service SSANGYONG MUSSO 1998 Workshop Repair Manual

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
5TCCU
Shift Motor
Synchronizer Clutch
Speed Sensor
Hub Solenoid
4WD
CHECK
Light
ON
OFF
Defective Code
4WD
CHECK
Light
ON
OFF
Defective Code
4WD
CHECK
Light
ON
OFF
Defective Code
4WD
CHECK
Light
ON
OFF
Defective Code
4WD
CHECK
Light
ON
OFF
Defective Code

5D1-10 TRANSFER CASE (PART TIME 4408)
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
MAINTENANCE OF TRANSFER CASE
LUBRICANT
Oil Level Check
lClean the oil level plug and surrounding area.
lRemove the oil level plug and check whether oil is drip
out or not.
lTighten the oil level plug.
Oil Change
lClean the oil level plug and surrounding area
lPlace a suitable container under the transfer case.
lRemove the oil and tighten the drain plug.
lFill the oil through the oil level plug until oil begins to
drip out.
lTighten the oil level plug.
Cautions for oil level check and plugs tightening
lDo 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 Torque 20 - 30 Nm

SECTION 5D2
TRANSFER CASE (TOD)
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D2-1
General 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
Model
Length (mm)
Weight (kg)
Shift Mode
Gear Ratio
Oil
Max. Torque
High
Low
Specification
Capacity
IntervalTOD(Torque On Demand) Transfer Case (4423E)
343.0
36.6
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 lb
·ft ( 76kg·m)
.=.
.
=.
ApplicationDescription 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 then
you 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.

TRANSFER CASE (TOD) 5D2-33
9 - 16 Vdc
6 - 16 Vdc
2 mA
1 A
7 A
20 A
Removal & Installation Procedure
1. Turn the ignition switch to "OFF" position.
2. Remove 30 pin connector from TOD control unit.
3. Unscrew 2 bolts (1).
Installation Notice
1 Bolt (M6 x 16, 2pieces)................ 9-11 Nm
2 TOD control unit
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
TOD CONTROL UNIT
TOD Electric Characteristics
Voltage
Parasitic Current
(Under max. operation Voltage)
Max. Operation Current
(Under max. operation Voltage)Normal Operation Range
CAN communication Operation Range
Ignition “OFF”
Ignition “ON”
Motor “OFF”
Motor “ON”
4. Installation should follow the removal procedure in the
reverse order.
Notice
When replace TOD control unit, it is required to make a
coding correspondent with vehicle specification.
Tightening Torque 9 - 11 Nm

5D2-40 TRANSFER CASE (TOD)
REPLACEMENT OF OIL
Oil Specification
Specified Oil Level
SpecificationStandard
Capacity
ServiceA.T.F S-3, S-4 or Dexron II, III
1.4 Litre
Inspection every 15,000km, Replacement every 50,000km=
Oil Replacement
1. Lift on vehicle then make sure on safety.
2. Prepare a vessel to drain transfer case oil.
3. Release filler plug.
4. Drain oil completely.
5. Wash drain plug and than tighten.
Installation Notice
Tightening Torque 19 - 30 Nm
6. Replenish standardized oil by specified level through filler
plug hole.
7. Tighten filler plug after washing.
Installation Notice
8. Check oil leakage.
Tightening Torque 19 - 30 Nm
.
.

5D2-48 TRANSFER CASE (TOD)
6. Install the front planet to the sun gear and input shaft.
Install the internal snap ring to the planetary carrier.
7. Place the tanged snap ring in the case. Expand snap ring
with snap ring pliers and install planetary carrier assembly.
Check installation by holding the case and carefully tapping
the face of the input shaft against a wooden block to make
sure the snap ring is installed.
8. Remove all traces of gasket sealant from the front case
and mounting adapter mating surfaces. Install a bead of
gasket sealant on the surface of the front case.
9. Install the high-low shift fork and high-low collar as an
assembly into the front planet.
Notice
Make sure that the nylon wear pads are installed on the
shift fork and snapped securely into place.
12 Rear Output Shaft
13 Oil Strainer
14 Coupling Hose
15 Hose Clamp
16 Pump Body
10. If new pump is used, align the flat of the output shaft and
the flat of the pump. Slide the pump onto the output shaft.
lDo not disassemble oil pump. It is serviced only as an
assembly. Check the pump to make sure the pump
rotates freely.
lDo not remove the plastic insert from the bore of the
new pump. Discard it after it slides out during pump
installation to the rear output shaft.
lWhile turning the output shaft, prime the pump through
the oil filter pickup tube or housing inlet hole with clean
Automatic Transmission Fluid or equivalent.
11. Inspect the outside surfaces and bore of the oil pump. If
there is no discoloration in the pump housing, gear or cover,
and the pump bore and the lube holes of the output shaft
show evidence of oil, the pump is working.

