SsangYong Rexton. Manual - part 588

PART TIME - T/C  5D1-43

SSANGYONG  Y200

Companion Flange

1. Install the 2 plugs to the cover.

2. Install the companion flange, oil seal and washer.

3. Holding the companion flange, tighten the nut.

Installation Notice

Notice:  A p p l y   L o c t i t e   # 2 6 2   t o   n u t   b e f o r e
installation.

Tightening Torque

346 - 380 N•m

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

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

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

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

SSANGYONG  Y200

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.

TRANSFER CASE - TOD  5D2-3

SSANGYONG  Y200

4WD Drive(High

Speed)

4WD Drive(Low

Speed)

4WD Drive

High Speed 

↔

Low Speed

4WD OPERATION OVERVIEW

Driving Type

Transferring

4H

4L

4H 

↔

 4L

Application

Normal Driving on the normal road or highway, or high

speed driving

Slipped road such as snow, rainy, sand, mud etc.

Max driving force requiring condition such as towing,

rough road.

Same function as part time transfer case 4L.

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.

Operation Condition

Mode Position

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.