tow SSANGYONG MUSSO 1998 Workshop Owner's Manual

TRANSFER CASE (TOD) 5D2-35
Removal & Installation Procedure
1. Disconnect (-) cable from battery.
2. Lift on vehicle and make sure on safety.
Notice
Be careful for catalytic converter due to high temperature
after driving or engine running.
3. Prepare a vessel to drain transfer case and manual
transmission oil.
4. Release drain plug and drain transfer case and manual
transmission oil.
If planar damper is installed, unscrew 4 bolts and remove
the planar damper.
Notice
Oil drain should be along with whole transfer case
disassembly and assembly.
5. Disconnect transmission extension wiring connector back
side transfer case.
Notice
When disconnect connector, make sure on direction of
locking tab towards inside.
6. Disconnect shift motor/clutch coil connect (Black 7 pin)
connector upper backside.
7. Disconnect front and rear speed sensor connector (white
7 pin).
8. Disconnect speedometer sensor connector right upper
side.
9. Disconnect breather tube front upper side transfer case
(upper connecting point of transfer case and front
propeller).
10. Prepare hydraulic jack and support transfer case assembly.

TRANSFER CASE (TOD) 5D2-47
Assembly Procedure
Assembly
Before assembly, lubricate all parts with Automatic Transmission
Fluid or equivalent.
1. If removed, drive the bearing into the front output case bore.
Drive the bearing in staight, making sure it is not cocked in
the bore. Install the internal snap ring that retains the bearing
to the front case.
2. If removed, install the front yoke to flange seal in the front
case bore.
3. If removed, install the yoke to flange seal into the mounting
adapter bore.
4 Sun Gear
5 Thrust Plate
6 Input Shaft
7 Thrust Washer
8 Bearing
9 External Snap Ring
10 Internal Snap Ring
4. If the input shaft needle bearing and bushing were removed,
install a new bearing and bushing as detailed in the following
steps:
Press a new needle bearing, then a new bushing in the
input shaft as follows:
a. Position the input shaft on Axle Bearing/Seal Plate or
equivalent, and Pinion Bearing Cone Replacer as a
spacer.
b. Press a new needle bearing into the end of the input
shaft until it seats in the input shaft.
c. Press in a new bushing.
5. The recessed face of the sun gear and the snap ring groove
on the bearing outer race should be toward the rear of the
transfer case. The stepped face of the thrust washer should
face toward the bearing.
Slide the sun gear, thrust plate and thrust washer into
position on the input shaft. Press the bearing over the input
shaft. Install the external snap ring to the input shaft.

TRANSFER CASE (TOD) 5D2-49
12. Install the output shaft and oil pump in the input shaft.
Make sure that the internal splines of the ouput shaft
engage the internal splines of the high-low shift collar. Make
sure that the oil pump retainer arm and oil filter leg are in
the groove and slot of the front case.
13. Install the magnet in the slot in the front case just above
the oil filter leg.
14. Install the front output shaft in the front case.
15. Install the thrust washer on the rear output shaft. Install
the chain, drive sprocket and driven sprocket as an
assembly over the output shaft.
Notice
lThe driven sprocket (on the front output shaft) must
be installed with the marking REAR facing toward the
rear case, if so marked.
lDrive sprocket has a bushing pressed into it.
16. Install tone wheel onto the front output shaft. Make sure
the spline on the tone wheel engages the spline on the
front output shaft.
17. Install clutch pack assembly onto the rear output shaft.
Make sure the spline of the clutch pack engages to the
spline of the sprocket.
18. Install snap ring onto the rear output shaft. Start the snap
ring over the spline and use the wave spring to seat the
snap ring in the snap ring groove. If the snap ring will not
install, the thrust washer inside the clutch pack may not
be seated properly.
1 2 Rear Output Shaft
1 6 Oil Pump6 1 Magnet 1 2 Rear Output Shaft
1 3 Oil Strainer
1 6 Oil Pump
16a Pump Retainer

TRANSFER CASE (TOD) 5D2-51
25. Install the pin on the tang end of the helical cam into the
hole in the front case. Position the torsion spring tangs so
that they are pointing toward the top side of the transfer
case and just touching the high-low shift fork.
CAUTION
Do not bend the helical cam during installation to the front
case because of possible damage to the pin at the tang
end of the motor shaft.
26. Install the shift rail through the high-low shift fork and make
sure that the reverse gear shift rail is seated in the front
case bore.
27. Install upper and lower speed sensors into the cover. Feed
the coil wire through the upper speed sensor wire shield.
28. Install upper tone wheel, speedometer gear and rear output
seal. Use Output Shaft Seal Replacer and Driver or
equivalent to install seal.
29. Coat the mating surface of the front case with a bead of
Black Non-Acid Cure Silicone Rubber or equivalent.
30. The following procedure must be followed prior to installing
the rear case onto the front case half:
a. Align the output shaft with the rear case output shaft bore.
b. Align the helical cam with the rear case motor bore.
If difficulty is encountered with seating the rear case, tap
the rear output shaft with a sharp blow using a rubber
mallet in a direction away from the triangular shaft while
pushing down on the rear case.
Tightening Torque 25 - 37 Nm 31. Install the bolts retaining the case halves and tighten.

6A-8 POWER STEERING SYSTEM
Tightening Torque 35 - 45 Nm
Removal & Installation Procedure
1. Remove the cotter pin and nut and separate the steering
gear box tie rod from the steering knuckle arm using the
puller.
Installation Notice
2. Remove the bolt and separate the lower sha from the
steering gear box.
Installation Notice
Tightening Torque 30 - 40 Nm
3. Remove the oil pipe from the steering gear box and drain
the oil.
Installation Notice
4. Remove the clamp bolts and remove the steering gear box
assembly.
Installation Notice
Tightening Torque 12 - 18 Nm
Notice
lBe careful not to damage the rubber(1).
lWhen installing tighten the bolt (3) with the rubber
(2)being inserted to the hole of clamp.
5. Bleed the air from system.
6. Check the toe-in.
Tightening Torque 70 - 90 Nm Tighten the bolt toward threadless side of lower shaft
coupling.

7B/C-10 MANUAL & SEMIAUTO-HVAC
REFRIGERANT CHARGING
Installation of Manifold Gauge
1. Close both high/low pressure hand valve of gauge before
installation of gauge to the charging valve.
2. Connect the low pressure hose of the gauge to the low
pressure charging valve and the high pressure hose of the
gauge to high pressure charging valve. Tighten the hose
nuts by hand.
Discharging of Refrigerant
1. Connect the manifold gauge to the charging valve.
2. Place the free end of center hose in a shop towel.
3. Slowly open the high pressure hand valve and discharge
refrigerant.
Notice
If refrigerant is allowed to escape too fast, compressor oil
will be drawn out of the system.
MAINTENANCE AND REPAIR

BODY FRONT END 9R-3
Removal & Installation Procedure
1. Remove the hood striker assembly.
Notice
When installing, tighten the bolt after setting the hole
between wratch and hood striker assembly.
Installation Notice
Tightening Toque 8 - 11 Nm
2. Remove the hood Mounting bolt and hood lifter assembly.
Installation Notice
3. Remove the hood lock, hood relese from the clip.
4. Remove the cable holder screw.
5. Pull the cable nut toward driver side.
6. Installation should follow the removal procedure in the
reverse order.
Tightening Toque 14 - 26 Nm