wiring SSANGYONG MUSSO 2003 Owner's Guide

AUTOMATIC TRANSMISSION 5A-123
23. Holding the separator plate to the upper valve body toprevent the check balls from falling out, install the upper
valve body on the lower valve body. Install all screws finger tight then tighten the screws to specification in the
prescribed sequence. Refer to figure 8.58.
24. Install solenoids 1,2,3,4 and 6. Ensure the solenoid is firmly secured by the retainer and that the screw is tightened to specification.
25. Install solenoid 5. Ensure that the solenoid is pushed firmly into the valve body by the retainer. NoticeThe wiring loom ground wire eyelet terminal is secured
beneath the solenoid retainer.
26. Install the line pressure relief valve, tapered end first, (refer to figure 8.59), and the spring and disc. Secure with theretaining pin.
Figure 8.58 - Tightening Sequence Upper to Lower Valve Body
Figure 8.59 - Line Pressure Relief Valve

5A-124 AUTOMATIC TRANSMISSION
27. Install the line pressure plug and tighten to specification.Refer to figure 8.62.
28. Install the detent spring assembly (spring, support plate and screw), ensuring that the screw is tightened to
specification. Check the spring for wear or damage.
29. Install the manual shift valve. Refer to figure 8.60. Notice Be aware that the manual valve will fall out of the valve
body.
Figure 8.62 - Wiring Installation
Figure 8.60 - Manual Shift Valve

AUTOMATIC TRANSMISSION 5A-125
30. Align the valve body assembly on the transmission caseand install the manual valve lever to manual valve link. Fit
the long end of the link to the manual valve first. Install the
securing bolts and tighten to specification in the specified
sequence. Refer to figure 8.61.
31. Check the alignment of the detent roller and the manual lever quadrant.
32. Connect the solenoid wiring as detailed below: Solenoid 1 - red
Solenoid 2 - bIue
Solenoid 3 - yellow
Solenoid 4 - orange
Solenoid 5 - green
Solenoid 6 - violet (Refer to figure 8.62.)
Notice All hardware must be correctly installed and torqued to specification.
Figure 8.61 - Tightening Sequence Valve Body to Case

MANUAL TRANSMISSION 5B-15
Removal & Installation Procedure
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug from the transmission housing anddrain the oil. Reinstall the drain plug.Installation Notice
Tightening Torque 25 Nm
4. Disconnect the back-up switch connector.
5. Remove the breather hose.
6. Remove the speedometer connector and other wiring harnesses and connectors.

TRANSFER CASE (PART TIME 4408) 5D1-3
Cannot Front Wheel Drive when Shifted 4H,4LDIAGNOSIS
Electric Shift Problems
Action
Overhaul and check, replace if necessary. Overhaul and check for wear and damage.
Replace if necessary.
Check sliding parts, replace if necessary.
Checks
Faulty or Damaged TCCU, Speed Sensor, Motor, Clutch or Internal Wirings Damaged or Worn Shift Cam, Hub, Fork and Rail Shift Binding Shift Fork, Hub Collar or Gear
Checks
Broken Drive Chain Action
Check sliding parts, replace if necessary.
Noise in 4WD Operation
Checks
Improper or low oil Loosened bolts or mounted partsNoisy T/C bearing Noisy gears Action
Drain and replace with specified oil. Retighten as specified.Disassemble bearings and parts and check for wear or
damage. Replace if necessary. Check for wear and damage including speedometer
gear, replace if necessary.
Noise in 4H or 4L
Checks
Worn or Damaged Sprockets or Drive Chain
Incorrect Tire Pressure Action
Disassemble and check for wear and damage, replace
if necessary. Adjust tire pressure.
Transfer Case Oil Leakage
Action
Replace the case. Clean case and parts and check for leakage.
Remove breather hose and clean, replace if necessary.Use specified oil and adjust oil level.Retighten Use specified sealant and retighten. Replace
Checks
Cracked Transfer CaseLeakage from Other PartsBreather CloggingImproper or too much OilLoosened Sealing Bolts Improperly Applied Sealant Worn or Damaged Oil Seal

5D1-12 TRANSFER CASE (PART TIME 4408)
Removal & Installation Procedure
1. Disconnect the negative terminal from the battery.
2. Lift up the vehicle and fix it safely.
3. Remove the drain plug and drain the oil.Reinstall the drain plug.
* If planar damper is installed, unscrew 4 bolts and remove the planar damper.
Installation Notice
Tightening Torque 19 - 30 Nm
4. Remove the breather hose.
5. Disconnect the speedometer cable connector and other cable connectors and wiring harnesses.
6. Support the transfer case with jack and remove the front and rear propeller shafts from the transfer case. Installation Notice
Front
Rear 81 - 89 Nm 70 - 80 NmTightening Torque

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
25 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 Housing 36 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
66 Nut
67 Plane Washer
68 Oil Seal
70 Companion Flange
71 Spacer
72 Front Output Assembly 73 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

TRANSFER CASE (PART TIME 4408) 5D1-17
1. Remove the 9 bolts, wiring harness clip andidentification tag. Notice Identification tag has information required for ordering replacement parts, so be careful not to lose it.
2. Using a ‘-‘ driver, pry and disconnect the sealant
bond of the cover and required case.
3. Remove the oil seal, bearing, 3 nuts and clutch coil assembly of the electric shift unit.

14 Bolt
15 Wiring Clip
16 Identification Tag
17 Cover Assembly
18 Oil Seal
19 Bearing
20 Nut
21 Clutch Coil Assembly
22 Snap Ring
23 Ball Bearing 4. Remove the snap ring and pull out the ball bearing
from the cover to remove the speed gear.
5. Pull out the needle bearing from the cover.
6. Pull out the oil seal from the slot in cover.
7. Remove the magnet form the slot in case.
8. Remove the return spring from the rail shaft.
9. Be careful not to damage the metal surface when removing the sealant of the cover and case.
24 Needle Bearing
25 Cover
26 Magnet
27 Speed Gear
28 Oil Seal
29 Return Spring
38 Rail Shaft
55 Output Shaft
111 Transfer Case

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

TRANSFER CASE (PART TIME 4408) 5D1-37
Inspection and Repair
1. 4H and 4L indicator light inspection When turn the ignition switch to "ON" position, 4H and
4L indicator light will turn on for 0.6 second and will turn
off immediately.
Notice
If indicator light does not turn on, check bulb, wiring harness and TCCU.
2. TCCU inspection
Pin No. Operation Condition
4H or 4L
2H
4H indicator light ON
4H indicator light OFF 2H or 4H4L
Clutch pedal applied
Clutch pedal released 4L indicator light ON
4L indicator light OFF Motor OFF
Motor ON
Motor OFF Motor ON
Auto locking hub ON
Auto locking hub OFF Voltage(V)
4.75 - 5.35
0 - 0.50< 1.00
> 11.00
4.75 - 5.35 0 - 0.50
< 0.50
> 11.00
< 1.00
> 11.00 < 1.00
> 11.00 < 1.00
> 11.00
> 11.00 < 1.00
J1 - 7
J1 - 8
J1 - 13 J1 - 14 J1 - 15 J1 - 16 J1 - 17 J1 - 23
Notice DC 12V for the TCCU operation should be maintained.
In case of J1-8 and J1-15, indicator light will turn on for 0.6
second when turn the ignition switch ON.
If 4H and 4L indicator lights remain turned on when turn the
ignition switch on or during driving, perform the TCCUdiagnosis.