SsangYong Korando II (1996-2006 year). Manual

SSAMGYONG MY2002

5C-16 CLUTCH

Lubricate or Replace

Repair

Poor Lubrication on Clutch Cable

Poor Lubrication on Pedal Shaft

Poor Lubrication on Clutch Pedal

Action

Checks

DIFFICULT PEDAL OPERATION

Insufficient Clutch Pedal Free play

Excessive Wear of Facing

Worn or Damaged Release Bearing

Poor Lubrication Contact Surface of Bearing

Faulty Installation of Clutch Assembly or Bearing

Damaged Pilot Bushing

Not Using the Clutch

After Disengagement

When Disengaging

Clutch Pedal is Partially Depressed

and Vehicle Speed is Reduced

Action

Checks

CLUTCH NOISY

Adjust

Replace

Repair

Replace

SECTION 5D1

TRANSFER CASE (TOD)

CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a
tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
other-wise noted.

TABLE OF CONTENTS

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

Torque on Demand (TOD) System

Transfer 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 Ignition

Switch ON .................................................... 5D1-14

4WD Low Indicator Stays on with Ignition

Switch ON .................................................... 5D1-16

No 4WD Check or 4WD Low Indicator with

Ignition 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 / Short

to Battery ..................................................... 5D1-28

DTC 1722 Electromagnetic Clutch Short to

Ground ......................................................... 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 Voltage

Low .............................................................. 5D1-44

DTC 1736 Speed Sensor Reference Voltage

High ............................................................. 5D1-46

DTC 1741 Motor Output Open / Shorted

to 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

DTC 1752 Position 2 Shorted to Ground ............ 5D1-60

DTC 1753 Position 3 Shorted to Ground ............ 5D1-62

DTC 1754 Position 4 Shorted to Ground ............ 5D1-64

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

TRANSFER CASE 5D1-3

SSANGYONG MY2002

A10

A11

A12

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

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

Position encoder 1 input

Position encoder 3 input

Rear propeller shaft speed sensor signal input

Position encoder 4 input

PIN DESCRIPTION

Pin No.

Description

SsangYong Korando II (1996-2006 year). Manual - part 343