lock SSANGYONG MUSSO 1998 Workshop Repair Manual

5C-6 CLUTCH
COMPONENT LOCATOR
CLUTCH ASSEMBLY
1 Clutch Disc
2 Clutch Cover
3 Clutch Housing
4 Release Bearing
5 Release Fork Pivot
6 Release Cylinder
7 Release Fork Boot8 Bolt
9 Release Fork
1 0 Bolt
11 Spring Lock Washer
12 Transmission Input Spline
13 Release Bearing Contacting Surface
14 Contacting Point of Release Fork and Pivot
Notice
Apply the long-term grease (DBL 6811.00) to No.12,13 and 14.

CLUTCH 5C-9
CLUTCH DISC
Preceding Work : Removal of the transmission
1 Clutch Disc
2 Clutch Cover Assembly
3 Release Bearing
4 Clutch Housing
Tools
602 589 00 40 00 Engine Lock
661 589 00 15 00 Centering Pin5 Washer
6 Bolt........................................................... 23 Nm
7 Washer
8 Bolt........................................................... 44 Nm

5C-10 CLUTCH
Removal & Installation Procedure
1. Remove the starter motor. Install the special tool to the
flywheel through the starter motor mounting holes.
Tightening Torque
47 Nm
Engine Lock 602 589 00 40 00
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.
Centering Pin 661 589 00 15 00
Tightening Torque
30 - 40 Nm

CLUTCH 5C-13
MASTER CYLINDER
1 Snap Pin
2 Clevis Pin
3 Clevis
4 Lock Nut
5 Flange Nut...........................................30-40 Nm
6 Push Rod
7 Cylinder Body
8 Oil Pipe................................................15-18 Nm9 Clamp
10 Reservoir
11 Spring
12 Piston Assembly
13 Boot
14 Plate
15 Snap Ring
Notice
Do not disassemble the No.12.

CLUTCH 5C-15
CLUTCH PEDAL
1 Snap Pin................................................ Replace
2 Clevis Pin......................................Apply Grease
3 Master Cylinder Push Rod
4 Gasket
5 Nut .......................................................16-22 Nm
6 Spring washer
7 Bolt........................................................8-18 Nm
8 Fulcrum Pin9 Turn Over Spring..........................Apply Grease
10 Bushing .........................Replace, Apply Grease
11 Full Stroke Stopper Contact Pad
12 Clutch Pedal
13 Pedal Pad
14 Pedal Mounting Bracket
15 Stopper Bolt..........................................21-25Nm
16 Clutch Interlock Switch
Notice
Assembly should follow the disassembly procedure in the reverse order.
Grease specification : Long - term grease (T/Mn DBL6611.00)

5C-16 CLUTCH
Inspection Procedure
1. Pedal Stroke (A).
Notice
To adjust the pedal stroke, loosen the lock nut (H) of the
interlock switch (G) and turn the two lock auto until the stroke
is correct.
Max. Stroke 158 mm
2. Pedal Height (B).
Notice
To adjust the pedal height, loosen the lock nut (C) of the
stopper bolt(D) and turn the stopper bolt until the height is
correct.
Height (From the Floor Carpet) 147 - 187 mm
3. Pedal Free Play (E).
Notice
To adjust the pedal free play, loosen the lock nut (F) of the
master cylinder and turn the push rod until the free play is
correct.
4. Check the fulcrum pin and the bushing for wear, the pedal
for bending and the spring for damage.
Free Play 5 - 10 Nm

Model
Type
Gear Ratio
Oil
Manufacturer
WeightPart-Time 4408 (E)
E.S.O.F. Type
1 : 1
2.48 : 1
ATF S-3, S-4 or DEXRON II, III
1.2 L
Check : Every 15,000 km
Replace : Every 50,000 km
Borg Warner
30 kg
SECTION 5D1
TRANSFER CASE (PART TIME 4408)
TABLE OF CONTENTS
SPECIFICATIONS
GENERAL SPECIFICATIONS
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 otherwise noted.
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D1-1
General Specifications . . . . . . . . . . . . . . . . . 5D1-1
Schematic and Routing Diagram . . . . . . . . 5D1-2
Part Time Transfer Case - 4408 . . . . . . . . . . 5D1-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . 5D1-3
Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . 5D1-4
System Description . . . . . . . . . . . . . . . . . . . . 5D1-4
Self-Diagnosis Test . . . . . . . . . . . . . . . . . . . . 5D1-8Diagnostic Diagram . . . . . . . . . . . . . . . . . . . 5D1-9
Maintenance and Repair . . . . . . . . . . . . . 5D1-10
On-Vehicle Service . . . . . . . . . . . . . . . . . . . 5D1-10
Maintenance of Transfer Case Lubricant . . 5D1-10
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-11
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . 5D1-14
Transfer Case Control Unit (TCCU) . . . . . . 5D1-36
High
Low
Specification
Capacity
Lubrication ApplicationDescription

