torque SSANGYONG KORANDO 1997 Service Repair Manual

SSANGYONG MY2002
5B-30 MANUAL TRANSMISSION
Assembly Procedure
1. Using a hydraulic press and a supporting tool,
press the counter shaft rear bearing into the case.
Be sure that the supporting tool inside of the case
should support the counter shaft.
YAD5B710
YAD5B720
YAD5B740
YAD5B730
2. Without the shim, install the retainer and counter
shaft rear bearing outer race. Tighten the 4 retainer
bolts.
Installation Notice
3. Place a dial indicator on the case and measure
counter shaft end play by moving up and down.
4. Select a shim which is the same thickness as the
indicator rearing (up to 0.004 inch) and assemble
it.
5. When the end play is correctly adjusted, remove
the counter shaft rear bearing retainer and outer
race.
6. Using a pin punch and rubber hammer, install the
reverse idler shaft, gear and O-ring.
Tightening Torque 20 Nm (15 lb-ft)

MANUAL TRANSMISSION 5B-31
SSANGYONG MY2002
7. Install the counter shaft rear bearing outer race,
shim and retainer.
Installation Notice
Notice: Using a punch and hammer, bend the lock
tabs on the retainer.
YAD5B750
YAD5B760
YAD5B770
8. Install the following parts :
Install the main shaft into case.
Install the main shaft rear bearing outer race
into the rear of the case.
Install the 4th speed blocking ring onto the front
of the main shaft.
Install the input shaft onto the front of the main
shaft.
Install the input bearing retainer without shim
onto the front of the case.
Using a torque wrench, tighten the 4 bolts.
Installation Notice
9. Install the 5th speed drive gear and blocking ring
on the counter shaft.
10. Install the 5th synchronizer and rail/fork.
11. Install the 5th synchronizer snap ring and oiling
funnel.
Tightening Torque 20 Nm (15 lb-ft)
Tightening Torque 20 Nm (15 lb-ft)

SSANGYONG MY2002
5B-32 MANUAL TRANSMISSION
12. Align the slots of the lever with the rollers of the
reverse fork and 5th shift rail. Apply sealer on the
5-R lever pivot bolt and install it into the case.
Installation Notice
13. Using a needle nose pliers, install the 5-R lever
clip.
YAD5B780
YAD5B790
YAD5B810
YAD5B800
14. Using a needle nose pliers, install the reverse fork
spring to its pin inside the case. Check the
operation of the 5-R shift mechanism at this time.
15. Using a snap ring piers, install the slip yoke snap
ring onto the end of the main shaft.
16. Make sure that the 1-2 and 3-4 synchronizer
sleeves and 5-R shift lever are in neutral position.
17. Align the holes the case and cover with alignment-
type bolts. Tighten the 10 bolts.
Installation Notice
18. Apply RTV sealant on the sealing surface of the
extension housing.
19. Apply grease on the detent/guide plate in the
extension housing. Install the detent ball in the 3-
4 position.
Tightening Torque 28 Nm (21 lb-ft)
Tightening Torque 15 Nm (11 lb-ft)

CLUTCH 5C-7
SSANGYONG MY2002
Removal & Installation Procedure
Tools Required
602589 00 40 00 Engine Lock
1. Remove the starter motor. Install the special tool
to the flywheel through the starter motor mounting
holes.
2. Unscren the release cylinder mounting bolts and
remove the release cylinder.
Installation Notice
3. Unscrew the clutch housing bolts and remove the
clutch housing, release fork and release bearing.
Installation Notice
4. Insert the centering pin into the clutch spline.
Loosen the clutch cover bolts 1/2 turn in crisscross
sequence until the spring tension is released.
Notice: Do not remove the bolts at a time, or
clutchcover can be damaged or deformed.
Tools Required
Centering Pin 661 589 00 15 00
KAA5C050
KAA5C060
KAA5C070
KAA5C080
Tightening Torque15 - 18 Nm
(11 - 13 lb-ft)
Tightening Torque 54 Nm (40 lb-ft)

