5D2 1 (EN)

SECTION 5D2 TRANSFER CASE - TOD TABLE OF CONTENTS General Operation and Description................... 5D2-2 TOD System Function ........................................ 5D2-2 4WD Operation Overview ................................... 5D2-3 System Structure ............................................... 5D2-4 4H Mode (4WD Drive - High Speed) ................... 5D2-5 4L Mode (4WD Drive - Low Speed)..................... 5D2-7 Specifications .................................................... 5D2-9 Tightening Specifications ................................. 5D2-10 Diagnostic Trouble Code (DTC) 1714 ................ 5D2-34 Diagnostic Trouble Code (DTC) 1715 ................

5D2-36 Diagnostic Trouble Code (DTC) 1716 ................ 5D2-38 Diagnostic Trouble Code (DTC) 1721 ................ 5D2-40 Diagnostic Trouble Code (DTC) 1722 ................ 5D2-42 Diagnostic Trouble Code (DTC) 1731 ................ 5D2-44 Diagnostic Trouble Code (DTC) 1732 ................ 5D2-46 Diagnostic Trouble Code (DTC) 1733 ................ 5D2-48 Diagnostic Trouble Code (DTC) 1734 ................ 5D2-50 Diagnostic Trouble Code (DTC) 1735 ................ 5D2-52 Diagnostic Trouble Code (DTC) 1736 ................ 5D2-54 Diagnostic Trouble Code (DTC) 1741 ................ 5D2-56 Diagnostic Trouble Code (DTC) 1742 ................

5D2-58 Diagnostic Trouble Code (DTC) 1743 ................ 5D2-60 Diagnostic Trouble Code (DTC) 1750 ................ 5D2-61 Diagnostic Trouble Code (DTC) 1751 ................ 5D2-63 Diagnostic Trouble Code (DTC) 1752 ................ 5D2-64 Diagnostic Trouble Code (DTC) 1753 ................ 5D2-65 Diagnostic Trouble Code (DTC) 1754 ................ 5D2-66 Component Locator ......................................... 5D2-11 Transfer Case Cross Sectional View ................. 5D2-11 Transfer Case Assembly .................................. 5D2-13 Function Description ........................................ 5D2-14 TOD System Select Mode................................

5D2-14 Component Function........................................ 5D2-14 Definition fo Terminology .................................. 5D2-16 Control Unit ..................................................... 5D2-18 System Operation ............................................ 5D2-20 Diagnosis .......................................................... 5D2-30 Diagnostic Tests.............................................. 5D2-24 Coding on TOD ................................................ 5D2-25 Schmatic Wiring Diagram................................. 5D2-27 TOD Control Unit Diagnostic System Check ..... 5D2-28 Diagnostic Trouble Codes (DTC’s) ...................

5D2-29 4WD Check Indicator Stays on with Ignition Switch on ...................................................... 5D2-30 4WD Low Indicator Stays on with Ignition Switch on ...................................................... 5D2-31 No 4WD Check or 4WD Low Indicator with Ignition Switch on ......................................... 5D2-32 4WD Low Indicator Blink Steadily ..................... 5D2-33 Maintenance and Repair ................................. 5D2-67 On-Vehicle Service ............................................. 5D2-67 Transfer Case (TOD) Component Locator ......... 5D2-67 Transfer Case Assembly ..................................

5D2-68 TOD Control Unit.............................................. 5D2-70 Shift Motor ....................................................... 5D2-70 Speed Sensor in Front and Rear Propeller Shaft 5D2-71 Unit Repair........................................................ 5D2-74 Transfer Case Assembly .................................. 5D2-76 Special Tools and Equipment .......................... 5D2-89 Special Tools Table ......................................... 5D2-89

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5D2-2 TRANSFER CASE - TOD GENERAL INFORMATION AND OPERATION TOD system means the full time 4WD system and the registered trade mark of Borg Warner. TOD is an abbreviation of Torque On Demand. TOD control unit automatically tailors torque distribution to road, offering full time four wheel drive. TOD distributes electronically-controlled power into front and rear wheels whose ratio change from 0 : 100 to 50 : 50 complying with wheel speed differences. Also TOD control unit analyzes data from wheel speed sensor and engine output then changes pressure of electromagnetic clutch. This pressure controls front propeller shaft and power to front wheel.

Power to front wheel depends on degree of pressure corresponding clutch slip. TOD is designed to distribute the power to front and rear axle by operation of 4H/4L switch and shift motor. Shifting 4WD high (4H) to 4WD low (4L) is performed towards reducing high-low collar by means for connection high-low shift fork with output shaft in order to join with planetary gear. Torque transmits input shaft then sun gear rotating front planetary gear. Front planetary gear joins with output shaft and drives at low position. The TOD system has 2 selectable mode, 4H and 4L. 4H is the normal operating mode when drive of which gear ratio is 1:1 and 4L mode distributes power to front and rear wheels 50 :

50 of which gear ratio is 2.48:1. TOD SYSTEM FUNCTION 4H Mode The TOD system transfer case controls the clutch mechanism to comply with rotation in front and rear propeller shaft and if its difference exceeds the permissible range, corresponding power is distributed into front wheel through electromagnetic clutch (EMC). Hall effect speed sensors are located front and rear propeller shafts, send signals to TOD transfer case control unit (TCCU). The EMC coil is activated by variable current on exceeding difference of speed in front and rear propeller shafts. 4L Mode When select 4L mode, EMC is locked to apply maximum torque into front and rear propeller shafts.

Shift motor rotates also 4L position by rotation of cam thus 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 and rear propeller shaft speed, shift motor position and 4H/4L switch signals and controls electromagnetic clutch (EMC), shift motor. TCCU communicates with scan tool with K-line for diagnosis. It located under the front LH seat. SSANGYONG Y200

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TRANSFER CASE - TOD 5D2-3 4WD OPERATION OVERVIEW Notice: After the vehicle stops and the mode switch is selected with applying the brake pedal, shifting [N- R-N] makes the mode transfer easier. SSANGYONG Y200 Application Mode Position Operation Condition Driving Type 4H 4WD Drive(High Speed) Normal Driving on the normal road or highway, or high speed driving Slipped road such as snow, rainy, sand, mud etc. 4L 4WD Drive(Low Speed) Max driving force requiring condition such as towing, rough road. Same function as part time transfer case 4L. Transferring 4H ↔ 4L 4WD Drive High Speed ↔ Low Speed A vehicle should stop for transfer.

Manual Transmission • Transfer starts after the vehicle stops and the clutch is applied Automatic Transmission • Transfer starts after the vehicle stops and the shift lever is shifted [N] position.

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5D2-4 TRANSFER CASE - TOD SYSTEM STRUCTURE yyy @@@ ЂЂ АА y @@ Ђ А yyy @@@ @@@ ЂЂ АА yy y @@@ @ @@ @ Ђ А @ yyy А yy @ y yyy @@@ ЂЂ АА yy @@ @ Ђ @@@ @@@ ЂЂ АА @@@ @@ Ђ А y yyy yy y y QQ ўў Q ў @@ Ђ @@ ЂЂ АА А @@ Ђ А Q ў @ yyy y yyy @ yy y y @@ y @@ А @@ @ @ Q ў y y @ yyy yyy QQ ўў @ y yy y @@ Ђ А @@ Ђ А @ y y @ @@ @@ А @@ yyy @@ @@@ ЂЂ АА yyy yyyy y @@@ yy yyyy yyyy yy yy yy yy YAD5D010 SSANGYONG Y200

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