY2002


Step

7

8

9

Action1. Turn the ignition switch to OFF.2. Disconnect the black 7-pin connector, for shift

motor, under the body.3. Measure the resistance between terminal G (ORN)

and terminal B (YEL).Is the resistance within the specified value?Replace the shift motor.Is the repair complete?Replace the TCCU.Is the repair complete?

Yes

Go to Step 2

System OK

System OK

No

Go to Step 8

-

Go to Step 7

Value(s)

1 - 250 Ω


SSANGYONG MY2002

BLANK

SSANGYONG MY2002


5D170

DIAGNOSTIC TROUBLE CODE (DTC) 1742MOTOR OUTPUT SHORTED TO GROUND

Circuit Description


Conditions for Setting the DTCIf the TCCU detects a shift motor fault continuously forone second, the 4WD CHECK indicator will illuminatedand the diagnostic trouble code (DTC) will stored tothe TCCU.



• Motor HI-LO circuits are shorted to motor LO-HI cir-cuits.

Diagnostic Aids

• Check for short to ground circuit.







Step

1


Yes

Go to Step 2

NoGo to “TCCU


Value(s)


SSANGYONG MY2002

Step

2

3

4

5

6







7. Turn the ignition ON.8. Request the DTC with scan tool.Is the DTC still current?1. Disconnect the black 7-pin connector for shift

motor under the body.2. Turn the ignition switch to ON.3. Position shift lever to N (neutral).4. Connect the voltmeter between terminal G of


switch from 4H to 4L.Is the voltage within the specified value?6. Connect the voltmeter between terminal B of


switch from 4L to 4H.Is the voltage within the specified value?1. Connect terminal A1/A6 (RED/YEL) and terminal


switch from 4H to 4L.Is the voltage within the specified value?3. Connect terminal A2/A7 (YEL) between terminals


switch from 4L to 4H.Is the voltage within specified range?1. Disconnect 12-pin connector from transfer case

control unit (TCCU) and black 7-pin connector.2. Measure the resistance between following termi-

nals.• A2/A7 (TCCU) and G (black 7-pin connector)• A1/A6 (TCCU) and B (black 7-pin connector)• A1/A6 (TCCU) and ground.• A2/A7 (TCCU) and ground.Is the resistance equal to specified value?Repair any short to ground or short between circuit.Is the repair complete?

Yes

Go to Step 3

Go to Step 7

Go to Step 5

Go to Step 7

System OK

No

System OK

Go to Step 4

Go to Step 9

System OK

Go to Step 7

Value(s)

11 - 14 v

11 - 14 v

11 - 14 v

11 - 14 v

0 Ω

SSANGYONG MY2002


Step

7

8

9

Action1. Turn the ignition switch to OFF.2. Disconnect the black 7-pin connector, for shift

motor, under the body.3. Measure the resistance between terminal G (ORN)

and terminal B (YEL).Is the resistance within the specified value?Replace the shift motor.Is the repair complete?Replace the TCCU.Is the repair complete?

Yes

Go to Step 9

System OK

System OK

No

Go to Step 8

-

-

Value(s)

1 - 250 Ω


SSANGYONG MY2002

DIAGNOSTIC TROUBLE CODE (DTC) 1743SHIFT SYSTEM TIMEOUT

Circuit Description



• Shifting to other drive range is failed within specifiedrange.

Diagnostic Aids



Test Description




Step

1

2

3

4

5

6


1. Turn the ignition switch to OFF.2. Connect a scan tool to the data link connector


3. Turn the ignition switch to ON.4. Request DTC with scan tool.Is the DTC 1741 or 1742 also shown?1. Turn the ignition switch to OFF.2. Disconnect two connectors of the transfer case






7. Turn the ignition ON.8. Request the DTC with scan tool.Is the DTC still current?1. Remove the shift motor.2. Connect the black 7-pin connector to shift motor.3. Check the motor operation by turning the 4H/4L

switch.Is the motor run?Replace the TCCU.Is the repair complete?Repair any problems in transfer case assembly.Is the repair complete?

YesGo to Step 2

Go to SpecificDTC Diagnos-

tic Chart

Go to Step 4

Go to Step 5

System OK

System OK

NoGo to “TCCU


Go to Step 3

System OK

Replace shifmotor and Go to

Step 3

Go to Step 6

-

Value(s)

SSANGYONG MY2002


KAA5D190

DIAGNOSTIC TROUBLE CODE (DTC) 1750GENERAL POSITION ENCODER FAULT (INVALID CODE)

Circuit Description

The transfer case control unit (TCCU) receives positionencoder signals from position encoder.


