wheel SSANGYONG RODIUS 2005 User Guide

0-22
RODIUS 2005.07
3650-01
DC 5-SPEED AUTOMATIC TRANSMISSION
3) Overrun
6) Reverse 1st Gear (3.160, “S” Mode)
Torque converter lockup clutch
Engine speed
Transmission, input shaft
1st gear ratio
2nd gear ratio 16.
A.
B.
C.
D.Mounting elements
Mounting elements
Rear planetary gear set
Stator E.
F.
H.
L.
Input shaft: Clockwise rotation
Front ring gear: Clockwise rotation
Front sun gear: Locked by one-way clutch F1
Front planetary gear carrier: Clockwise rotation (reduced speed)
Rear planetary gear ring gear: Clockwise rotation
Rear planetary gear carrier: Locked by B3
Rear sun gear and center sun gear: Counterclockwise rotation (increased speed)
Center ring gear: Locked by B3
Center planetary gear carrier: Counterclockwise rotation (reduced speed)
Output shaft: Counterclockwise rotation -
-
-
-
-
-
-
-
-
-Center planetary gear set
Impeller
Turbine wheel
Front planetary gear set M.
P.
T.
V.

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DC 5-SPEED AUTOMATIC TRANSMISSION
RODIUS 2005.07
3650-01
7) Reverse 2nd Gear (1.930, “W” Mode)
Torque converter lockup clutch
Engine speed
Transmission, input shaft
1st gear ratio 16.
A.
B.
C.2nd gear ratio
Mounting elements
Rear planetary gear set
Stator D.
E.
H.
L.
Input shaft: Clockwise rotation
Front ring gear: Clockwise rotation
Front planetary gear carrier: Clockwise rotation by clutch C1 activation (direct connection)
Rear ring gear: Clockwise rotation
Rear planetary gear carrier and center ring gear: Locked by brake B3
Rear sun gear and center sun gear: Counterclockwise rotation (increased speed)
Center planetary gear carrier: Counterclockwise rotation (reduced speed)
Output shaft: Counterclockwise rotation -
-
-
-
-
-
-
-Center planetary gear set
Impeller
Turbine wheel
Front planetary gear set M.
P.
T.
V.

0-4
RODIUS 2005.07
3410-01
TRANSFER CASE
1. PART TIME TRANSFER CASE OVERVIEW
By using the planetary gear sets, two-gears shift type part time transfer case achieves direct
connection when selecting 4WD “HIGH” and 2.48 of reduction gear ratio when selecting
4WD “LOW”.
The silent chain in transfer case transfers the output power to front wheels.
Simple operation of switches on instrument panel allows to shift to “2H”, “4H” and “4L”
easily while driving.
The warning lamp alarms the driver when the system is defective.

0-9
TRANSFER CASE
RODIUS 2005.07
3410-01
Ring, snap
Ring, snap
Ring, snap
Bearing
Hub, circular
Asm. -shaft, input
Plate, thrust
Gear, sun
Snap ring
Asm. -carrier (complete)
Hub reduction
Asm. -shaft, main
Clamp hose
Hose
Filter
Asm. -coil, electric
Asm. -cam/coil hsg.
Ring, snap
Armature
Hub, lockup
Spring, sleeve return
Collar, lockup
Sprocket, driving
Spring, return
Rail, shift
Fork, shift
Asm. -fork, shift
Cam, electric shift
Spring, torsion
Spacer
Shaft, shift
Ring, retaining
Asm. -case, transfer
Barb, breather 1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.Decal
Shaft, output
Deflector, dust
Magnet
Ring snap
Sprocket lower
Spacer
Chain
Ring retaining
Bearing
Bearing
Cover
Bendable clip
Bolt, Metric
Seal, oil
Washer
Nut, Metric
Flange, companion
Seal, oil
Spacer
Tone wheel (upper)
Nut, Metric
Clip, “J”
Bolt, hex head
Bracket, relay mounting
Locking clip
Connector
Bolt, hex head
Capscrew, hex head
Asm. -motor, electric
Seal, oil
Plug, pipe
Sealing Compound 35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.

0-11
TRANSFER CASE
RODIUS 2005.07
3410-01
1) 2H Mode (Rear Wheel Drive)
Power Flow ▶

0-16
RODIUS 2005.07
3410-01
TRANSFER CASE
8. SYSTEM OPERATION
1) Transfer Case Control Unit (Tccu)
(1) 4WD Operation
TCCU is located under the front left seat and
permits the vehicle to shift from two-wheel
drive to four-wheel drive (and back shift)
according to drivers switch operation during
driving (For the shifting between 4WD HIGH
and 4WD LOW, stop the vehicle).
2H → 4H ▶
Change the 4WD switch in instrument panel from 2H to 4H.
This shift is available during driving.
“4WD HIGH” indicator in meter cluster comes on. -
-
-
When the system is defective
“4WD CHECK” warning lamp comes
on -
Change the 4WD switch in instrument panel from 4H to 2H.
This shift is available during driving.
“4WD HIGH” indicator in meter cluster goes out.
“4WD CHECK” warning lamp comes on when the system is defective. -
-
-
- 4H → 2H ▶

