torque SSANGYONG MUSSO 2003 Service Manual

TRANSFER CASE (PART TIME 4408) 5D1-33
4. Install the cover onto the transfer case as follows : Align the cover bores with transfer case pins.
Align the cover bearings with output shafts.
Align the cover blind hole with rail shaft and make sure that return spring is not cocked.
29 Return Spring
38 Rail Shaft
55 Output Shaft
71 Front Output Shaft
103 Shift Shaft
109 Dowel Pin
Cover Assembly
14 Bolt
15 Wiring Clip
16 Identification Tag
17 Cover Assembly
2 6 Magnet
27 Speed Gear
28 Oil Seal
29 Return Spring
38 Rail Shaft
111 Case
1. Install the return spring over rail shaft in the transfer case.
2. Insert the magnet into the transfer case slot.
3. Apply 1.6mm bead of Loctite RTV 598 to the transfer case
mounting surface.Notice
For installation of cover, align the transfer case with cover not to use excessive force.
13 Motor Assembly
14 Bolt
15 Wiring Clip
16 Identification Tag
5. Tighten 9 bolts positioning identification tag and wiring clip.
6. Install the speed gear over output shaft spline in the cover
assembly.
7. Press the new oil seal into the cover assembly.
Tightening Torque 28 - 48 Nm

5D1-34 TRANSFER CASE (PART TIME 4408)
External Electric Shift
1. Align the motor with shift shaft and position the motorassembly onto the cover.
2. Install the motor to the shift shaft and contact cover androtate the motor clockwise direction to check correctengagement.
6 Bolt
7 Washer
8 Bolt
9 Sensor and Harness Bracket
10 Sensor Assembly
14 Speed Sensor
12 O-ring
13 Motor Assembly
2 5 Cover
13 Motor Assembly
103 Shift Shaft
3. Insert the 0-ring on the speed sensor speed sensor
assembly to the cover.
4. Install the bracket to the motor assembly and tighten 3bolts.
Tightening Torque 8 -11 Nm

TRANSFER CASE (PART TIME 4408) 5D1-35
Companion Flange
1. Install the 2 plugs to the cover.
2. Install the companion flange, oil seal and washer.
3. Holding the companion flange, tighten the nut.1 Nut
2 Washer
3 Oil Seal
4 Companion Flange
5 Plug
2 5 Cover
Notice Apply Loctite 262 to nut before installation.
Tightening Torque 346 - 380 Nm

SECTION 5D2
TRANSFER CASE (TOD)
Specifications . . . . . . . . . . . . . . . . . . . . . . . 5D2-1General 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
ModelLength (mm)Weight (kg)Shift ModeGear Ratio Oil
Max. Torque
High Low SpecificationCapacityInterval TOD(Torque On Demand) Transfer Case (4423E)
343.036.6
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 lbft ( 76kg m)
.
= .
.
= .
Application Description
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

5D2-4 TRANSFER CASE (TOD)FUNCTION DESCRIPTION
TOD System Select Mode (4H and 4L) 4H is the mode when drive normally of which gear ratio is 1:1 and 4L mode distributes power to front and rear wheels 50:50 of which gear ratio is 2.48:1.
TOD System Function (select 4H mode) TOD system controls clutch mechanism to comply with rotation in front and rear propeller shaft and if its difference exceeds the permissible range, corresponding power is distributed into front wheel through EMC (Electro-MagneticClutch). Hall effect sensor signals speed on front and rear propeller shafts going through with TOD control unit.
Transfercase clutch coil is activated by variable current on exceeding difference of speed in front and rear propeller shafts.
Function of 4L Mode When select 4L mode, EMC is locked to apply maximum torque into front and rear propeller shafts. Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from 1:1 to 2.48:1 by planetarygear set.
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.
Transfer Case
TOD transfer case distributes power into front and rear axle by operation of 4H/4L switch and shift motor. Shifting 4H to 4L, is performed towards reducing HI-LO collar by means for connection HI-LO shift fork with
output shaft in order to join with planetary gear. Torque transmits input shaft then sun gear rotating front planetary
gear. Front planetary gear join with output shaft and drives LO position.