If the TCCU detects a shift motor fault continuously forone second, the 4WD CHECK indicator will illuminatedand the diagnostic trouble code (DTC) will stored tothe TCCU.

• Any position code which does not correspond tothe valid 9 codes.


Diagnostic Aids


Test Description


3. This step checks the continuity of the positionencoder line.


Step

1

2




3. Turn the ignition switch to ON.4. Request DTC with scan tool.Is the DTC 1751, 1752, 1753, or 1754 also shown?

Yes

Go to Step 2

Go to Step 3

NoGo to “TCCU


Go to Step 5

Value(s)


SSANGYONG MY2002

Step

3

4

5

6

7

Action1. Disconnect 18-pin connector from the transfer case

control unit (TCCU).2. Measure the resistance between following termi-

nals:• B15 (TCCU) and ground.• B5 (TCCU) and ground.• B16 (TCCU) and ground.• B18 (TCCU) and ground.Is any of the resistance equal to specified value?Repair all of the short to ground circuit.Is the repair complete?1. Turn the ignition switch to OFF.2. Disconnect two connectors of the transfer case






7. Turn the ignition ON.8. Request the DTC with scan tool.Is the DTC still current?Replace the shift motor with position encoder.Is the repair complete?Replace the TCCU.Is the repair complete?

Yes

Go to Step 4

System OK

Go to Step 6

System OK

System OK

No

Go to Step 5

System OK

Go to Step 7

-

Value(s)

0 Ω

SSANGYONG MY2002


KAA5D190

DIAGNOSTIC TROUBLE CODE (DTC) 1751POSITION 1 SHORTED TO GROUND

Circuit Description

The transfer case control unit (TCCU) receives position

encoder signals from position encoder.


• Position 1 code does not correspond to the specificcodes.


Diagnostic Aids


Test Description

The number(s) below refer to step(s) on the diagnostic

table.



Step

1

2

3

4




3. Turn the ignition switch to ON.4. Request DTC with scan tool.Is the DTC 1751 only current trouble code?1. Turn the ignition switch to OFF.2. Disconnect 18-pin connector from the transfer case

control unit (TCCU).3. Measure the resistance between terminal B15 ofTCCU connector and ground.Is the resistance equal to specified value?Repair short to ground circuit.Is the repair complete?

Yes

Go to Step 2

Go to Step 3

Go to Step 4

System OK

NoGo to “TCCU


Go to “DTC1750 General

PositionEncoder Fault

(Invalid Code)”

Go to Step 5

-

Value(s)

0 Ω


SSANGYONG MY2002

Step

5

6

7







7. Turn the ignition ON.8. Request the DTC with scan tool.Is the DTC still current?Replace the shift motor.Is the repair complete?Replace the TCCU.Is the repair complete?

Yes

Go to Step 6

System OK

System OK

No

System OK

Go to Step 7

-

Value(s)

SSANGYONG MY2002


KAA5D190


Circuit Description





Diagnostic Aids


Test Description




Step

1

2

3

4





control unit (TCCU).3. Measure the resistance between terminal B10 of

TCCU connector and ground.Is the resistance equal to specified value?Repair short to ground circuit.Is the repair complete?

Yes

Go to Step 2

Go to Step 3

Go to Step 4

System OK

NoGo to “TCCU




(Invalid Code)”

Go to Step 5

-

Value(s)

0 Ω


SSANGYONG MY2002

Step

5

6

7

Action1. Turn the ignition switch to OFF.2. Disconnect two connectors of the TCCU and black

7-pin connector under the body.3. Inspect the terminals for damage or improper

connection.4. Repair any damaged pins or terminals on the

wiring harness and TCCU.5. Reconnect the connectors and make sure it is


(DLC).7. Turn the ignition ON.8. Request the DTC with scan tool.Is the DTC still current?Replace the shift motor.Is the repair complete?Replace the TCCU.Is the repair complete?

