SSANGYONG KORANDO 1997 Service Repair Manual

TRANSFER CASE (PART TIME - 4408) 5D2-11
SSANGYONG MY2002
KAA5D080
KAA5D090
KAA5D100
SELF-DIAGNOSIS TEST
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 under instrument pannel 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
KAA5D110
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 malfunctioning parts 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.
Notice: Before replacing the malfunction parts with
defective code, check the wires and connectors
for proper condition.

SSANGYONG MY2002
5D2-12 TRANSFER CASE (PART TIME - 4408)
KAA5D120
KAA5D130
Defective Code Reading
1. Position the ignition switch to OFF.
2. Using a service connector, connect the diagnosis
socket under instrument pannel.
3. Position the ignition switch to ON.
4. Read the flashing 4WD CHECK indicator light and
identify the malfunctioning part (See Diagnosis
Table).
How to Clear the Fault Code
1. Position the ignition switch to OFF.
2. Using a service connector, connect the diagnosis
socket in under instrument pannel.
3. Position the ignition switch to ON over 5 seconds.
4. Do defective code reading and make sure that all
defective codes are eliminated.

TRANSFER CASE (PART TIME - 4408) 5D2-13
SSANGYONG MY2002
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.
4WD CHECK
Light
ON
OFF
4WD CHECK
Light
ON
OFF
4WD CHECK
Light
ON
OFF
4WD CHECK
Light
ON
OFF
4WD CHECK
Light
ON
OFFTCCU
Shift Motor
Synchronizer Clutch
Speed Sensor
Locking Hub Solenoid Defective Code No.
1
2
3
4
5
Malfunctioning Part
KAA5D140
KAA5D150
KAA5D160
KAA5D170
KAA5D180

SSANGYONG MY2002
5D2-14 TRANSFER CASE (PART TIME - 4408)
4WD CHECK
Light
ON
OFF
4WD CHECK
Light
ON
OFFSelector Switch
Motor Position Sensor Defective Code No.
6
7
Malfunctioning Part
KAA5D190
KAA5D200

SSANGYONG MY2002
5D2-16 TRANSFER CASE (PART TIME - 4408)

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COMTONENT LOCATOR
CROSS SECTIONAL VIEW
KAA5D250

TRANSFER CASE (PART TIME - 4408) 5D2-17
SSANGYONG MY2002
TRANSFER CASE ASSEMBLY
KAA5D260
1 Rear Companion Flange
2 Case Cover
3 Front Companion Flange
4 Breather Plug
5 Transfer Case
6 Input Shaft
7 Mounting Bolt8 Transmission Extension Housing
9 Bolt
10 Washer
11 Front Propeller Shaft
12 Bolt
13 Washer
14 Rear Propeller Shaft

SSANGYONG MY2002
5D2-18 TRANSFER CASE (PART TIME - 4408)
DISASSEMBLY AND ASSEMBLY
KAA5D370

TRANSFER CASE (PART TIME - 4408) 5D2-19
SSANGYONG MY2002
1 Transfer Case
2 Spring Washer
3 Oil Seal
4 Companion Flange
5 Shift shaft
6 Oil Seal
7 Pipe Plug
8 Screw
9 Bolt
10 Speed Sensor and Harness Bracket
11 Speed Sensor Assembly
12 Speed Sensor
13 O-Ring
14 Locking Clip
15 Connector
16 Motor Assembly
17 Oil Seal
18 Bearing
19 Bolt
20 Pump Assembly
21 Output Shaft Assembly
22 Bearing
23 Ring Gear
24 Cover Assembly
25 Nut
26 Snap Ring
27 Bearing
28 Needle Bearing
30 Clutch Coil Assembly
31 Speed Gear
32 Oil Seal
33 Return Spring
34 Magnet
35 Clutch Housing
36 Snap Ring (option)
37 Snap Ring
38 Lock-up Hub
39 Sleeve Return Spring
40 Lock-up Collar41 Rail Shaft
42 Lock-up Fork
43 Snap ring
44 Spacer
45 Driven Sprocket
46 Driving Sprocket
47 Drive Chain
48 Nut
49 Gasket
53 Spring Pin
54 Hose Clamp
55 Hose Coupling
56 Oil Strainer
58 Reduction Hub
59 Shift Fork Assembly
60 Shift Fork Facing
61 Roller and Retainer
66 Nut
67 Plane Washer
68 Oil Seal
71 Spacer
72 Front Output Assembly
73 Breather
74 Bolt
75 Front Adapter Assembly
76 Snap Ring
80 Snap Ring
81 Bearing
82 Input Shaft Assembly
83 Sleeve Assembly
84 Needle Bearing
86 Thrust Washer
87 Retaining Ring
88 Thrust Plate
89 Sun Gear
90 Gear Carrier Assembly
97 Electric Shift Cam
99 Spacer

SSANGYONG MY2002
5D2-20 TRANSFER CASE (PART TIME - 4408)

KAA5D220
ON-VEHICLE SERVICE
MAINTENANCE OF TRANSFER
CASE LUBRICANT
1. 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.
Installation Notice
KAA5D230
MAINTENANCE AND REPAIR
2. 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.
Installation Notice
Fill the oil through the oil level plug until oil
begins to drip out.
Tighten the oil level plug.
3. Cautions for oil level check and plugs tightening
Do not use an impact wrench to remove or
tighten the oil level plug or drain plug since this
will damage the threads in the transfer case.
Tightening Torque4 - 6 Nm
(35 - 53 lb-in)
Tightening Torque20 - 30 Nm
(15 - 22 lb-ft)

TRANSFER CASE (PART TIME - 4408) 5D2-21
SSANGYONG MY2002
KAA5D240
4H AND 4L INDICATOR
When the ignition switch turns on, 4H and 4L indicators
turn on for 0.6 seconds and turn off.
Notice: If 4H and 4L indicators do not turn on, check
the related bulb, the wiring harness and TCCU.
J1 - 7
J1 - 8
J1 - 13
J1 - 14
J1 - 15
J1 - 16
J1 - 17
J1 - 234H or 4L
2H
4H indicator light ON
4H indicator light OFF
2H or 4H
4L
Clutch pedal applied
Clutch pedal released
4L indicator light ON
4L indicator light OFF
Motor OFF
Motor ON
Motor OFF
Motor ON
Auto locking hub ON
Auto locking hub OFF
TCCU INSPECTION
4.75 - 5.35
0 - 0.50
< 1.00
> 11.00
4.75 - 5.35
0 - 0.50
< 0.50
> 11.00
< 1.00
> 11.00
< 1.00
> 11.00
< 1.00
> 11.00
> 11.00
< 1.00
Pin No. Voltage(V)Operation Condition
Notice:
DC 12V for the TCCU operation should be
maintained.
In case of J1-8 and J1-15, indicator light will turn
on for 0.6 second when turn the ignition switch ON.
If 4H and 4L indicator lights remain turned on when
turn the ignition switch on or during driving, perform
the TCCU diagnosis.