TRANSFER CASE (TOD) 5D2-5
Definitions
Rear Speed Sensor A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal inresponse to a rotating 30 tooth wheel coupled to the rear propshaft inside the
Transfer Case. Each rotation of the rear propshaft will result in 30 speed sensor pulse.
Front Speed Sensor A Hall Effect speed sensor which produces a square wave. 0-5Vdc signal in response to a rotating 30 tooth wheel coupled to the front propshaft inside the
Transfer Case. Each rotation of the front propshaft will result in 30 speed sensor pulse.
EMC An Electromagnetic clutch used to control the amount of torque applied to the front propshaft.
TOD TM
Torque on DemandTM
.
Duty Cycle Duty Cycle is the time the EMC is on divided by the period in which it is being modulated.
Touch-off A minimum amount of duty cycle applied to the EMC.
Front OverrunA condition where the front propshaft is turning at a rate which is faster than the rear propshaft.
Rear Overrun A condition where the rear propshaft is turning at a rate which is faster than the
front propshaft.
High Range The highest (numerically lowest = 1 :1) gear ratio between the input and outputsof the Transfer Case.
Low Range The lowest (numerically highest = 2.48:1) gear ratio between the input and outputs
of the Transfer Case.
4H/4L Switch A switch which selects the desired gear ratio.
Shift Motor Electric motor which changes the Transfer Case range.
Position Encoder A set of 4 Gray code switches which provide feedback to the TCCU indicating theposition of the Shift Motor.
Clutch Interlock Switch A switch on vehicles equipped with a manual transmission which indicates that the clutch pedal is depressed.
Neutral Safety Switch A switch on vehicles equipped with an automatic transmission which indicatesthat the transmission is in neutral.
Shift Inhibit Speed The vehicle speed above which Transfer Case shifts are disallowed. Vehicle speedis indicated by propshaft speed measurement.

TRANSFER CASE (TOD) 5D2-11
4. Electric Shift Default ModeIf the motor fails to reach its destination, the TCCU will attempt the following (in order):
a. The TCCU will wait 3 seconds then attempt the shift again.
b. If the second attempt to reach the destination fails the TCCU will wait 3 seconds then attempt to rotate the motor back to the original position. If successful, all future shifts will be inhibited until the Ignition is cycled.
c. If the attempt to return to the original position fails, the TCCU will wait 3 seconds then attempt to rotate the motor to the original position again. If the second attempt to return to the original position is successful, the “4WD CHECK ” lamp will be illuminated, and all future shifts will be inhibited until the Ignition is cycled.
d. If the second attempt to return to the original position fails the motor will be turned off, the “4WD CHECK ” lamp
will be illuminated, and all future shifts will be inhibited until the Ignition is cycled.
TOD TM
System Operation
The TOD TM
System is responsible for distributing torque between the front and rear axles. The TCCU monitors the
propshaft speeds, operating range (High/Low), and ABS activity and then applies a calculated amount of torque tothe front axle by Pulse Width Modulating the current applied to the EMC.
1. Touch-off Torque
The minimum EMC Duty Cycle is based on the vehicle speed and throttle positionThe TCCU receives the TPS signal from the following sources:On vehicles equipped with CAN, the TCCU receives the TPS signal from the CAN bus.
2. When Slip Detection
The TCCU continuously monitors the front and rear propshaft speeds to detect wheel slip.
3. Wheel Slip Control When wheel slip is detected the TCCU controls the EMC duty cycle 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.
4. 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.
5. 4L Strategy When the system is operating in 4L, the TCCU continues TOD TM
(operation provided that the propshaft speed is
below 175 rpm (5220 pulses/minute)). When the speed increases above 175 rpm, the EMC Duty Cycle is set tothe maximum value (88%) which applies the maximum available torque to the front axle.

TRANSFER CASE (TOD) 5D2-33
9 - 16 Vdc 6 - 16 Vdc2 mA1 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 CharacteristicsVoltage 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

5D2-36 TRANSFER CASE (TOD)
11. Unscrew 4 units of M12 bolts from case flange thendisconnect front propeller shaft from transfer case. Installation Notice
Tightening Torque 81 - 89 Nm
12. Unscrew 4 units of M12 bolts from case flange then disconnect rear propeller shaft from transfer case. Installation Notice
13. Unscrew 5 units of mounting bolt (M12) from extension housing in transmission.Installation Notice
Tightening Torque 81 - 89 Nm
Tightening Torque 35 - 60 Nm
Notice Make sure the connecting surface is clean.Applying long-life grease spline inside transfer case input shaft.
14. Installation should follow the removal procedure in the reverse order.

TRANSFER CASE (TOD) 5D2-37
Replacement of Shift Motor
1. Disconnect (-) cable from battery.
2. Disconnect shift motor/clutch coil connector (black pin7)upper backside.
3. Unscrew 3 units of shift motor mounting bolts (M10).
4. Unscrew 1unit of bracket mounting bolt (M10). Installation Notice
Tightening Torque 9 - 11 Nm
Notice When disconnecting shift motor and mounting bracket, it is required to unscrew 2 units of adjusting bolts (M10) formmotor and bracket.
5. Keep shift motor even then pull rearward.
6. Clean connection surface of transfer case and shift motor.
7. If necessary, make a test by SCANNER with shift motor assembly.Notice
Do not disassemble shift motor. If necessary, replace by shift motor assembly unit.
8. Applying sealant into connecting surface for new shift motor.
9. Installation should follow the removal procedure in the reverse order. Before installation, make sure that motor position match with mode of 4H/4L switch. ReferenceWhen accord position of motor with 4H/4L switch and transfer case match position of the disconnected motor and newone.