Yes

Go to Step 6

System OK

System OK

No

System OK

Go to Step 7

-

Value(s)

SSANGYONG MY2002


KAA5D190


Circuit Description




• A short to ground on any of the encoder lines.Diagnostic Aids


Test Description




Step

1

2

3

4



(DLC) and follow the directions given in the scan3. Turn the ignition switch to ON.4. Request DTC with scan tool.Is the DTC 1753 only current trouble code?1. Turn the ignition switch to OFF.2. Disconnect 18-pin connector from the transfer case



Yes

Go to Step 2

Go to Step 3

Go to Step 4

System OK

NoGo to “TCCU




(Invalid Code)”

Go to Step 5

-

Value(s)

0 Ω


SSANGYONG MY2002

Step

5

6

7







Yes

Go to Step 6

System OK

System OK

No

System OK

Go to Step 7

-

Value(s)

SSANGYONG MY2002


KAA5D190


Circuit Description




• A short to ground on any of the encoder lines.Diagnostic Aids


Test Description




Step

1

2

3

4







Yes

Go to Step 2

Go to Step

Go to Step 4

System OK

NoGo to “TCCU




(Invalid Code)”

Go to Step 5

-

Value(s)

0 Ω


SSANGYONG MY2002

Step

5

6

7







Yes

Go to Step 6

System OK

System OK

No

System OK

Go to Step 7

-

Value(s)

SSANGYONG MY2002


KAA5D240

KAA5D250

ON-VEHICLE SERVICEOIL REPLACEMENTImportant: Use only recommended oil or not the trans-fer case will be severely damaged. Inspect every10,000 km and replace every 60,000 km.

Specified Oil LevelThe oil level should be just under the filler hole.

REPAIR INSTRUCTIONS

Oil Replacement1. Lift the vehicle and make sure safety.

2. Prepare a vessel to drain transfer case oil.

3. Remove the planner damper, if equipped.

4. Remove the drain plug and filler plug, and drainthe oil completely.

5. Install and tighten the drain plug.

Installation Notice

6. Replenish recommended transfer case oil to speci-fied oil level through the filler plughole.

7. Install and tighten the filler plug.

Installation Notice

8. Check oil leakage.

9. Install the planner damper.

Installation Notice

Tightening Torque 19 - 30 N•m (14 - 22 lb-ft)

Tightening Torque 4 - 6 N•m (35 - 53 lb-in)



SSANGYONG MY2002

KAA5D260

KAA5D270

TRANSFER CASE CONTROL UNIT(TCCU)Removal and Installation Procedure

1. Turn the ignition switch to OFF.

2. Disconnect two connectors from the TCCU underthe driver seat.

3. Remove two bolts and the TCCU.

Installation Notice

Tightening Torque 10 N•m (7 lb-ft)

• When replacing the TCCU, it is required to acod-ing correspondent with the vehiclespecification. Refer to “TCCU Coding” in thissection.

4. Installation should follow the removal procedurein the reverse order.

TRANSFER CASERemoval and Installation Procedure

1. Disconnect the negative battery cable.

2. Lift the vehicle and make sure safety.

Notice: Be careful not to touch the catalyticconverter which is very hot after driving or enginerunning.

3. Remove the drain plug and drain the transfer caseoil. Refer to “Oil Replacement” in this section.

Installation Notice

4. Disconnect the transmission extension wiring con-nector on backside of transfer case.

5. Disconnect shift motor and clutch coil connector(black 7 pin) on upper backside of transfer case.

6. Disconnect front and rear speed sensor connector(white 7 pin).

7. Disconnect speedometer sensor connector.


SSANGYONG MY2002


KAA5D280

KAA5D290

KAA5D300

KAA5D310

8. Disconnect breather hose on the front upper sideof the transfer case near front propeller shaft.

12. Remove five bolts that connect transfer case andtransmission adapter housing.

Installation Notice

11. Remove 4 bolts that connecting the rear propellershaft and rear output shaft flange.

Installation Notice

9. Prepare a hydraulic jack and support the transfercase assembly.

10. Remove 4 bolts that connecting the front propellershaft and front output shaft/flange.

Installation Notice

• Make sure the connecting surface is clean.

• Apply long life grease inside transfer case inputshaft.


Tightening Torque 81 - 89 N•m(60 - 66 lb-ft)

Tightening Torque 81 - 89 N•m(60 - 66 lb-ft)



SSANGYONG MY2002

KAA5D320

KAA5D330

SHIFT MOTORRemoval and Installation Procedure

1. Disconnect the negative battery cable.

2. Disconnect shift motor and clutch coil connector(black 7 pin) on upper backside of transfer case.

3. Remove three shift motor mounting bolts.

Installation Notice

6. Keeps the shift motor even and pull out carefully.

Notice: When removing shift motor, pay attentionto the location of triangular slot and shaft intransfer case inside motor and mark the position.


