SSANGYONG KORANDO 1997 Service Repair Manual
Page 1401 of 2053
SECTION 5D2
TRANSFER CASE (PART TIME - 4408)
TABLE OF CONTENTS
General Infromation and Operation..................5D2-2
4WD Operation Overview...................................5D2-2
System Structure...............................................5D2-3
2H Mode (Rear Wheel Drive)..............................5D2-5
4H Mode (4WD Drive - High Speed)...................5D2-6
4H Mode (4WD Drive - Low Speed)....................5D2-7
System Description...........................................5D2-8
Specifications....................................................5D2-9
Diagnostic Infromation and Procedures..........5D2-10
General Diagnosis...........................................5D2-10
Self-Diagnosis Test..........................................5D2-11
Diagnostic Diagram .........................................5D2-15
Component Locator .........................................5D2-16
Cross Sectional View.......................................5D2-16Transfer Case Assembly..................................5D2-17
Disassembly and Assembly............................5D2-18
Maintenance and Repair.................................5D2-20
On-Vehicle Service.............................................5D2-20
Maintenance of Transfer Case Lubricant...........5D2-20
4H and 4L Indicator .........................................5D2-21
TCCU Inspection.............................................5D2-21
Transfer Case Assembly..................................5D2-22
TCCU..............................................................5D2-24
Unit Repair........................................................5D2-25
Disassembly Procedure...................................5D2-25
Assembly Procedure.......................................5D2-35
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SSANGYONG MY2002
5D2-2 TRANSFER CASE (PART TIME - 4408)
2WD Drive (Rear
Wheel Drive)
4WD Drive (High
Speed)
4WD Drive (Low
Speed)
2WD Drive
↔ 4WD
Drive (High Speed)
2WD Drive, 4WD
Drive (High Speed)
↔ 4WD Drive (Low
Speed)
GENERAL INFORMATION AND OPERATION
4WD OPERATION OVERVIEW
Driving Type
Transferring2H
4H
4L
2H
↔ 4H
2H, 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.
When a vehicle is driven in turning at low speed on
the paved road, a vibration and a noise may be
occurred by tight corner braking.
2WD ↔ 4WD transfer is possible below 70 km
without operating the clutch.
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.
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.
Operation ConditionMode Position
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TRANSFER CASE (PART TIME - 4408) 5D2-3
SSANGYONG MY2002
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SYSTEM STRUCTURE
KAA5D010
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SSANGYONG MY2002
5D2-4 TRANSFER CASE (PART TIME - 4408)
Power Flow
TCCU
Switch Transfer
2H, 4H
↔ 4L
Rear Propeller Shaft
Rear Wheel
Front Axle
Transfer
Locking Hub Solenoid
Locking Hub
OperationVacuum System Operation
Front Propeller Shaft
Front Wheel
Rear Axle
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TRANSFER CASE (PART TIME - 4408) 5D2-5
SSANGYONG MY2002
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2H MODE (REAR WHEEL DRIVE)
KAA5D020
Power Flow
Rear Axle
Rear Wheel
Transmission Output
Shaft
T/C Input Shaft
Output ShaftRear Propeller Shaft
Rear Wheel
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SSANGYONG MY2002
5D2-6 TRANSFER CASE (PART TIME - 4408)
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4H MODE (4WD DRIVE - HIGH SPEED)
KAA5D030
Power Flow
Hub
Chain
Motor
Output Shaft
Front Propeller
Shaft
Transmission
Input Shaft
Rear Propeller
Shaft
Shift Cam, Rail,
Fork
Magnetic
Clutch
TCCU
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TRANSFER CASE (PART TIME - 4408) 5D2-7
SSANGYONG MY2002
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4L MODE (4WD DRIVE - LOW SPEED)
KAA5D040
Power Flow
Chain
Motor
Output Shaft
Front Propeller
Shaft
Transmission
Input Shaft
Rear Propeller
Shaft
Shift Cam, Rail,
Fork
TCCU
Planetary Gear
(2.483)
Hub
Page 1408 of 2053
SSANGYONG MY2002
5D2-8 TRANSFER CASE (PART TIME - 4408)
KAA5D050
KAA5D060
KAA5D070
1. Shifting from 2H to 4H
Position the transfer case switch from ‘2H’ to
‘4H’.
Shifting is possible during driving.
‘4WD Hl’ indicator light will turn on.
2. Shifting from 4H to 2H
Position the transfer case switch from ‘4H’ to
‘2H’.
Shifting is possible during driving.
4WD Hl’ indicator light will turn off.
SYSTEM DESCRIPTION
Transfer Case Control Unit (TCCU)
TCCU is located under the front left handed seat and
permits the vehicle to shift from two-wheel drive to
four-wheel drive (and back shift) according to drivers
switch operation during driving (For the shifting
between 4WD HIGH and 4WD LOW, stop the vehicle).
3. Shifting between 4H and 4L
Shifting is possible when the vehicle is almost
stopped (below approx. 2 km/h), so it would be
better stop the vehicle.
In case of manual transmission equipped
vehicle, apply clutch pedal.
In case of auto transmission equipped vehicle,
put the lever position into ‘N’.
Position the transfer case switch ‘4H’ to ‘4L’
or ‘4L’ to ‘4H’.
According to the shifted position, indicator light
will turn on.
Notice: If there are malfunctions during shifting,
‘4H’ or ‘4L’ indicator light will blink.
Page 1409 of 2053
TRANSFER CASE (PART TIME - 4408) 5D2-9
SSANGYONG MY2002
Model
Type
Gear Ratio
Oil
Manufacturer
WeightHigh
Low
Specification
Capacity
Lubrication
SPECIFICATIONS
Part-Time 4408 (E)
E.S.O.F. Type
1 : 1
2.48 : 1
ATF S-3, S-4 or DEXRON II, III
1.2 L
Check : Every 10,000 km
Replace : Every 60,000 km
Borg Warner
30 kg
Page 1410 of 2053
SSANGYONG MY2002
5D2-10 TRANSFER CASE (PART TIME - 4408)
DIAGNOSTIC INFORMATION AND PROCEDURES
GENERAL DIAGNOSIS
Faulty or damaged TCCU, speed
sensor, motor, clutch or internal wirings
Damaged or worn shift cam, hub, fork
and rail shift
Binding shift fork, hub collar or gear
Broken drive chain
Improper or low oil
Loosened bolts or mounted parts
Noisy T/C bearing
Gear abnormal noise
Worn or damaged sprockets or drive
chain
Incorrect tire pressure
Cracked transfer case
Leakage from other parts
Breather clogging
Improper or too much oil
Loosened sealing bolts
Improperly applied sealant
Worn or damaged oil seal
Overhaul and check, replace if neces-
sary.
Overhaul and check for wear and
damage.
Replace if necessary.
Check sliding parts, replace if neces-
sary.
Drain and replace with specified oil.
Retighten as specified.
Disassemble bearings and parts and
check for wear or damage. Replace if
necessary.
Check for wear and damage including
speedometer gear, replace if neces-
sary.
Disassemble and check for wear and
damage, replace if necessary.
Adjust tire pressure.
Replace the case.
Clean case and parts and check for
leakage.
Remove breather hose and clean,
replace if necessary.
Use specified oil and adjust oil level.
Retighten
Use specified sealant and retighten.
Replace Check Symptoms
Electric shift problems
Cannot front wheel
drive when shifted 4H,
4L
Noise in 4WD opera-
tion
Noise in 4H or 4L
Transfer case oil
leakage
Action