SsangYong Korando II (1996-2006 year). Service manual

TRANSFER CASE 5D1-9

SSANGYONG MY2002

1 Bearing
2 Bushing
3 Carrier Assembly
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Output Shaft Thrust Washer
8 Bearing
9 Snap Ring

10 High-Low Collar
11 Rear Output Shaft
12 Oil Strainer
13 Coupling Hose
14 Hose Clamp
15 Pump Assembly
16 Thrust Washer
17 Sprocket, Drive (214t)
18 lutch Pack Assembly
19 Insulator Washer
20 Armature
21 Snap Ring
22 Wave Washer
23 Apply Cam
24 Ball
25 Cam And Coil Assembly
26 Nut, Metric (2)
27 Output Shaft Yoke Washer
28 Oil Seal
29 Case Flange
30 Bolt
31 Upper Speed Sensor (Rear)
32 Nut
33 Washer
34 Bolt (M10 X 1.5 X 30)
35 Tag, Identification
36 Thrust Bearing
37 Clutch Coil Assembly
38 Fork, Reduction Shift

39 Shift Rail
40 Shaft, Shift
41 Spacer
42 Torsion Spring
43 Spring, Electric Shift
44 Transfer Case Shift Motor
45 Bolt
46 J-Clip
47 Connector Retainer
48 Bolt
49 Support Stud
50 Lower Speed Sensor (Front)
51 Plug
52 Identification Decal
53 Case
54 Tone Wheel, Lower
55 Chain, Drive
56 Sprocket, Driven (24t)
57 Oil Pan Magnet
58 Case Flange And Output Shaft
59 Case Assembly
60 Barb, Breather
61 Spirol Pin
62 Oil Seal
63 Pin, Dowel
64 Ring Gear
65 Retaining Ring
66 Snap Ring
67 Bearing
68 Snap Ring
69 Bearing
70 Speedometer Drive Gear
71 Facing, Shift Fork
72 Upper Tone Wheel
73 Oil Seal
74 Bearing Sleeve
75 Bearing

TRANSFER CASE 5D1-11

SSANGYONG MY2002

DIAGNOSIS

While the transfer case control unit (TCCU) is active it
periodically monitors its inputs and outputs. If a fault
is detected the 4WD CHECK lamp is illuminated and a
fault code is stored in the TCCU memory.

When requested, fault codes are downloaded to scan
tool through a diagnostic connector (K-line) serial com
munication.

SELF-DIAGNOSTIC TESTS

TCCU Internal Function

When the ignition is turned on the TCCU tests its read
only memory (ROM) and random access memory
(RAM). If there is a fault, the TCCU immediately resets
itself and re-tests the ROM and RAM. If the fault
persists the TCCU continues to reset and re-test until
the fault is corrected or the ignition is turned off. All
TCCU functions are inhibited until the fault is corrected.
The 4WD CHECK lamp is not illuminated if there is a
ROM or RAM fault.

If the ROM/RAM passes the electronically erasable
programmable read only memory (EEPROM) is tested.
If there is a fault the 4WD CHECK lamp is illuminated
and the TCCU continues to operate using the default
calibration data stored in ROM. Fault codes are not
stored when there is an EEPROM fault.

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

Shift Motor Assembly Test

If the TCCU detects a shift motor or position encoder
fault continuously for one second the 4WD CHECK
lamp is turned on and the appropriate fault code is
stored in memory.

1. A shift motor fault when the motor is off is defined

as 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 is

defined as follows:

•

Motor HI-LO circuits are shorted to ground.

•

Motor LO-HI circuits are shorted to ground.

•

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

•

Motor circuits are open.

3. A position encoder fault is defined as follows:

•

Any position code which does not correspond
to the valid 9 codes.

•

A short to ground on any of the encoder lines.

4. If no shifts are in progress when a failure occurs

the TCCU will not respond to any shift commands.

5. If a shift command has been received but not

acted upon when a failure occurred the TCCU
would cancel the command and not respond to
any subsequent shift commands.

6. If a shift command is in progress when an invalid

position code is confirmed it will be halted and
the TCCU will turn the motor toward the high
position. Afterwards the TCCU will not respond to
any shift commands.

7. If the shift motor or position encoder assembly

failures, other than a motor failure which occurs
when the motor is energized, recovers continuously
for one second the TCCU will function normally.
The 4WD CHECK lamp is turned off but the fault
code will remain in memory.

8. A motor failure (i.e. open or short circuit) which

occurs when the motor is energized can only be
cleared by cycling the ignition OFF-ON.

Front Speed Sensor Test

If a front speed sensor fault is detected continuously
for 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 the

rear speed sensor to determine the EMC touch off
level and wheel slip control is suspended.

2. If the system is in low range, the EMC duty cycle

is 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 Ignition

is cycled. If a shift is in progress it will be
completed.

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

Rear Speed Sensor Test

If a rear speed sensor fault is detected continuously
for 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 the

front speed sensor to determine the EMC touch
off level and wheel slip control is suspended.

2. If the system is in low range, the EMC duty cycle

is 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 Ignition

is cycled. If a shift is in progress it will be
completed.

4. If the rear speed sensor recovers continuously for

0.5 second the TCCU will function normally. The
4WD CHECK lamp is turned off but the fault code
will remain in memory.

SsangYong Korando II (1996-2006 year). Service manual - part 345