Installation Notice:

• Clean the connection surface between transfercase and shift motor.

• Apply black non-acid cure silicone rubber orequivalent to the surface.

• Do not disassemble the shift motor and replacewith new one, if necessary.

• Make sure the motor position to match with 4H/4L switch selection.

4. Remove one shift motor bracket bolt.

Installation Notice

5. Loose two adjusting bolts on the shift motor ifneces-sary.

Installation Notice




SSANGYONG MY2002


KAA5D340

KAA5D350

FRONT AND REAR PROPELLERSHAFT SPEED SENSORRemoval and Installation Procedure

1. Disconnect negative battery cable.

2. Disconnect front and rear speed sensor connector(white 7 pin).

3. Remove shift motor. Refer to “Shift Motor” in thissec-tion.

4. Remove front and rear propeller shaft speedsensor retaining bolts.

Installation Notice

6. Disassemble the connector of front and rearpropeller shaft speed sensor.

7. Replace front or rear propeller shaft speed sensor,as necessary.

Notice:

• While replacing the speed sensor, make surethe proper pin position.

• Do not remove one wire to clutch coil in thetransfer case.

• Make tidy on the wiring harness includingconduct tube.


5. Remove the speed sensors by lifting up usinga tool such as flat screw drive.

Notice: Do not shock the speed sensor becauseit is too sensitive at shock.



SSANGYONG MY2002

KAA5D360

KAA5D330

KAA5D380

UNIT REPAIRTRANSFER CASE OVERHAULDisassembly Procedure

1. Remove the transfer case assembly. Refer to“Transfer Case” in this section.

2. Disassemble the white 7 pin connector of propellershaft speed sensor and separate the pinconnected to brown wire to clutch coil.

3. Remove the propeller shaft speed sensors withwires. Refer to “Front and Rear Propeller ShaftSpeed Sensor” in this section.

4. Remove vehicle speed sensor. Refer to Section1F, Engine Control.

7. Remove the bolts that retain the front case to therear cover.

Notice:

• Make sure that the front case is facingdownward so that the rear cover is facingupwards.

• Pry on the bosses and separate the front casefrom the rear cover.

• Remove all traces of gasket sealant from themating surfaces of the front case and rear cover.

5. Remove shift motor/clutch coil. Refer to “ShiftMotor and Clutch Coil” in this section.

Notice: When removing shift motor, pay attentionto the location of triangular slot and shaft intransfer case inside motor and mark the position.

6. Using a 30 mm thin-wall socket, first remove therear output shaft nut, rear output shaft yokewasher, oil seal then the rear output shaft flange.

SSANGYONG MY2002


KAA5D390

KAA5D400

KAA5D410

KAA5D420

8. Remove the rear output shaft oil seal and discardit, if required.

9. Remove the speedometer drive gear and rear pro-peller shaft speed sensor tooth wheel.

10. Remove the internal snap ring that retains the rearoutput shaft bearing in the bore.

Notice: Push the bearing from the outside of thecase.

14. Remove the balls, apply cam and wave washerfrom the output shaft.

15. Remove snap ring from output shaft.

16. Remove clutch pack assembly from output shaft.

12. Remove thrust bearing from the rear output shaft.

13. Remove the clutch coil housing from the rearoutput shaft.

11. Remove three nuts retaining the clutch coil assem-bly and pull the clutch coil assembly along withthe wire from the case.


SSANGYONG MY2002

KAA5D430

KAA5D440

KAA5D450

KAA5D460

17. Remove the front propeller shaft speed sensortooth wheel.

18. Remove the chain, driven sprocket and drivesprocket as an assembly.

19. Remove thrust washer from output shaft.

25. With expanding the tangs of the snap ring underthe planetary carrier assembly using SST snap ringplier support the input shaft against a bench, pushthe case down and slide the input shaft bearing.Remove the input shaft and planetary carrier.

26. Remove and discard the input shaft oil seal as required.

27. Remove the internal snap ring from the planetarycarrier and separate the planetary carrier from theinput shaft.

22. Remove the helical cam and shift rail as an assem-bly by gently pulling out the shift rail. Check thehelical cam for damages and replace it if required.

23. Remove the high-low shift fork and high-low collaras an assembly.

24. Remove the shift shaft.

20. Remove the magnet from the slot in the front ofthe case bottom.

21. Remove the rear output shaft and oil pump as anas-sembly.

Notice: If there is removal resistance, do notpound or use force to disassemble the pump. Donot disassemble oil pump. It is serviced only asan assembly. Check the pump to make sure thepump rotates freely.

