SsangYong Rexton. Manual - part 594

SSANGYONG  Y200

5D2-24  TRANSFER CASE - TOD

While the TOD 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
TOD memory.

When requested, fault codes are downloaded to a
diagnostic connector (K-line) serial communications
using SCAN-100.

DIAGNOSTIC TESTS

TOD Internal Function

When the Ignition is turned on the TOD tests its ROM
and RAM. If there is a fault, the TOD immediately resets
itself and re-tests the ROM and RAM. If the fault
persists the TOD continues to reset and re-test until
the fault is corrected or the ignition is turned off. All
TOD 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 EEPROM memory is
tested. If there is a fault the 4WD CHECK lamp is
illuminated and the TOD 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 TOD 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 H-L shorted to Ground

•

Motor L-H shorted to Ground

•

Motor open circuit

2. A shift motor fault when the motor is energized is

defined as follows:

•

Motor H-L shorted to Ground

•

Motor L-H shorted to Ground

•

Motor H-L shorted to Motor L-H

•

Motor open circuit

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 TOD will not respond to any shift commands.

DIAGNOSIS

5. If a shift command has been received, but not

acted upon when a failure occurs the TOD will
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 TOD will turn the motor toward the high
position. Afterwards the TOD will not respond to
any shift commands.

7. If the shift motor/position encoder assembly

failure (other than a motor failure which occurs
w h e n   t h e   m o t o r   i s   e n e r g i z e d )   r e c o v e r s
continuously for one second the TOD 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 TOD then responds as follows:

1. If the system is in High Range the TOD 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 4L.

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 TOD 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 TOD then responds as follows:

1. If the system is in High Range the TOD 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 4L.

3. All Electric Shift activity is halted until the Ignition

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

If the Rear Speed Sensor recovers continuously for
0.5 second the TOD will function normally. The “4WD
CHECK” lamp is turned off but the fault code will remain
in memory.

TRANSFER CASE - TOD  5D2-25

SSANGYONG  Y200

Both Speed Sensor Faulty

If both the Front and Rear Speed Sensors are faulty
continuously for 0.5 seconds the “4WD CHECK” lamp
is illuminated. The TOD then responds as follows:

1. If the system is in High Range the TOD sets the

EMC Touch off level based on a vehicle speed of
0 and wheel slip control is suspended.

2. If the system is in Low Range, the EMC Duty Cycle

is set to maximum until the system is shifted out
of 4L.

3. All Electric Shift activity is halted until the Ignition

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

If both Speed Sensors recover continuously for 0.5
second the TOD will function normally. The “4WD
CHECK” lamp is turned off but the fault code will remain
in memory.

EMC Test

The EMC is tested for open circuit or short circuit to
ground. If a fault is detected continuously for 0.8
second the “4WD CHECK” lamp is turned on and all
TODTM activity is halted.

If the EMC recovers continuously for 0.8 second the
TOD will function normally. The “4WD CHECK” lamp
is turned off but the fault code will remain in memory.

CODING ON TOD

Connection of Coding Tool

Construct SCANNER into diagnosis connector (20
pins) near fuse box in engine room as below figure.

1. Diagnosis Connector

2. SCANNER

Notice: Coding ; An input activity of data for the
proper performance by matching specification,
devices and system with control unit.

Coding required

1. Replacement of TOD control unit.

2. Adjustment by input error.

3. Change of tire specification.

Coding method

1. Check and record engine type, axle ratio and tire

size.

2. Ignition “OFF”.

3. Connect SCANNER with diagnosis connector in

engine room.

4. Ignition “ON”.

5. Read the current memorized specification in TOD

control unit.

YAD5D150

SSANGYONG  Y200

5D2-26  TRANSFER CASE - TOD

6. Compare memorized specification with the

checked record. If not matched, perform a coding.

7. Read again memorized coding specification in

TOD control unit for confirmation of coding.

8. Check coding specification whether it matches

with vehicle or not. If not, perform a coding again.

8. Press the function key “F2”.

9. Press “Yes”.

10. I f   t h e   m e m o r i z e d   f a u l t   c o d e   i s   c l e a r e d

successfully, it appears on the screen as following;
“Self Diagnosis Result is Normal”.

6. When system confirmation screen displays, press

“ENTER” key.

7. If there is any fault in the system, it displays as

shown.

Eliminate the Memorized Fault Code

When diagnose by SCANNER, it is required that you
make adequate service on defects against all fault
codes. And then you should delete the memorized fault
codes in TOD control unit using SCANNER as follows;

1. Connect SCANNER with diagnosis connector.

2. Ignition turns “ON”.

3. Select “Vehicle Type” and press “ENTER” key.

4. Select “Model Type” and press “ENTER” key.

5. Select “Control System” and then select “06

Transfer Case (TOD)”. Press “ENTER” key.

YAD5D160

YAD5D170

YAD5D180

TRANSFER CASE - TOD  5D2-27

SSANGYONG  Y200

SCHEMATIC  WIRING DIAGRAM

YAD5D190