SSAMGYONG MY2002
5C-8 CLUTCH
5. Unscrew the bolts and remove the clutch cover,
pressure plate and clutch disc.
Notice: Be careful not to drop the pressure plate
and clutch disc.
Installation Notice
6. Installation should follow the removal procedure
in the reverse order.
Notice:
Before installation, clean oil and grease on the
flywheel surface.
Do not clean the clutch disc and release bearing
in solvent.
2. Clutch Disc
Check the facing for rivet looseness, excessive
runout, sticks, oil and grease.
Measure the rivet head depth.
If out limit, replace the disc.
Inspection Procedure
1. Clutch Cover
Check the diaphragm spring tip for wear and
height unevenness.
Check the pressure plate surface for wear, crack
and discoloration.
Check the strap plate rivet for looseness and
replace the clutch cover if loosened.
KAA5C090
KAA5C100
KAA5C110
Tightening Torque21 - 27 Nm
(15 - 20 lb-ft)
Wear Limit 0.3 mm
Unevenness Limit 0.8 mm

CLUTCH 5C-11
SSANGYONG MY2002
Removal & Installation Procedure
1. Draw out the fluid.
2. Pull out the snap pin and clevis pin from the clutch
pedal connection.
3. Remove the clutch tube.
Installation Notice
Notice: Be careful not the fluid contact a painted
surface.
4. Remove the master cylinder mounting nuts and
pull off the master cylinder.
Installation Notice
5. Check the clutch pedal operation.
6. Bleed the clutch system.
KAA5C140
Tightening Torque15 - 18 Nm
(11 - 13 lb-ft)
Tightening Torque8 - 18 Nm
(6 - 13 lb-ft)

SECTION 5D1
TRANSFER CASE (TOD)
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 this cable
will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless
other-wise noted.
TABLE OF CONTENTS
Description and Operation.................................5D1-2
Torque on Demand (TOD) System
Transfer Case.................................................5D1-2
Transfer Case Control Unit (TCCU).....................5D1-2
TCCU Coding....................................................5D1-2
Pin Description..................................................5D1-3
Components of the TOD Transfer Case System ..5D1-4
Definition of Terminology....................................5D1-4
Operation of the TOD Transfer Case System......5D1-4
Component Locator...........................................5D1-7
Torque on Demand (TOD) Type Transfer Case....5D1-7
Transfer Case Disassembled View.....................5D1-8
TOD Control Unit..............................................5D1-10
Diagnosis..........................................................5D1-11
Self-Diagnostic Tests.......................................5D1-11
Diagnostic Trouble Codes (DTCs)....................5D1-12
Clearing Diagnostic Trouble Codes..................5D1-12
4WD Check Indicator Stays on with Ignition
Switch ON....................................................5D1-14
4WD Low Indicator Stays on with Ignition
Switch ON....................................................5D1-16
No 4WD Check or 4WD Low Indicator with
Ignition Switch ON........................................5D1-18
4WD Low Indicator Blink Steadily.....................5D1-20
TCCU Diagnostic System Check......................5D1-21
DTC 1714 Eeprom Checksum Fault..................5D1-22
DTC 1715 Tp Sensor Loss of Signal.................5D1-24
DTC 1716 Tp Sensor Out of Range...................5D1-26
DTC 1721 Electromagnetic Clutch Open / Short
to Battery.....................................................5D1-28
DTC 1722 Electromagnetic Clutch Short to
Ground.........................................................5D1-32
DTC 1731 Front Speed Sensor Voltage Low......5D1-36
DTC 1732 Front Speed Sensor Voltage High.....5D1-38DTC 1733 Rear Speed Sensor Voltage Low......5D1-40
DTC 1734 Rear Speed Sensor Voltage High.....5D1-42
DTC 1735 Speed Sensor Reference Voltage
Low ..............................................................5D1-44
DTC 1736 Speed Sensor Reference Voltage
High.............................................................5D1-46
DTC 1741 Motor Output Open / Shorted
to Battery.....................................................5D1-48
DTC 1742 Motor Output Shorted to Ground......5D1-52
DTC 1743 Shift System Timeout.......................5D1-55
DTC 1750 General Position Encoder Fault
(Invalid Code)...............................................5D1-56
DTC 1751 Position 1 Shorted to Ground............5D1-58
DTC 1752 Position 2 Shorted to Ground............5D1-60
DTC 1753 Position 3 Shorted to Ground............5D1-62
DTC 1754 Position 4 Shorted to Ground............5D1-64
Repair Instructions............................................5D1-66
On-Vehicle Service.............................................5D1-66
Oil Replacement..............................................5D1-66
Transfer Case Control Unit (TCCU)...................5D1-67
Transfer Case..................................................5D1-67
Shift Motor.......................................................5D1-69
Front and Rear Propeller Shaft Speed Sensor ...5D1-70
Unit Repair........................................................5D1-71
Transfer Case Overhaul...................................5D1-71
Specifications...................................................5D1-79
General Specification.......................................5D1-79
TCCU Electric Characteristics..........................5D1-79
Fastener Tightening Specifications...................5D1-79
Schematic and Routing Diagram....................5D1-80
TOD Transfer Case Control Unit (TCCU)............5D1-80
Special Tools and Equipment..........................5D1-82
Special Tool Table ...........................................5D1-82

