section 2c SSANGYONG KORANDO 1997 Service Repair Manual

SSANGYONG MY2002
5D2-38 TRANSFER CASE (PART TIME - 4408)
KAA5D830
KAA5D840
KAA5D850
Input Shaft
Cross Sectional View
Tightening Torque346 - 380 Nm
Front Output Shaft
1. Install the deflector on the yoke.
2. Position the output shaft in transfer case and install
the companion flange assembly, oil seal, washer
and nut.
3. Holding the companion flange, tighten the nut.
Installation Notice
Reduction Shift Parts
1. Install the new pin, roller and retainer into the
reduction shift fork.
2. Press the pin, roller and retainer into the reduction
spilt fork bore completely.
Notice: Make sure that the cam roller turns freely.
3. Install the 2 fork facing on the reduction shift fork
assembly.
4. Install the reduction shift fork onto the previously
installed reduction hub in the transfer case.
5. Install the output shaft spline into the reduction
hub and engage the output shaft end with input
shaft bearing.
Notice: For installation of the output shaft,
assemble the oil pump temporarily.

SECTION 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
Description and Operation...................................6A-2
General Description.............................................6A-2
Component Locator.............................................6A-3
Diagnostic Information and Procedures..............6A-4
Power Steering System Pressure Test..................6A-4
Power Steering System Leak Test........................6A-4
Maintenance .........................................................6A-5
Bleeding the Power Steering System....................6A-5
Checking and Adding Fluid..................................6A-5Repair Instructions................................................6A-6
On-Vehicle Service.................................................6A-6
Power Steering Fluid Reservoir.............................6A-6
Power Steering Pump Hoses and Pipes................6A-7
Specifications.......................................................6A-9
General Specification...........................................6A-9
Fastener Tightening Specifications.......................6A-9
Special Tools and Equipment............................ 6A-10
Special Tools Table............................................6A-10

SSANGYONG MY2002
6A-4 POWER STEERING SYSTEM
KAA6A020
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER STEERING SYSTEM
PRESSURE TEST
Tools Required
124 589 06 21 00 Power Steering Pump Testing Unit
Check the fluid pressure as follow to trouble is in the
pump or gear unit.
Test Procedure
1. Disconnect the pressure hose from the oil pump
and connect a pressure 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 gauge valve fully, and read pressure.
The pump pressure with the valve closed should
be between 7,355 kPa to 8,041 kPa (1,067 psi to
1,166 psi).
Notice: Do not keep the valve closed for more
than 10 seconds.
5. Remove the pressure gauge and connect the pres-
sure hose.
6. Do bleeding procedure.
POWER STEERING SYSTEM
LEAK TEST
General Procedure
Inspect the following :
The power steering fluid reservoir for overfill.
Fluid for aeration and overflow.
The hoses for loose connections.
The torsion bar, stub shaft and adjuster seals for
leaks.
The component sealing surfaces for damage.
Important: Verify the exact point of the leak. The point
from which the fluid is dripping is not necessarily the
point at which the system is leaking. When service is
required, clean the leak area upon disassembly,
replace the leaking seal, check the component sealing
surfaces for damage and reset the torque bolt to
specifications required.
External Leak Check
The purpose of this procedure is to pinpoint the location
of the leak. In some cases, the leak can be easily lo-
cated, but seepage-type leaks may be harder to find.
To locate seepage leaks, use the following method:
1. With the engine off, wipe dry the complete power
steering system.
2. Check the power steering fluid level in the pump’s
reservoir. Adjust the fluid level as necessary.
Refer to “Checking and Adding Fluid” in this
section.
Notice: Do not hold the steering wheel at a stop
for any length of time as this can damage the
power steering pump.
3. Start the engine. Turn the steering wheel counter-
clockwise and clockwise from stop to stop several
times.
4. Find the exact area of the leak and repair it.

SSANGYONG MY2002
6A-6 POWER STEERING SYSTEM
KAA6A040
3. Remove the power steering fluid reservoir
mounting bolts (1).
Removal Notice:
One power steering fluid reservoir mounting bolt
(2) is located in the fluid reservoir.
Installation Notice
KAA6A030
ON-VEHICLE SERVICE
POWER STEERING FLUID
RESERVOIR
Tools Required
DW310-021Power Steering Pump Pulley Remover/
Installer
Removal and Installation Procedure
1. Remove the power steering pump. Refer to
Section 6B, Power Steering Pump.
2. Remove the power steering pump pulley nut, using
the power steering pump pulley remover/installer
DW310-021.
Installation Notice
REPAIR INSTRUCTIONS
Tightening Torque 61 Nm (44 lb-ft)
15 Nm (11 lb-ft)
18 Nm (13 lb-ft)
Tightening
TorqueBolts (1)
Bolt (2)
4. Remove the power steering fluid reservoir upward.
After installing the power steering fluid reservoir,
bleed the power steering system. Refer to
“Bleeding the Power Steering System” in this
section.
5. Installation should follow the removal procedure
in the reverse order.

