SSANGYONG MUSSO 2003 Service Manual

5D2-52 TRANSFER CASE (TOD)
32. Install shift shaft oil seal if it is not installed.
33. Using pliers equipped with soft jaws, rotate the triangularshaft so it is aligned with the triangular slot in the transfer
case shift motor. If triangular shaft will not rotate, rotate the rear output shaft.
34. Slightly loosen the two nuts that attach the slotted support bracket to the end of the motor house.
35. Apply Black Non-Acid Cure Silicone Rubber or equivalent to motor housing base and install on transfer case.
36. Install the transfer case shift motor and three bolts along with speed sensor wire harness bracket and tighten. NoticeThe wire harness must be routed as shown to provide clearance and to prevent the wire harness from grounding
the damper.
37. Holding the slotted support bracket tight against the motor housing end, secure the bracket to the transfer case,
tightening the bolt with lockwasher to 8-11 Nm (72-96 lb-in).
38. Retighten the two nuts that attach the slotted support bracket to the end of the motor.
39. Install the clutch coil wire terminal and sensor wires.

TRANSFER CASE (TOD) 5D2-53
40. Install the rear case flange on the output shaft. Install therubber seal, output shaft yoke washer and nut. Tighten the nut.
Tightening Torque 137 - 196 Nm
41. Install the drainplug and tighten.
42. Fill the transfer case with 1.4 liters of Automatic Transmission Fluid or equivalent. NoticeFluid level should be just below the filler plug hole.
Tightening Torque 19 - 30 Nm
Tightening Torque 19 - 30 Nm
43. Install the fill pulg and tighten.
44. Install the transfer case as outlined in removal and
Installation, transfer case in the section. NoticeMake sure proper drain and fill plugs are installed if case is replaced.

Application
Steering Wheel Steering Gear Box Oil Pump Steering Column
Minmum Turning Radius Oil SECTION 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6A-1
General Specifications . . . . . . . . . . . . . . . . . . 6A-1
Fastener Tightening Specifications . . . . . . . . . 6A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Hard Steering . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Steering Pulls to One Side . . . . . . . . . . . . . . . 6A-2
Excessive Wheel Play . . . . . . . . . . . . . . . . . . . 6A-2
Poor Return of Steering Wheel . . . . . . . . . . . . 6A-2
Steering Wheel Shimmy . . . . . . . . . . . . . . . . . 6A-3
SPECIFICATIONS
GENERAL SPECIFICATIONS Abnormal Noise From Steering System . . . . . 6A-3
Component Locator . . . . . . . . . . . . . . . . . . . 6A-4
Steering System . . . . . . . . . . . . . . . . . . . . . . . 6A-4
Maintenance and Repair . . . . . . . . . . . . . . . 6A-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 6A-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Oil Pump Pressure Check . . . . . . . . . . . . . . . . 6A-6
Bleeding of Power Steering System . . . . . . . . 6A-6
Steering Gear Box . . . . . . . . . . . . . . . . . . . . . 6A-7
Number of Spoke Outer Diameter
Type Gear Ratio Inner Steering AngleOuter Steering Angle
TypeMaximum Pressure
Upper Tilting Angle
Lower Tilting Angle
Type Capacity Change Interval
Description
4
396 mm
Rack and Pinion

33°37'
31°50' Vane
75-82 kg/cm 2
4.646° 6.969°
5.25m
ATF DEXRON II
1 L
Every 24,000 km
FASTENER TIGHTENING SPECIFICATIONS
Application
Steering Shaft Bolt Pressure Hose BoltReturn Pipe Nut Slotted Nut Steering Gearbox Bolt
N m
30 - 40 12 - 1812 - 1835 - 45 35 - 45

6A-2 POWER STEERING SYSTEMChecks
Damaged or Binding Steering Ball Joint Improper Preload of Steering Pinion
Damaged Wheel or TireFaulty Suspension System Checks
Worn Steering Gear Worn or Damaged Steering Ball Joint Loosened Steering Gearbox Bolts Checks
Damaged Steering Linkage
Damaged Wheel and Tire Faulty Brake System Faulty Suspension System Checks
Lack of Lubrication Abnormal Wear or Binding of Steering Ball Joint Damaged or Faulty Steering GearImproper Preload of Steering PinionFaulty Steering Shaft JointSteering Fluid Leaks Lack of Fluid or Air-in System Faulty Steering Oil PumpDamaged or Loosened Pump Drive BeltClogging Oil Line
Damaged Wheel or Tire Faulty Suspension System DIAGNOSIS
HARD STEERING
Action
Lubricate
Replace
Replace gear assembly
Adjust
Replace
Repair or replace
Replenish or bleed Replace
Adjust or replace
Repair or replace Repair or replace Repair or replace
STEERING PULLS TO ONE SIDE
Action Repair
Repair or replace Repair or replace Repair or replace
EXCESSIVE WHEEL PLAY
Action
Replace gear assembly
Replace
Retighten
POOR RETURN OF STEERING WHEEL
Action
Replace
Replace gear assembly Repair or replace Repair or replace

