SsangYong Korando II (1996-2006 year). Manual — part 343
SSAMGYONG MY2002
5C-16 CLUTCH
Lubricate or Replace
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
Replace
Replace
Repair
Replace
CLUTCH 5C-17
SSANGYONG MY2002
SPECIAL TOOLS AND EQUIPMENT
SPECIAL TOOLS TABLE
602 589 00 40 00
Engine Lock
KAA5C180
661 589 00 15 00
Centering Pin
KAA5C190
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
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
Position encoder 1 input
Position encoder 3 input
Rear propeller shaft speed sensor signal input
Position encoder 4 input
PIN DESCRIPTION
Pin No.
Description
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