lock SSANGYONG RODIUS 2012 Repair Manual

02-14
3166-00 Extension housing ▶
Lever assembly - Semi remote
Lever - Shift
Boot - Rubber
Ring - Retainer
O-ring
Bearing
Shim
Arm - Control
Damper assembly
Rod assembly
Bushing assembly - TGS mounting
Pin - TGS mounting
Pin - Spring
Pin - Spring
Adapter - Case 1.
3.
4.
5.
6.
7.
8.
9.
10.
13.
14.
15.
16.
17.
20.Bolt - Flange (42.1 ~ 53.9 Nm)
Seal - Oil
Seal - Oil
Pin - Dowel
Switch - Neutral (29.4 ~ 34.3 Nm)
Gasket
Bolt - Interlock (14.7 ~ 21.5 Nm)
Pin - Detent
Switch - Backup lamp (29.4 ~ 34.3
Nm)
Bolt - Fork hinge (53.9 ~ 67.6 Nm)
Bearing - Poppet ball (29.4 ~ 41.1
Nm)
Bolt - Guide (14.7 ~ 21.5 Nm)
Bolt (2.9 ~ 4.9 Nm)
Bracket - Wiring 21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.

02-153170-01
Sectional viewFront view
1. OVERVIEW
1) Characteristics of Transmission
Forward and Reverse gears are helical gear.
The clutch is operated by concentric slave cylinder (CSC).
To prevent the improper gear shift, semi-remote control system has been introduced.
To prevent the gears from engaging improperly, the synchronizer mechanisms and
independent interlock systems are installed on 1/2 gears, 3/4 gears, 5/6 gears and reverse
gear.
The High-Force system for reverse gear shift has been introduced.
The synchronizer has three types: Triple (1, 2, 3, R), Double (5), Single (4, 6) -
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-
-
-
-
6-speed M/T

03-53010-00
3. INSPECTION
Pedal stroke and height ▶
Pedal stroke (A) A.
Stop the engine.
Measure the current pedal position.
Depress the clutch pedal all the way and
measure the pedal stroke (A). 1)
2)
3)
Stroke (A)150 ± 3mm
Pedal height (B) B.
Stop the engine.
Remove the floor mat from the driver’s
footwall.
Measure the pedal height (B). 1)
2)
3)
Height (B)95.2 ± 3mm
Adjustment -
Release the lock nut (D) on stopper bolt (C).
Turn the stopper bolt to adjust the pedal
height.
Tighten the lock nut to the specified
tightening torque. 1)
2)
3)

03-6
Pedal free play ▶
Pedal free play (A) A.
Stop the engine.
Measure the current pedal position.
Lightly depress the clutch pedal until you
feel the resistancefrom the pedal and
measure the distance. 1)
2)
3)
Free play (A)5~15 mm
Adjustment -
Release the lock nut (B) from the master
cylinder.
Turn the push rod (C) to adjust the pedal
free play.
Tighten the lock nut to the specified
tightening torque. 1)
2)
3)

05-73240-01
2. LAYOUT
Front axle
Front locking hub
Front propeller shaft
Part-time transfer case
Rear propeller shaft
Rear axle

05-93240-01
4. IWE LOCKING HUB SYSTEM
1) Overview
The vacuum locking hub uses the IWE (Integrated Wheel End) system, and in this system, the
vacuum is generated only within the hub actuator.
It is structured to transmit power to the front section after the actuator hub is engaged following
the release of vacuum from the drive shaft end gear and the hub end gear
Booster
Operating Process
Vacuum pump
Vacuum generation process in front hub actuator ▶

05-10
(2) Vacuum System Related to 4WD
In 4WD mode, the TCCU blocks the
transferring of vacuum pressure from
vacuum pump to locking hub by supplying
the power to solenoid valve.Check valve
This valve allows the vacuum pressure to
flow through it in only one direction. This
prevent the vacuum from abruptly
releasing due to faulty vacuum pump.
4WD:
The vacuum pressure is released from the
hub actuator. At this time, the front hub end
gear is engaged.2WD:
The vacuum pressure pulls in the locking
hub actuator so that it will not be engaged
with the front end hub gear.
Vacuum solenoid valve
To atmosphere Block the vacuum
pressure
Hub actuator (RH)
Gear disengagedGear engaged

05-113240-01
5. POWER FLOW
Switching 2H, 4H → 4L
TCCU
Vacuum solenoid
Locking hub operation
(Released internal vacuum)
Front propeller shaft
Front axle
Front wheelRear propeller shaft
Rear axle
Rear wheel
Transfer case

07-4
3. MAJOR CHANGES
Front Sub Frame
Old New
The engine mounting insulators (A) have been changed according to newly equipped engine
(D20DTR). It improves the durability and NVH.
Front Knuckle Assembly
Old New
The front knuckle assembly has been changed according to new 4WD system (Part-time T/C).
Hub bearingLocking hub
actuator

07-74411-01
Coil Spring ▶
Description 4WD 2WD
Spring rate (kg/mm)10.01 ± 5% 10.01 ± 5%
Coil diameter (mm)16.7 16.7
Inner diameter
(mm)D 158.3 58.3
D 288.3 88.3
Spring identificationNone + Red or Blue Yellow + Red or Blue
Number of windings8.49 8.49
Number of active windings6.99
CVW (Curved
Vehicle Weight)Height (mm)256.0 256.0
Weight (kg)976.9 ± 4% 834.9 ± 4%
Stress (kg/mm)69.53 59.42
Winding directionClockwise Clockwise