service SSANGYONG MUSSO 2003 Service Manual

MANUAL TRANSMISSION 5B-11
MAINTENANCE AND REPAIRON-VEHICLE SERVICE
SHIFT CONTROL CABLE
1 Shift Lever Assembly
2 Bolt ...................................................... 20-30 Nm
3 Select Cable
4 Shift Cable
5 Snap Pin
6 Snap Pin
7 Transmission
8 Shift Cable 9 Select Cable
10 Clip 11 Clip
12 Snap Pin
13 Snap Pin
14 Protector
15 Washer

Type Clutch Pedal Clutch Disc Clutch Master Cylinder Clutch Release Cylinder Clutch FluidDescription
Hydraulic
Suspended 158 mm
5 - 10 mm
Single Dry Diaphragm
9.85 - 10.2 mm 9.2 mm
19.8 mm
15.87 mm
14.0 mm
17.46 mm
SAE J1703 / DOT3
SECTION 5C
CLUTCH
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 5C-1 General Specifications . . . . . . . . . . . . . . . . . . 5C-1
Fastener Tightening Specifications . . . . . . . . . 5C-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . 5C-3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . 5C-3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4 Clutch Slips . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-4
Poor Disengagement . . . . . . . . . . . . . . . . . . . 5C-4
Hard to Shift or Will not Shift . . . . . . . . . . . . . . 5C-4
Clutch Chatters When Starting . . . . . . . . . . . . 5C-4
Difficult Pedal Operation . . . . . . . . . . . . . . . . . 5C-5
SPECIFICATIONS
GENERAL SPECIFICATIONS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
Application
Type Max. Pedal StrokePedal Free Play
TypeThickness of Disc Stroke Inner DiameterStrokeInner DiameterFree
With Load
Clutch Noisy . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-5
Component Locator . . . . . . . . . . . . . . . . . . . 5C-6 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . 5C-6
Pedal and Master Cylinder . . . . . . . . . . . . . . . 5C-7
Maintenance and Repair . . . . . . . . . . . . . . . 5C-8
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 5C-8
Bleeding of Clutch System . . . . . . . . . . . . . . . 5C-8
Clutch Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C-9
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 5C-13
Clutch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 5C-15
Clutch Oil Chamber . . . . . . . . . . . . . . . . . . . 5C-17

5C-8 CLUTCH
MAINTENANCE AND REPAIR ON-VEHICLE SERVICE BLEEDING OF CLUTCH SYSTEM Bleeding procedure Notice Keep the fluid level over ‘MAX ’ in reservoir during
bleeding operation.Do not let fluid contact a painted surface.
1. Remove the air bolt cap of the release cylinder.
Connect a vinyl tube to the bolt.
2. Insert the other end of the tube in a vacant container.
3. Slowly depress the clutch pedal several times.
4. With clutch pedal fully depressed, open the air bolt and release air rind fluid in the fluid line,
5. Repeat this procedure until there are no more air bubbles in the fluid flows.

Model
TypeGear Ratio Oil Manufacturer WeightPart-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 15,000 km
Replace : Every 50,000 km Borg Warner30 kg
SECTION 5D1
TRANSFER CASE (PART TIME 4408)
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting thiscable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCKunless otherwise noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D1-1
General Specifications . . . . . . . . . . . . . . . . . 5D1-1
Schematic and Routing Diagram . . . . . . . . 5D1-2 Part Time Transfer Case - 4408 . . . . . . . . . . 5D1-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D1-3
Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . 5D1-4 System Description . . . . . . . . . . . . . . . . . . . . 5D1-4
Self-Diagnosis Test . . . . . . . . . . . . . . . . . . . . 5D1-8Diagnostic Diagram . . . . . . . . . . . . . . . . . . .
5D1-9
Maintenance and Repair . . . . . . . . . . . . . 5D1-10
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D1-10
Maintenance of Transfer Case Lubricant . . 5D1-10
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-11
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case Control Unit (TCCU) . . . . . . 5D1-36
High LowSpecification Capacity Lubrication
Application
Description

5D1-4 TRANSFER CASE (PART TIME 4408)SELF-DIAGNOSIS
SYSTEM DESCRIPTION
1. TCCU detects transfer case system malfunctions and indicates malfunctioning part(s) through flashing 4H,4L indicator lights.
Using a service connector, connect it to the diagnosis box in the engine room and read the flashing of the ‘4WD
CHECK ’ indicator light.
The flashing indicator light will show you defective code(s).
2. Identify 7 defective codes after reading the flashing indicator light.
TCCU
Shift motor
Magnetic synchronizer clutch
Speed sensor
Hub solenoid
Selector switch
Motor position sensor
3. Transfer case system is malfunctioning when: 4H ,4L indicator lights are remain on after 0.6 second when turning the ignition switch ‘ON ’
4H,4L indicator lights are continuously come on during driving.
4. If only 1 part is malfunctioning, ‘4WD CHECK ’ indicator light
will display defective code 3 times continuously.
5. If more then 2 part is malfunctioning, the first malfunctioning part will be displayed 3 times and following malfunctioningparts will be displayed .
6. To read defective code, connect the service connector and turn the ignition switch 'ON'.
7. After repairing, eliminate the defective code stored in the TCCU. NoticeBefore replacing the malfunction parts with defective code, check the wires and connectors for proper condition.