SSANGYONG MY2002


KAA5D470

KAA5D480

KAA5D490

KAA5D500

28. Remove the external snap ring from the input shaft.

29. Place the input shaft in a vise and remove thebear ing.

30. Remove the thrust washer, thrust plate and thesun gear off the input shaft.

Assembly ProcedureImportant: Lubricate all parts with automatic transmis-sion fluid (ATF) or equivalent before assemble. Remove

all traces of gasket sealant from the front case andmounting adapter mating surfaces

1. Install the front output shaft bearing, if removed.

Notice: Press the bearing in straight, making sureit is not cocked in the bore.

2. Install the internal snap ring that retains the frontoutput shaft bearing.

33. Remove the external snap ring retaining the frontoutput shaft.

34. Remove the front output shaft/flange.

35. Remove and discard front output shaft oil seal,as required.

36. Remove the internal snap ring and remove the frontoutput shaft bearing, as required.

31. Position the input shaft on SST input shaft support.

32. Remove the needle bearing and bushing usingSST bearing installer/remover, as required.

Notice: Under normal use, the needle bearing andbushing may not require replacement. Afterinspection, If replacement is required, the bushingand needle bearing must be replaced as a set.


SSANGYONG MY2002

KAA5D510

KAA5D520

KAA5D460

3. Install the front output shaft oil seal using oil sealinstaller, if removed.

4. Install the front output shaft/flange and install thesnap ring.

8. Assemble the planetary carrier to the sun gear andinput shaft and install the internal snap ring to theplanetary carrier.

9. While expanding the tanged snap ring with SSTsnap ring pliers install planetary carrier assembly.

10. Install the high-low shift fork and collar as anassembly.

Notice: Make sure that the nylon wear pads areinstalled on the shift fork and snapped securelyinto place.

6. Slide the sun gear, thrust plate and thrust washerinto position on the input shaft.

Notice: The recessed face of the sun gear andthe snap ring groove on the bearing outer raceshould be toward the rear of the transfer case.The stepped face of the thrust washer should facetoward the bearing.

7. Install the bearing over the input shaft using inputshaft bearing installer SST. Install the external snapring.

5. Install a new input shaft needle bearing and a newbushing, if removed. Keep the following steps toinstall the bearing and the bushing:

• Position the input shaft on input shaft support.

• Press a new needle bearing into the end of theinput shaft until it seats in the input shaft usingbearing remover/installer.

• Press in a new bushing.

SSANGYONG MY2002


KAA5D440

KAA5D430

KAA5D420

KAA5D410

11. Install the output shaft and oil pump in the inputshaft

Notice:

• If a new pump is used, align the flat of theoutput shaft and the flat of the pump. Slide thepump onto the rear output shaft.

• Do not remove the plastic insert from the boreof the new pump. Discard it after it slides outduring pump installation to the rear output shaft.

• While turning the output shaft, prime the pumpthrough the oil filter pickup tube or housing inlethole with clean ATF or equivalent.

12. Install the magnet in the slot in the front case justabove the oil filter leg.

13. Install the thrust washer on the rear output shaft.

14. Install the chain, drive sprocket and drivensprocket as an assembly over the output shafts.

Notice: The driven sprocket on the front outputshaft must be installed with the marking REARfacing toward the rear case, if so marked.

15. Install front propeller shaft speed sensor toothwheel onto the front output shaft.

19. Install cam and coil housing assembly onto rearout-put shaft.

20. Install thrust bearing assembly onto output shaft.

21. Install the rear output shaft bearing, if removed.

Notice: Make sure that the bearing is not cockedin the bore.

22. Install the internal snap ring that retains thebearing to the rear case.

16. Install clutch pack assembly onto the rear outputshaft

17. Install snap ring onto the rear output shaft.

Notice: If the snap ring will not install, the thrustwasher inside the clutch pack may not be seatedproperly.

18. Install wave spring, apply cam and balls.


SSANGYONG MY2002

KAA5D420

KAA5D590

23. Install the clutch coil and tighten three bolts.

Installation Notice

Caution: Do not kink or trap the wire whileseating the clutch coil to the case.

24. Install the pin on the tang end of the helical caminto the hole in the front case.

25. Position the torsion spring tangs so that they arepointing toward the top side of the transfer caseand just touching the high-low shift fork.