SSANGYONG MY2002
5D1-4 TRANSFER CASE
COMPONENTS OF THE TOD
TRANSFER CASE SYSTEM
Shift Motor
It locates backside transfer case, which drives rotary
helical cam. When mode select switch changes to 4L,
shift fork is on position for 2.48 : 1 by rotation of helical
cam.
Rear Speed Sensor
A hall effect speed sensor which produces a square
wave. 0 to 5 volts direct current signal in response to
a rotating 30-tooth wheel coupled to the rear propeller
shaft inside the transfer case. Each rotation of the rear
propeller shaft will result in 30 speed sensor pulse.
Front Speed Sensor
A hall effect speed sensor which produces a square
wave. 0 to 5 volts direct current signal in response to
a rotating 30-tooth wheel coupled to the front propeller
shaft inside the transfer case. Each rotation of the front
propeller shaft will result in 30 speed sensor pulse.
Electro-Magnetic Clutch
An electromagnetic clutch used to control the amount
of torque applied to the front propeller shaft.
Position Encoder
A set of 4 gray code switches which provide feedback
to the TCCU indicating the position of the shift motor.
Clutch Pedal Position Switch
A switch on vehicles equipped with a manual transmis-
sion which indicates that the clutch pedal is depressed
Park/Neutral Position Switch
A switch on vehicles equipped with an automatic trans-
mission which indicates that the transmission is in neu-
tral.
4H/4L Switch
A switch selects the desired gear ratio.
DEFINITION OF TERMINOLOGY
Shift Inhibit Speed
The vehicle speed limit, which transfer case shifts, is
disallowed. Vehicle speed is indicated by propeller
shaft speed measurement.
Duty Cycle
Duty cycle is the time the electromagnetic clutch is on
divided by the period in which it is being modulated.
Touch-off
A minimum amount of duty cycle applied to the electro
magnetic clutch.
Front Overrun
A condition where the front propeller shaft is turning at
a rate which is faster than the rear propeller shaft.
Rear Overrun
A condition where the rear propeller shaft is turning at
a rate which is faster than the front propeller shaft.
High Range
The highest (numerically lowest = 1 : 1) gear ratio be-
tween the input and outputs of the transfer case.
Low Range
The lowest (numerically highest = 2.48 : 1) gear ratio
between the input and outputs of the transfer case.
OPERATION OF THE TOD
TRANSFER CASE SYSTEM
Initial Operation of TOD Control Unit
When ignition switch is turned to ON, 4WD LOW and
4WD CHECK lamp illuminates for 0.6 second to check
bulb in instrument panel, then perform diagnosis of
system. Refer to “Self-Diagnosis Test” in this section.
Electric Shift System Operation
The electric shift system is responsible for changing
the transfer case gear ratio by controlling the electric
shift motor. The TCCU monitors the 4H/4L switch, park/
neutral position switch, speed sensors, position
encoder, and ignition switch.
A range change is initiated when:
The 4H/4L switch is changed from 4H to 4L or from
4L to 4H.
The motor position (as indicated by the position
encoder) does not match the 4H/4L switch
immediately after the ignition is turned on.
Shift Criteria
When a range change is initiated a diagnostic test will
be completed on the motor, speed sensors, and
position encoder. If the diagnostic test fails, the shift
will not be attempted. If all components are operating
properly, the TCCU will attempt a range change after
the following shift criteria are met:
The transmission is in neutral for 2 seconds after
the shift is requested.
Both propeller shaft speeds are below 87 rpm (2580
pulses/minute). If the transmission is taken out of
neutral before 2 seconds has passed, or either
propeller shaft speed increases above the limit, the
shift will be suspended and the 4L indicator will
continue to blink until the criteria are met again or
the 4H/4L switch is returned to the original position.
Range Change
When the shift criteria are met, the motor is rotated in
the appropriate direction (as determined by the selector
switch) until one of the following occurs:

TRANSFER CASE 5D1-5
SSANGYONG MY2002
The motor reaches its destination.
The motor is on for 5 seconds without reaching its
destination. The shift has failed and the TCCU will
respond as default mode.
A fault occurs with either the motor or position
encoder. Refer to the diagnosis requirement.
When the motor is energized, the Ignition, 4H/4L
switch, propeller shaft speeds, and transmission
neutral inputs are ignored.
Indicator Function
Once a range change has been initiated the 4WD LOW
indicator will begin to blink at a rate of 0.3 seconds
on, 0.3 seconds off until the shift is completed or
canceled. If a successful shift has been completed,
the 4WD LOW indicator will be illuminated if the motor
is in low range and it will be turned off if the motor is in
high range.
4WD LOW indicator illuminates as below figure.
KAA5D000
TODTM System Operation
The TODTM System is responsible for distributing torque
between the front and rear axles. The TCCU monitors
the propeller shaft speeds, operating range (high/low),
and ABS activity and then applies a calculated amount
of torque to the front axle by pulse width modulating
(PWM) the current applied to the electromagnetic clutch
(EMC).
Touch-off Torque
The minimum EMC duty cycle is based on the vehicle
speed and throttle position. The TCCU receives the
throttle position (TP) sensor signal from the engine con
trol module (ECM) through CAN bus line.
Wheel Slip Detection and Control
The TCCU continuously monitors the front and rear pro-
peller shaft speeds to detect wheel slip.
When wheel slip is detected the TCCU controls the
EMC duty cycles as necessary until the wheel slip is
reduced below the allowable limit. The EMC duty cycle
will then be reduced to the touch-off value.Brake/ABS Strategy
When the ABS System is active, the EMC duty cycle
is set to a fixed duty cycle (30%) to aid in braking
without counteracting the ABS System.
4L Strategy
When the system is operating in 4WD low range, the
TCCU continues TOD
TM operation provided that the pro
peller shaft speed is below 175 rpm (5220 pulses/min-
ute). When the speed increases above 175 rpm, the
EMC duty cycle is set to the maximum value (88 %)
which applies the maximum available torque to the front
axle.
Position Encoder
The position encoder is used by the TCCU to determine
the position of the shift motor. Each motor position is
identified by a position code as shown.
Motor Position
Left Stop
Left of High
High
Right of High
Zone 1
Neutral
Zone 2
Low
Right Stop Position code 1/2/3/4
1111
1010
0010
0000
1110
1001
0001
0101
0100
Notice:
All other position codes are invalid
Position input : open circuit (> 4.5V) = 1
Position input : Shorted to speed/position return
(< 0.5V) = 0
Position Sensor Interpretation
1. When the module powers up, it will read the position
sensor and the 4H/4L switch input and respond to
the possible codes as following tables.
2. A command to shift will only be acted upon if the
TCCU is reading a valid code at the time the com-
mand to shift is made.
3. After a shift has started, the TCCU will power the
shift motor until the code for the requested position
is read. If an invalid code is read, the TCCU will go
into a default mode.
4. During a shift attempt, the shift motor will be ener-
gized for a maximum of 5 second

TRANSFER CASE 5D1-7
SSANGYONG MY2002
COMPONENT LOCATOR
TORQUE ON DEMAND (TOD) TYPE TRANSFER CASE
KAA5D010
1 Transmission
2 Transfer Case
3 Rear Propeller Shaft
4 Bolt5 Bolt
6 Front Propeller Shaft
7 Bolt