POWER STEERING SYSTEM 6A-7
SSANGYONG MY2002
KAA6A050
KAA6A060
4. Disconnect the return line pipe from the power
steering gear outlet.
Installation Notice
KAA6A070
5. Disconnect the pressure line pipe from the power
steering gear inlet.
Installation Notice
POWER STEERING PUMP HOSES
AND PIPES
Removal and Installation Procedure
1. Remove the battery. Refer to Section 1E, Engine
Electrical.
2. Siphon the power steering fluid from the fluid reser-
voir.
3. Disconnect the pressure line pipe from the outlet
connection on the power steering pump and return
hose from the inlet connection on the power
steering fluid reservoir.
Installation Notice
Tightening Torque 44 Nm (33 lb-ft)
Tightening Torque 17 Nm (13 lb-ft)
Tightening Torque 17 Nm (13 lb-ft)

SSANGYONG MY2002
6A-8 POWER STEERING SYSTEM
KAA6A080
6. Remove the return line support clip from the front
frame.
Installation Notice
Tightening Torque 9 Nm (80 lb-in)
After installing the power steering fluid reservoir,
bleed the power steering system. Refer to
“Bleeding the Power Steering System” in this
section.
7. Installation should follow the removal procedure
in the reverse order.

SSANGYONG MY2002
6A-4 POWER STEERING SYSTEM
KAA6A020
DIAGNOSTIC INFORMATION AND PROCEDURES
POWER STEERING SYSTEM
PRESSURE TEST
Tools Required
124 589 06 21 00 Power Steering Pump Testing Unit
Check the fluid pressure as follow to trouble is in the
pump or gear unit.
Test Procedure
1. Disconnect the pressure hose from the oil pump
and connect a pressure 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 gauge valve fully, and read pressure.
The pump pressure with the valve closed should
be between 7,355 kPa to 8,041 kPa (1,067 psi to
1,166 psi).
Notice: Do not keep the valve closed for more
than 10 seconds.
5. Remove the pressure gauge and connect the pres-
sure hose.
6. Do bleeding procedure.
POWER STEERING SYSTEM
LEAK TEST
General Procedure
Inspect the following :
The power steering fluid reservoir for overfill.
Fluid for aeration and overflow.
The hoses for loose connections.
The torsion bar, stub shaft and adjuster seals for
leaks.
The component sealing surfaces for damage.
Important: Verify the exact point of the leak. The point
from which the fluid is dripping is not necessarily the
point at which the system is leaking. When service is
required, clean the leak area upon disassembly,
replace the leaking seal, check the component sealing
surfaces for damage and reset the torque bolt to
specifications required.
External Leak Check
The purpose of this procedure is to pinpoint the location
of the leak. In some cases, the leak can be easily lo-
cated, but seepage-type leaks may be harder to find.
To locate seepage leaks, use the following method:
1. With the engine off, wipe dry the complete power
steering system.
2. Check the power steering fluid level in the pump’s
reservoir. Adjust the fluid level as necessary.
Refer to “Checking and Adding Fluid” in this
section.
Notice: Do not hold the steering wheel at a stop
for any length of time as this can damage the
power steering pump.
3. Start the engine. Turn the steering wheel counter-
clockwise and clockwise from stop to stop several
times.
4. Find the exact area of the leak and repair it.

SSANGYONG MY2002
6A-6 POWER STEERING SYSTEM
KAA6A040
3. Remove the power steering fluid reservoir
mounting bolts (1).
Removal Notice:
One power steering fluid reservoir mounting bolt
(2) is located in the fluid reservoir.
Installation Notice
KAA6A030
ON-VEHICLE SERVICE
POWER STEERING FLUID
RESERVOIR
Tools Required
DW310-021Power Steering Pump Pulley Remover/
Installer
Removal and Installation Procedure
1. Remove the power steering pump. Refer to
Section 6B, Power Steering Pump.
2. Remove the power steering pump pulley nut, using
the power steering pump pulley remover/installer
DW310-021.
Installation Notice
REPAIR INSTRUCTIONS
Tightening Torque 61 Nm (44 lb-ft)
15 Nm (11 lb-ft)
18 Nm (13 lb-ft)
Tightening
TorqueBolts (1)
Bolt (2)
4. Remove the power steering fluid reservoir upward.
After installing the power steering fluid reservoir,
bleed the power steering system. Refer to
“Bleeding the Power Steering System” in this
section.
5. Installation should follow the removal procedure
in the reverse order.

POWER STEERING SYSTEM 6A-7
SSANGYONG MY2002
KAA6A050
KAA6A060
4. Disconnect the return line pipe from the power
steering gear outlet.
Installation Notice
KAA6A070
5. Disconnect the pressure line pipe from the power
steering gear inlet.
Installation Notice
POWER STEERING PUMP HOSES
AND PIPES
Removal and Installation Procedure
1. Remove the battery. Refer to Section 1E, Engine
Electrical.
2. Siphon the power steering fluid from the fluid reser-
voir.
3. Disconnect the pressure line pipe from the outlet
connection on the power steering pump and return
hose from the inlet connection on the power
steering fluid reservoir.
Installation Notice
Tightening Torque 44 Nm (33 lb-ft)
Tightening Torque 17 Nm (13 lb-ft)
Tightening Torque 17 Nm (13 lb-ft)

SSANGYONG MY2002
6A-8 POWER STEERING SYSTEM
KAA6A080
6. Remove the return line support clip from the front
frame.
Installation Notice
Tightening Torque 9 Nm (80 lb-in)
After installing the power steering fluid reservoir,
bleed the power steering system. Refer to
“Bleeding the Power Steering System” in this
section.
7. Installation should follow the removal procedure
in the reverse order.