Caution: Do not bend the helical cam duringinstallation to the front case because of possibledamage to the pin at the tang end of the motorshaft.

26. Install the shift rail through the high-low shift forkand make sure that the reverse gear shift rail isseated in the front case bore.

27. Install rear propeller shaft speed sensor toothedwheel, vehicle speedometer gear and rear outputshaft seal if removed. Use oil seal installer or equiv-alent.


SSANGYONG MY2002


31. Install the rear output shaft flange on rear outputshaft. Install the rubber seal, output shaft yokewasher and nut. Tighten the nut and calk the nuton the flat area.

Installation Notice

32. Install the shift motor. Refer to the “Shift Motor”in this section.

33. Insert the brown wire and pin to speed sensor con-nect and assemble the connector. Refer to “Frontand Rear Propeller Shaft Speed Sensors” in thissection.

34. Install the drain plug and tighten the drain plug.

Installation Notice

35. Fill the transfer case with 1.4 liters of ATF or equivalent.

Notice: Fluid level should be just below the fillerplug-hole.

36. Install the filler plug and tighten.

Installation Notice

37. Install the transfer case to the vehicle. Refer to“Transfer Case” in the section.

5D380

28. Coat the mating surface of the front case with abead of black non-acid cure silicone rubber orequivalent.

29. Assemble the rear case on to front case.

Notice: Align the rear output shaft with the rearcase output shaft bore. Align the helical cam withthe rear case motor bore.

30. Install the bolts retaining the case halves andtighten the bolts.

Installation Notice






SSANGYONG MY2002

Normal Operation Range

CAN Communication

Ignition OFF

Ignition ON

Motor OFF

Motor ON

Voltage

Parasitic Current (Under Max

Operation Voltage)

Max. Operation Current

Application

Model

Length (mm)

Weight (kg)

Shift Mode

Gear Ratio

Oil

Max. Torque

High

Low

Specification

Capacity

Interval

Description

TOD (Torque On Demand) Transfer Case (4423E)

343

37

4H and 4L

1 : 1

2.48 : 1

ATF S-3, S-4 or DEXRON II, III

1.4 L (1.48 qt)

Inspect Every 10,000 km

745 N•m (550 lb-ft)

SPECIFICATIONSGENERAL SPECIFICATION

TCCU ELECTRIC CHARACTERISTICS

Application Value

9 - 16 V

6 - 16 V

2 mA

1 A

7 A

20 A

FASTENER TIGHTENING SPECIFICATIONS

8 - 13

14 - 22

-

21 - 30

60 - 66

21 - 30

103 - 148

60 - 66

7

-

6 - 8

-

6 - 8

28 - 38

Clutch Coil Retaining Bolt

Drain Plug

Filler Plug

Front Case-to-Rear Case Bolts

Front Propeller Shaft-to-Front Output Shaft Flange Bolts

Planner Damper to Transfer Case Bolts

Rear Output Shaft Flange Nut

Rear Propeller Shaft-to-Rear Output Shaft Flange Bolts

Shift Motor Adjusting Bolts

Shift Motor Bracket Bolt

Shift Motor Mounting Bolts

Speed Sensor Retaining Bolts

Transfer Case Control Unit (TCCU) Retaining Bolts

Transfer Case-to-Transmission Adapter Housing Bolts

N•mApplication Lb-InLb-Ft

11 - 18

19 - 30

4 - 6

28 - 40

81 - 89

29 - 41

140 - 200

81 - 89

10

3 - 5

8 - 11

3 - 6

8 - 11

38 - 52

-

-

35 - 53

-

-

-

-

-

89

27 - 44

71 - 97

27 - 53

71 - 97

-

SSANGYONG MY2002


TO

D T

RA

NS

FE

R C

AS

E C

ON

TR

OL

UN

IT (

TC

CU

) -

1 O

F 2

KAA5D610

SCHEMATIC AND ROUTING DIAGRAMS

SSANGYONG MY2002


SPECIAL TOOLS AND EQUIPMENTSPECIAL TOOLS TABLE

Snap Ring Plier

KAA5D630

Input Shaft Support

KAA5D640

Bearing Installer

KAA5D650

Bearing

Installer/Remover

KAA5D660

Seal Installer

KAA5D670

Documents

TRANSFER CASE (TOD)212.113.105.12/library/BOOKS/CAR/SsangYong/Korando/Koran...TRANSFER CASE 5D1-3 SSANGYONG MY2002 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 B1 B2 B3 B4 B5 B6 B7 B8 B9