POWER STEERING SYSTEM 6A-3
Checks
Loosened Steering Gearbox Mounting Bolt Faulty Steering Gear Steering Column LinterferenceLoosened Steering LinkageDamaged or Loosened Oil Pump Drive BeltLoosened Oil Pump Bracket Loosened Oil Pump Mounting Bolt Air-in SystemFaulty Oil Pump Checks
Damaged Steering LinkageLoosened Steering Gearbox Mounting Bolt Damaged or Binding Steering Ball Joint Worn or Damaged Front Wheel Bearing
Damaged Wheel or TireFaulty Suspension System STEERING WHEEL SHIMMY
Action
Replace
Retighten
Replace Replace
Repair or replaceRepair or replace
ABNORMAL NOISE FROM STEERING SYSTEM
Action
Retighten
Replace gear assembly Replace
Retighten
Adjust or replace Retighten RetightenBleed
Replace

6A-4 POWER STEERING SYSTEM
1 Steering Wheel
2 Steering Column Shaft
3 Steering Gear Box
4 End Ass'y - Tie RodCOMPONENT LOCATOR
STEERING SYSTEM5 Lower Shaft
6 Oil Reservoir
7 Oil Pump
8 Steering Knuckle

POWER STEERING SYSTEM 6A-5
MAINTENANCE AND REPAIR ON-VEHICLE SERVICE INSPECTION Steering Wheel Freeplay Inspection Procedure
1. Start the engine and set the wheels in straight ahead position.
2. Slightly move the steering wheel to the left and right andmeasure steering wheel free play when the front wheel is
start to move. Notice
If exceeds specification, the steering column shaft
connections and steering linkage .clearance. Replace orrepair if necessary.
Steering Angle Inspection Procedure
1. Place the front wheel on a measuring tool.
2. Rotate steering wheel all the way right and left and measure steering angle Notice If out of standard, check or adjust toe-in.
Standard 33°37'
31°50'Inner
Outer
Steering Effort Inspection Procedure
1 Place a vehicle on the paved flat ground with front wheels in a straight ahead position.
2 Start the engine and run it at 1,000rpm.
3 Using a scale, measure the steering effort in both directions.
NoticeThe difference in steering effort of left and right should be within 0.6 kg.
Standard Max. 3.0kg
StandardMax. 30mm

6A-6 POWER STEERING SYSTEM
OIL PUMP PRESSURE CHECK Oil Pump Pressure Check
1. Disconnect the pressure hose from the oil pump connect apressure gauge between the oil pump and pressure hose
2. Bleed the system . Start the engine and turn the steering wheel form lock several times until oil temperature is up to
50°C
3. Run the engine at 1,000 rpm.
4. Close the pressure gauge valve and check oil pressure.
NoticeDo not keep the valve closed for more than 10 seconds.
5. Remove the pressure gauge and connect the pressure hose.
6. Do bleeding procedure. BLEEDING OF POWER STEERING SYSTEM Bleeding of Power Steering System
1. Disconnect the fuel line. Using a starter motor, crank the engine and turn the steering wheel from lock to lock 5 or 6 times. Notice Do bleeding with engine cranking. If bleed with idling, there can be a air contact with oil.
2. Connect the fuel feed line and start the engine at idle speed.
3. Turn the steering wheel from lock to lock until there is no more air in oil reservoir.
4. Connect the oil level is within specification.
5. By turning the steering wheel left to right, check the oil level change. Notice
If oil is not changes more than 5mm, do bleeding again.
If oil level rises suddenly when stopped engine, again.
Relief Pressure
75 - 82 kg/cm2

POWER STEERING SYSTEM 6A-7
STEERING GEAR BOX1 Bolt ....................................................... 30-40Nm
2 Spring Washer
3 Lower Shaft
4 Pressure Hose ...................................... 12-18Nm
5 Return Pipe .......................................... 12-18Nm
6 Cotter Pin
7 Slotted Nut ............................................ 35-45Nm
8 Nut
9 Spring Washer
10 Bolt ....................................................... 35-45Nm
11 Washer
12 Steering Gearbox Assembly

6A-8 POWER STEERING SYSTEM
Tightening Torque 35 - 45 Nm
Removal & Installation Procedure
1. Remove the cotter pin and nut and separate the steering
gear box tie rod from the steering knuckle arm using the
puller. Installation Notice
2. Remove the bolt and separate the lower sha from the steering gear box. Installation Notice
Tightening Torque 30 - 40 Nm
3. Remove the oil pipe from the steering gear box and drain the oil. Installation Notice
4. Remove the clamp bolts and remove the steering gear box assembly. Installation Notice
Tightening Torque 12 - 18 Nm
Notice
Be careful not to damage the rubber(1).
When installing tighten the bolt (3) with the rubber
(2)being inserted to the hole of clamp.
5. Bleed the air from system.
6. Check the toe-in.
Tightening Torque 70 - 90 Nm
Tighten the bolt toward threadless side of lower shaft coupling.