TRANSFER CASE (PART TIME 4408) 5D1-15
1 Nut
2 Spring Washer
3 Oil Seal
4 Companion Flange
5 Snap Ring
6 Torsional Damper
7 Pipe Plug
8 Bolt
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 Tag
21 Decal
22 Wiring Harness Clip
23 Bolt
24 Cover Assembly
2 5 Nut
26 Snap Ring
27 Bearing
28 Needle Bearing
29 Cover
30 Clutch Coil Assembly
31 Speed Gear
32 Oil Seal
33 Return Spring
34 Magnet
35 Clutch Housing36 Lock-up Assembly
37 Snap Ring
38 Lock-up Hub
39 Sleeve Return Spring
40 Lock-up Collar
41 Rail Shaft
42 Lock-up Fork
43 Snap ring
44 Spacer
45 Driven Sprocket
46 Driven Sprocket
47 Drive Chain
48 Shaft and Pump Assembly
49 Screw
50 Pump Housing
51 Pump Gear Set
52 Pump Cover
53 Spring Pin
54 Hose Clamp
55 Hose Coupling
56 Oil Strainer
57 Output Shaft
58 Reduction Hub
59 Shift Fork Assembly
60 Shift Fork Facing
61 Pin, Roller and Retainer
62 Pin
63 Cam Roller
64 Retainer
65 Reduction Shift Fork
6 6 Nut
67 Plane Washer
68 Oil Seal
70 Companion Flange
71 Spacer
72 Front Output Assembly73 Breather Hose
74 Bolt
75 Front Adapter Assembly
76 Snap Ring
77 Oil Seal
78 Spiral Pin
79 Front Adapter
80 Snap Ring
81 Bearing
82 Input Shaft Assembly
83 Sleeve Assembly
84 Needle Bearing
85 Input Shaft
86 Thrust Washer
87 Retaining Ring
88 Thrust Plate
89 Sun Gear
90 Gear Carrier Assembly
91 Planet Carrier
92 Pinion Shaft
93 Thrust Washer
94 Pinion Gear
95 Needle Roller Bearing
96 Pinion Needle Spacer
97 Electric Shift Cam
98 Torsion Spring
99 Spacer
100 Shift Shaft
101 Case Assembly
102 Oil Seal
103 Snap Ring
104 Bearing
105 Dowel Pin
106 Ring Gear
107 Case

5D1-18 TRANSFER CASE (PART TIME 4408)

1. Remove the retaining ring and clutch housing from the shift
collar hub.
2. Remove the shift collar hub from the output shaft.
3. Separate the 2WD - 4WD lock-up assembly and lock-up
fork from the output shaft and remove the rail shaft.
4. To remove the 2WD - 4WD lock-up assembly, separate the
return spring, lock-up hub and snap ring from the lock-up
collar.
30 Retaining Ring
31 Clutch Housing
32 Shift Collar Housing
33 2WD/4WD Lock-up Assembly
34 Snap Ring
35 Lock-up Hub
36 Return Spring
37 Lock-up Collar
38 Rail Shaft
39 Lock-up Fork
55 Output Shaft
40 Snap Ring
41 Spacer
42 Drive Sprocket
43 Driven Sprocket
44 Drive Chain
55 Output Shaft(Rear)
71 Output Shaft(Front)

1. Remove the snap ring and spacer from the output shaft.
2. Remove the drive chain, driven sprocket and drive sprocket
from the output shaft.
3. Separate the chain and sprocket when removing the
assembly.

1. Remove the 4 bolts and retainer and separate the output
shaft and rear pump cover.
2. Loosen the hose clamp and remove the hose coupling from
the pump housing.
3. Remove the hose clamp, hose coupling and strainer.
4. Remove 2 pump pins and spring from the output shaft.
5. Separate the front pump and remove the output shaft.
45 Shaft and Pump Assembly
46 Bolt
47 Pump Retainer
48 Rear Pump Cover
49 Hose Clamp
50 Hose Coupling
51 Pump Housing
52 Pump Pin
53 Spring
54 Front Pump Cover
55 Output Shaft
56 Strainer

TRANSFER CASE (PART TIME 4408) 5D1-31
Lockup Shift
1. Install the lockup hub and return spring to the lockup collar
and insert the snap ring.
2. Install the rail shaft through reduction shift fork assembly
previously installed and into the blind hole in case.
3. Engage the lockup fork into the 2WD/4WD groove and
check operation.
4. Install the shift collar hub to the output shaft spline.
5. Install the previously assembled electric shift cam and
assemble the clutch housing as follows.
lRotate the shift cam assembly to right so that the end of
the torsion spring contacts with reduction shift fork side.
lHolding the rail shaft, lift up the fork assembly slightly.
Adjust electric shift cam assembly so that the roller on
reduction shift fork assembly is in groove in shift cam
and button on lockup fork is on cam end.
lInstall the clutch housing over shift collar hub and insert
the retaining ring into the clutch collar hub groove.
30 Retaining Ring
31 Clutch Housing
32 Shift Collar Housing
33 2WD/4WD
Lockup Assembly
34 Snap Ring
38 Rail Shaft
39 Lockup Fork
59 Reduction Shift Fork Assembly
100 Electric Shift Cam
101 Torsion Spring35 Lockup Hub
36 Return Spring
37 Lockup Collar
38 Rail Shaft
39 Lockup Fork
55 Output Shaft