SSANGYONG MUSSO 1998 Workshop Repair Manual

5D2-34 TRANSFER CASE (TOD)
TRANSFER CASE (TOD)
1 Transmission
2 TOD Transfer Case
3 Extension Housing
4 Bolt.......................................................35-60Nm5 Front Propeller Shaft
6 Bolt.......................................................81-89Nm
7 Rear Propeller Shaft
8 Bolt.......................................................81-89Nm

TRANSFER CASE (TOD) 5D2-35
Removal & Installation Procedure
1. Disconnect (-) cable from battery.
2. Lift on vehicle and make sure on safety.
Notice
Be careful for catalytic converter due to high temperature
after driving or engine running.
3. Prepare a vessel to drain transfer case and manual
transmission oil.
4. Release drain plug and drain transfer case and manual
transmission oil.
If planar damper is installed, unscrew 4 bolts and remove
the planar damper.
Notice
Oil drain should be along with whole transfer case
disassembly and assembly.
5. Disconnect transmission extension wiring connector back
side transfer case.
Notice
When disconnect connector, make sure on direction of
locking tab towards inside.
6. Disconnect shift motor/clutch coil connect (Black 7 pin)
connector upper backside.
7. Disconnect front and rear speed sensor connector (white
7 pin).
8. Disconnect speedometer sensor connector right upper
side.
9. Disconnect breather tube front upper side transfer case
(upper connecting point of transfer case and front
propeller).
10. Prepare hydraulic jack and support transfer case assembly.

5D2-36 TRANSFER CASE (TOD)
11. Unscrew 4 units of M12 bolts from case flange then
disconnect front propeller shaft from transfer case.
Installation Notice
Tightening Torque 81 - 89 Nm
12. Unscrew 4 units of M12 bolts from case flange then
disconnect rear propeller shaft from transfer case.
Installation Notice
13. Unscrew 5 units of mounting bolt (M12) from extension
housing in transmission.
Installation Notice
Tightening Torque 81 - 89 Nm
Tightening Torque 35 - 60 Nm
Notice
Make sure the connecting surface is clean.
Applying long-life grease spline inside transfer case input
shaft.
14. Installation should follow the removal procedure in the
reverse order.

TRANSFER CASE (TOD) 5D2-37
Replacement of Shift Motor
1. Disconnect (-) cable from battery.
2. Disconnect shift motor/clutch coil connector (black pin7)
upper backside.
3. Unscrew 3 units of shift motor mounting bolts (M10).
4. Unscrew 1unit of bracket mounting bolt (M10).
Installation Notice
Tightening Torque 9 - 11 Nm
Notice
When disconnecting shift motor and mounting bracket, it is
required to unscrew 2 units of adjusting bolts (M10) form
motor and bracket.
5. Keep shift motor even then pull rearward.
6. Clean connection surface of transfer case and shift motor.
7. If necessary, make a test by SCANNER with shift motor
assembly.
Notice
Do not disassemble shift motor. If necessary, replace by
shift motor assembly unit.
8. Applying sealant into connecting surface for new shift motor.
9. Installation should follow the removal procedure in the
reverse order. Before installation, make sure that motor
position match with mode of 4H/4L switch.
Reference
When accord position of motor with 4H/4L switch and transfer
case match position of the disconnected motor and new
one.

5D2-38 TRANSFER CASE (TOD)
SPEED SENSOR IN FRONT AND
REAR PROPELLER SHAFT
Replacement Procedure
1. Disconnect (-) cable from battery.
2. Detach shift motor assembly.
3. Disconnect front and rear speed sensor connector (white 3
pin) upper backside transfer case.
4. Disconnect speed sensor connect from locking sleeve by
pushing.
5. Disconnect wire stick cap from the detached connector.
6. Unscrew rear speed sensor mounting bolt (M10) from upper
side of rear case flange.
7. Detach sensor from transfer case by lifting up using tool.
Notice
When disconnect sensor, make sure on adequate pressure
due to sensitiveness with shock.
8. Disconnect taping from both protection tube ends that wrap
3 wires of speed sensor and 1 wire of clutch coil.
9. Disconnect tube.