0-4
RODIUS 2005.07
3010-01
CLUTCH
1. OVERVIEW
1) Driving Elements
The driving elements consist of two flat surfaces machined to a smooth finish.
One of these is the rear face of the engine flywheel and the other is the clutch cover pressure
plate. The clutch pressure plate is fitted into a clutch steel cover, which is bolted to the flywheel.
2) Driven Elements
The driven element is the clutch disc with a splined hub which is free to slide lengthwise along
the splines of the input shaft. The driving and driven elements are held in contact by spring
pressure. This pressure is exerted by a diaphragm spring in the clutch cover pressure plate
assembly.
3) Operating Elements
The clutch control system consists of the clutch pedal, clutch master cylinder, concentric slave
cylinder. This system directly releases the clutch by using hydraulic pressure while the
conventional clutch system releases the clutch by using release lever and release fork. This
system provides higher efficiency than conventional clutch system, and its durability is superior.
Adaptor (mounted on transmission case) Concentric slave cylinder pipe (mounted inside o
f
transmission) Concentric slave cylinder (mounted inside of transmission)

0-5
CLUTCH
RODIUS 2005.07
3010-01
4) SAT (Self Adjusting Technology)
SAT is new clutch which adjusts the clutch free play according to the wearness of clutch disc. Operation description
▶
Diaphram spring rotates the adjusting equipment as clutch disc is wearing and so,
pressure plate is pushed to clutch disc side at the amount of wearness.
Disc wear (Free play) → Diaphram spring (1) → Adjusting equipme nt (2, 3)
→ Pressure plate (4)
*
Clutch assembly Adjusting
equipment
Disassembly of clutch disc & cover
▶
- When reinstall the clutch assembly without the special zig, Disc can be slip and worn
easily.
Installation of special zig
▶
Identify the SAT clutch with adjusting equipment around the clutch cover.
Adapt the zig set(4 pieces) between the clutch cover and diaphram spring around (Refer to
the picture).
1)
2)
Diaphram
Cover Zig for clutch removal and installationAdjusting
equipmen
t
1) When clutch disc is replaced (Disc change)
- Replace the clutch disc and clutch cover assembly together
2) When clutch disc is not replaced (Engine disassembly, Flywheel related job, Checking
the clutch assy)
- Apply the zig set (SST) on the clutch cover set for re-usage

0-5
TORQUE ON DEMAND
RODIUS 2005.07
3240-01
2. GENERAL DESCRIPTION
TOD system means the full time 4WD system and the registered trade mark of Borg Warner.
TOD is an abbreviation of Torque On Demand.
TOD (Torque On Demand) system, which is superior than existing Full Time 4WD, checks the
road surface and vehicle conditions via various sensors and, subsequently, according to the
situations and conditions, distributes the most optimal driving force to front wheels and rea
r
wheels by activating the electro-magnetic clutch located inside of TOD Transfer Case.
TOD receives the speed signals from speed sensors installed in front axle and rear axle, the
TPS signals from engine, and the operating signals from ABS control unit via CAN.
Based on these data, TOD control unit controls the electro-magnetic clutch to distribute the
3:97 ~ 44:56 of driving force to front wheels and rear wheels.
The conventional system uses “FR driving” (theoretically, the 100 % of driving force is
transferred to rear wheels) on normal paved road.
When the system detects a slip in the rear wheels, a proper percentage of driving force is
transferred to front wheels.
TOD control unit receives the wheel speed signals from the speed sensors in propeller shaft o
f
transfer case and engine output information from the engine control unit.
TOD control unit changes the pressure force of the electromagnetic clutch based on the
analyzed data.
1) Distribution of Driving Force According to Road Surface
On normal road surface ▶
In vehicle with existing part time transfer case, when a driver turns the steering wheel to park in
the 4WD mode, the vehicle may halt sensation of tight corner braking phenomena. However, in
vehicle with TOD system, this phenomena does not occur and the driving force is properly and
automatically distributed.
On paved road with high speed ▶
Driving at high speed on roads such as highway mainly uses rear wheels as driving wheel.
At this moment, some of torques is also distributed to front wheels so that the vehicle could
maintain safe ground grab capacity against side winds and rain.
Distribution ratio: 15 % for front wheels and 85% for rear wheels.

0-6
RODIUS 2005.07
3240-01
TORQUE ON DEMAND
When turning on the road with low friction rate ▶
During cornering on roads such as unpaved, snowy, icy and muddy, ground grab capacity is
increased by distributing required torque and, at the same time, comfortable steering operation
is maintained by controlling the ground grab capacity at high level.
Distribution ratio: 30 % for front wheels and 70 % for rear wheels.
When climbing or starting off on the road with low friction rate ▶
In order to secure the maximum ground grab capacity and driving force during climbing o
r
starting off on the roads such as unpaved, snowy and icy road, the system controls the driving
force to distribute properly in full 4WD mode.
Distribution ratio: 44 % for front wheels and 56 % for rear wheels.