TRANSFER CASE (PART TIME 4408) 5D1-5
Defective Code Reading
1. Position the ignition switch to ‘OFF ’
2. Using a service connector, connect the No.2 pin ( lgnition ) and No.6 pin (TCCU) of the diagnosis socket in the engine room.
3. Position the ignition switch to 'ON'.
4. Read the flashing ‘4WD CHECK ’ indicator light and identify
the malfunctioning part.
How to Eliminate the Falut Code
1. Position the ignition switch to ‘OFF ’
2. Using a service connector, connect the No.2 pin (GND) and No.6 pin (TCCU) of the diagnosis socket in the engine room.
3. Position the ignition switch to ‘ON ’ over 5 seconds.
4. Do defective code reading and make sure that all defective codes are eliminated.

5D1-6 TRANSFER CASE (PART TIME 4408)
Diagnostic Table
Connect a service connector. If turn the ignition switch ‘ON ’
‘ 4WD CHECK ’ indicator light will come on for 0.6 second and
turn off for 3 seconds and then display a defective code 3
times continuously.
No. Defective Code
Malfunctioning Part
1
2 3 4
5 TCCU
Shift Motor
Synchronizer Clutch
Speed SensorHub Solenoid
4WD CHECK Light ON OFF
Defective Code
4WD CHECK Light ON OFF
Defective Code
4WD CHECKLight ONOFF
Defective Code
4WD CHECKLight ONOFF
Defective Code
4WD CHECK Light ONOFF
Defective Code

5D1-10 TRANSFER CASE (PART TIME 4408)
MAINTENANCE AND REPAIR ON-VEHICLE SERVICE MAINTENANCE OF TRANSFER CASE LUBRICANT Oil Level Check Clean the oil level plug and surrounding area.
Remove the oil level plug and check whether oil is drip out or not.
Tighten the oil level plug.
Oil Change Clean the oil level plug and surrounding area
Place a suitable container under the transfer case.
Remove the oil and tighten the drain plug.
Fill the oil through the oil level plug until oil begins todrip out.
Tighten the oil level plug.
Cautions for oil level check and plugs tightening Do not use an impact wrench to remove or tighten theoil level plug or drain plug since this will damage thethreads in the transfer case.
Tightening Torque 20 - 30 Nm

SECTION 5D2
TRANSFER CASE (TOD)
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D2-1General Specifications . . . . . . . . . . . . . . . . . 5D2-1
Schematic and Routing Diagrams . . . . . . . 5D2-2 TOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-2
T.C.C.U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-3
Function Description . . . . . . . . . . . . . . . . . 5D2-4
TOD Control Unit . . . . . . . . . . . . . . . . . . . 5D2-12
Control Unit Diagram . . . . . . . . . . . . . . . . 5D2-14
TOD Control Unit . . . . . . . . . . . . . . . . . . . . 5D2-14
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-15 Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . 5D2-15
Diagnostic Trouble Codes (DTC's) . . . . . . . 5D2-17
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
ModelLength (mm)Weight (kg)Shift ModeGear Ratio Oil
Max. Torque
High Low SpecificationCapacityInterval TOD(Torque On Demand) Transfer Case (4423E)
343.036.6
4H and 4L
1 : 1
2.48 : 1
ATF S-3, S-4 or Dexron II, III 1.4 L
Inspect Every 15,000km, Replace Every 50,000km 550 lbft ( 76kg m)
.
= .
.
= .
Application Description
Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-18
Eliminate the Memorized Fault Code . . . . .
5D2-20
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D2-21
Maintenance and Repair . . . . . . . . . . . . . 5D2-33
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D2-33
TOD Control Unit . . . . . . . . . . . . . . . . . . . . 5D2-33
Transfer Case (TOD) . . . . . . . . . . . . . . . . . 5D2-34
Speed Sensor in Front and Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . . 5D2-38
Replacement of Oil . . . . . . . . . . . . . . . . . . . 5D2-40
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D2-41 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D2-41

5D2-20 TRANSFER CASE (TOD)
ELIMINATE THE MEMORIZED FAULT CODE When diagnose by SCANNER, it is required that you make adequate service on defects against all fault codes. And thenyou should delete the memorized fault codes in TOD control unit using SCANNER as follows;
1. Connect SCANNER with diagnosis connector.
2. Select “trouble code clear ” in SCANNER.
3. In “trouble code clear ” screen, press “enter ” key to erase
the fault code.
4. Confirm deletion of fault code and, if not, repeat 2.-3. process.