TRANSFER CASE (TOD) 5D2-39
10. Disconnect pin and wire from speed sensor connector by
pulling sticking long-nose plier into “L” pin in connector.
11. On the same way, disconnect pin and wire “M” and “N”
from connector.
Notice
Do not touch the wires related with EMC.
12. Prepare new speed sensor.
13. Connect 3 pins with wires of speed sensor to coincide with
each connection position.
14. Using long-nose plier, connect tightly by pulling pins.
15. Apply rubber cap into connector using long-nose plier not
to detach.
16. Connect protection tube with wire.
17. Tape both ends of tube.
18. Putting rear speed sensor into hole, connect exactly
pushing both ends.
19. Screw 1 unit of bolt (M10).
Installation Notice
Tightening Torque 9 - 11 Nm
20. Connect speed sensor connector, then locking sleeve.
Reference
Front propeller shaft should be premised by removal of
shift motor.
After disconnecting shift motor, procedure of replacement
on sensor assembly of accords with one of rear speed
sensor.

5D2-40 TRANSFER CASE (TOD)
REPLACEMENT OF OIL
Oil Specification
Specified Oil Level
SpecificationStandard
Capacity
ServiceA.T.F S-3, S-4 or Dexron II, III
1.4 Litre
Inspection every 15,000km, Replacement every 50,000km=
Oil Replacement
1. Lift on vehicle then make sure on safety.
2. Prepare a vessel to drain transfer case oil.
3. Release filler plug.
4. Drain oil completely.
5. Wash drain plug and than tighten.
Installation Notice
Tightening Torque 19 - 30 Nm
6. Replenish standardized oil by specified level through filler
plug hole.
7. Tighten filler plug after washing.
Installation Notice
8. Check oil leakage.
Tightening Torque 19 - 30 Nm
.
.

TRANSFER CASE (TOD) 5D2-41
UNIT REPAIR
TRANSFER CASE
Transfer Case, Diassembled View

5D2-42 TRANSFER CASE (TOD)
1 Bearing
2 Bushing
3 Carrier Assembly
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Output Shaft Thrust Washer
8 Bearing
9 Retaining Ring
10 Snap Ring
11 High-low Collar
12 Rear Output Shaft
13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Assembly
17 Thrust Washer
18 Sprocket, Drive (24T)
19 Clutch Pack Assembly
20 Insulator Washer
21 Armature
22 Snap Ring
23 Wave Washer
24 Apply Cam
2 5 Ball
26 Cam and Coil Assembly
27 Nut, Metric
28 Output Shaft Yoke Washer
29 Oil Seal
30 Case Flange
3 1 Bolt
32 Upper Speed Sensor (Rear)
3 3 Nut
34 Washer
3 7 Bolt
38 Tag, Identification
39 Thrust Bearing
40 Clutch Coil Assembly
41 Fork, Reduction Shift42 Shift Rail
43 Shaft, Shift
44 Spacer
45 Torsion Spring
46 Shift Cam
47 Transfer Case Shift Motor
4 8 Bolt
4 9 J-clip
50 Connector Retainer
5 1 Bolt
52 Support Stud
53 Lower Speed Sensor (Front)
5 4 Plug
55 Identification Decal
56 Cover
57 Tone Wheel, Lower
58 Chain, Drive
59 Sprocket, Driven (24T)
61 Magnet
62 Case
63 Case Flange and Output Shaft
64 Barb, Breather
68 Spiral Pin
69 Oil Seal
70 Pin, Dowel
71 Ring Gear
72 Retaining Ring
73 Snap Ring
74 Bearing
75 Snap Ring
76 Bearing
77 Speedometer Drive Gear
78 Facing, Shift Fork
79 Upper Tone Wheel
80 Oil Seal
81 Bearing Sleeve
82 Bearing

TRANSFER CASE (TOD) 5D2-43
Disassembly Procedure
1. Disconnect transfer case from vehicle
2. Using a 30mm thin-wall socket, first remove the rear output
nut, output shaft yoke washer, oil seal then the case flange.
Installation Notice
27 Nut
28 Washer
30 Case Flange
Tightening Torque 137 - 196 Nm
3. Disconnect shift motor/clutch coil connector and speed
sensor connector from upper bracket of transfer case.
Notice
When disconnect connector, pull forwards grasping
connector housing.
4. Remove outer tube on speed sensor connector.
5. Remove wire supporting cape back side of speed sensor
connector.
6. Disconnect pin of clutch coil wire (yellow) from speed sensor
connector (white 7 pin) using long-nose plier.
7. Remove shift motor.
Notice
When remove shift motor, pay attention to the location of
triangular slot and shaft in transfer case inside motor.
8. Disconnect front and rear speed sensor.