Application
Steering Wheel
Steering Gear Box
Oil Pump
Steering Column
Minmum Turning Radius
Oil
SECTION 6A
POWER STEERING SYSTEM
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6A-1
General Specifications . . . . . . . . . . . . . . . . . . 6A-1
Fastener Tightening Specifications . . . . . . . . . 6A-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Hard Steering . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Steering Pulls to One Side . . . . . . . . . . . . . . . 6A-2
Excessive Wheel Play . . . . . . . . . . . . . . . . . . . 6A-2
Poor Return of Steering Wheel . . . . . . . . . . . . 6A-2
Steering Wheel Shimmy . . . . . . . . . . . . . . . . . 6A-3
SPECIFICATIONS
GENERAL SPECIFICATIONS
Abnormal Noise From Steering System . . . . . 6A-3
Component Locator . . . . . . . . . . . . . . . . . . . 6A-4
Steering System . . . . . . . . . . . . . . . . . . . . . . . 6A-4
Maintenance and Repair . . . . . . . . . . . . . . . 6A-5
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . 6A-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Oil Pump Pressure Check . . . . . . . . . . . . . . . . 6A-6
Bleeding of Power Steering System . . . . . . . . 6A-6
Steering Gear Box . . . . . . . . . . . . . . . . . . . . . 6A-7
Number of Spoke
Outer Diameter
Type
Gear Ratio
Inner Steering Angle
Outer Steering Angle
Type
Maximum Pressure
Upper Tilting Angle
Lower Tilting Angle
Type
Capacity
Change Interval
Description
4
396 mm
Rack and Pinion
¥
33°37'
31°50'
Vane
75-82 kg/cm
2
4.646°
6.969°
5.25m
ATF DEXRON II
1 L
Every 24,000 km
FASTENER TIGHTENING SPECIFICATIONS
Application
Steering Shaft Bolt
Pressure Hose Bolt
Return Pipe Nut
Slotted Nut
Steering Gearbox BoltNlm
30 - 40
12 - 18
12 - 18
35 - 45
35 - 45

POWER STEERING SYSTEM 6A-5
MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE
INSPECTION
Steering Wheel Freeplay Inspection Procedure
1. Start the engine and set the wheels in straight ahead position.
2. Slightly move the steering wheel to the left and right and
measure steering wheel free play when the front wheel is
start to move.
Notice
If exceeds specification, the steering column shaft
connections and steering linkage .clearance. Replace or
repair if necessary.
Steering Angle Inspection Procedure
1. Place the front wheel on a measuring tool.
2. Rotate steering wheel all the way right and left and measure
steering angle
Notice
If out of standard, check or adjust toe-in.
Standard33°37'
31°50'Inner
Outer
Steering Effort Inspection Procedure
1 Place a vehicle on the paved flat ground with front wheels
in a straight ahead position.
2 Start the engine and run it at 1,000rpm.
3 Using a scale, measure the steering effort in both directions.
Notice
The difference in steering effort of left and right should be
within 0.6 kg.
StandardMax. 3.0kg
StandardMax. 30mm

SECTION 6E
STEERING WHEEL AND COLUMN
TABLE OF CONTENTS
Specification . . . . . . . . . . . . . . . . . . . . . . . . 6E-1
Fastener Tightening Specifications . . . . . . . . . 6E-1
Maintenance and Repair . . . . . . . . . . . . . . . 6E-2
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application
Steering Wheel Mounting Nut
Steering Lower Shaft Bolt
Steering Column Shaft Bolt
Steering Column Mounting BoltNlm
50 - 80
30 - 40
9 - 14
15 - 20
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 6E-2
Steering Column . . . . . . . . . . . . . . . . . . . . . . . 6E-2