SSANGYONG MUSSO 2003 Service Manual

5D2-32 TRANSFER CASE (TOD)
Phenomenon “4L ” lamp on cluster continuous blinking and can not go off,
when operated 4H/4L switch as 4L « 4H.
CauseShifting failure.
1. Stop the vehicle
2. Return the 4H/4L switch to first position (before
operating).
- The blinking of 4L indicator lamp is stopped.
NoteIf the first position before switch operating is ‘4L ’ ,
lamp goes on after stopping blink, otherwise it is ‘4H ’ lamp goes off.
3. Reoperate 4H/4L switch to 4H 4L on the below
condition. Positioned Auto T/M to neutral.
 At this time, keep the neutral position for 2 second.
 Stop the vehicle (The R.P.M of front & Rear propeller
shaft is below 80).
4. ‘4L ’ lamp blinks based on 0.3 second.
5. When the shifting is engaged, the blinking of ‘4L ’ lamp
is stopped.
-4H 4L : goes on ‘4L ’ lamp
-4L 4H : goes on ‘4L ’ lamp
6. When the ‘4L ’ indicator lamp continuous blinking,
repositioned to first position and diagnose the system and then fix it. Ye s
No
G1
Ye sNo
Test Stage / Contents
Result
Stage T est Contents and Procedure Specified Value
/Yes/No Countermeasure
Perform 2 stage Diagnose TOD control unit Normal system Perform system test Auto T/N positioned to neutral Check/Replace therelay

TRANSFER CASE (TOD) 5D2-33
9 - 16 Vdc 6 - 16 Vdc2 mA1 A 7 A
20 A
Removal & Installation Procedure
1. Turn the ignition switch to "OFF" position.
2. Remove 30 pin connector from TOD control unit.
3. Unscrew 2 bolts (1). Installation Notice
1 Bolt (M6 x 16, 2pieces)................ 9-11 Nm
2 TOD control unit
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
TOD CONTROL UNIT TOD Electric CharacteristicsVoltage Parasitic Current
(Under max. operation Voltage)Max. Operation Current
(Under max. operation Voltage) Normal Operation Range
CAN communication Operation Range Ignition “OFF ”
Ignition “ON ”
Motor “OFF ”
Motor “ON ”
4. Installation should follow the removal procedure in the
reverse order. Notice When replace TOD control unit, it is required to make a coding correspondent with vehicle specification.
Tightening Torque 9 - 11 Nm

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 Procedure1. Disconnect (-) cable from battery.
2. Lift on vehicle and make sure on safety. NoticeBe 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. NoticeOil 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 thendisconnect 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) formmotor 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. ReferenceWhen accord position of motor with 4H/4L switch and transfer case match position of the disconnected motor and newone.

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 3pin) 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 bypulling 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 Service A.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