change wheel SSANGYONG RODIUS 2005 Service Manual

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 ▶

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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

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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.

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TORQUE ON DEMAND
RODIUS 2005.07
3240-01
2) 4WD Operation Overview
To make the mode shift easier, stop the vehicle, depress the brake pedal, select the mode
switch, and move the selector lever with the sequence of [N-P-N].
3) Mode Switch
Selection Mode ▶
The TOD system has 2 selectable mode, 4H and 4L.
4H is the normal operating mode when drive 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.
4L Mode ▶
When selecting 4L mode, EMC is locked to apply maximum torque into front and rear propelle
r
shafts (when the wheel speed is more than 87Hz).
Shift motor rotates also 4L position by rotation of cam thus propeller shaft torque changes from
1:1 to 2.48:1 by planetary gear set.
Releasing the 4L Mode ▶
When selecting 4H mode, 4L drive mode is
released and 4H mode is resumed.
“4H” switch: Self-return type
“4L” switch: Push lock type ·
·

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ESP SYSTEM
RODIUS 2005.07
4892-01
Over steeringOversteering is when the steering wheel is
steered to a certain angle during driving and
the rear tires slip outward losing traction.
When compared with under steering
vehicles, the controlling of the vehicle is
difficult during cornering and the vehicle can
spin due to rear wheel moment when the
rear tires lose traction and the vehicle speed
increases.
ESP controls during oversteering
The ESP system recognizes the directional
angle with the steering wheel angle senso
r
and senses the slipping route that occurs
towards the vehicle cornering direction
during oversteering with the yaw rate senso
r
and the lateral sensor. Then the ESP system
applies the brake at the front outer wheel to
compensate the yaw moment value.
In this way, the vehicle does not lose its
driving direction and the driver can steer the
vehicle as he or she intends.
2) ESP Control
The ESP system includes the ABS/EBD and ASR systems allowing the system to be able to
operate depending to the vehicle driving conditions. For example, when the brakes are applied
during cornering at the speed of 100 km/h, the ABS system will operate at the same time the
ASR or ABD systems operate to reduce the power from the slipping wheel. And when yaw rate
sensor detects the rate exceeding 4¡Æ/seconds, the ESP system is activated to apply the
brake force to the corresponding wheel to compensate the yaw moment with the vehicle
stability control function. When various systems operate simultaneously under a certain
situation, there may be vehicle control problems due to internal malfunction of a system o
r
simultaneous operations. In order to compensate to this problem, the ESP system sets the
priority among systems. The system operates in the order of TCS (ASR or ABD), ESP and
ABS. The order may be changed depending on the vehicle driving situations and driving
conditions. As the single-track vehicle model used for the calculations is only valid for a vehicle
moving forward, ESP intervention never takes place during backup.

0-8
RODIUS 2005.07
4892-01
ESP SYSTEM
2) ESP Control
The ESP system includes the ABS/EBD and ASR systems allowing the system to be able to
operate depending to the vehicle driving conditions. For example, when the brakes are applied
during cornering at the speed of 100 km/h, the ABS system will operate at the same time the
ASR or ABD systems operate to reduce the power from the slipping wheel. And when yaw rate
sensor detects the rate exceeding 4¡Æ/seconds, the ESP system is activated to apply the
brake force to the corresponding wheel to compensate the yaw moment with the vehicle
stability control function. When various systems operate simultaneously under a certain
situation, there may be vehicle control problems due to internal malfunction of a system o
r
simultaneous operations. In order to compensate to this problem, the ESP system sets the
priority among systems. The system operates in the order of TCS (ASR or ABD), ESP and
ABS. The order may be changed depending on the vehicle driving situations and driving
conditions. As the single-track vehicle model used for the calculations is only valid for a vehicle
moving forward, ESP intervention never takes place during backup.

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RODIUS 2005.07
4892-01
ESP SYSTEM
4) HBA (Hydraulic Brake Assist System)
(1) Purpose
HBA (Hydraulic Brake Assist) system helps in an emergency braking situation when the driver
applies the brake fast, but not with sufficient pressure, which leads to dangerously long braking
distance. ECU recognizes the attempt at full braking and transmits the signal calling for full
brake pressure from the hydraulic booster. An inexperienced, elderly or physically weak drive
r
may suffer from the accident by not fully pressing the brake pedal when hard braking is
required
under emergency. The HBA System increases the braking force under urgent situations to
enhance the inputted braking force from the driver.
Based on the fact that some drivers depress the brake pedal too soft even under when hard
braking is necessary, the HECU system is a safety supplementary system that builds high
braking force during initial braking according to pressure value of the brake pressure senso
r
and the pressure changes of the pressure sensor intervals.
When the system is designed to apply high braking force when brake pedal is depressed softly
by an elderly or physically weak driver, the vehicle will make abrupt stopping under normal
braking situation due to high braking pressure at each wheels.

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ESP SYSTEM
RODIUS 2005.07
4892-01
(2) Operation
The brake pressure value and the changed value of the pressure sensor are the conditions in
which the HBA System operates. There are 2 pressure sensors under the master cylinder.
When the ESP ECU system determines that emergency braking is present, the pump operates,
the brake fluid in the master cylinder is sent to the pump and the braking pressure is delivered
to the wheels via the inlet valves.
If the drive depress the brake pedal slowly, the pressure change is not high. In this case, only
the conventional brake system with booster is activated.

0-14
RODIUS 2005.07
4892-01
ESP SYSTEM
(1) System Overview
When equipped with ABS, the braking force at each wheel will be controlled with 3-channel 4-
sensor method. And when equipped with ESP, 4 wheels will be controlled independently with 4-
channel method. (When controlling ABS system only, it will be operated with 3-channel
method.) When compared to the vehicle equipped with ABS/EBD only, the internal hydraulic
circuit has a normally-open separation valve and a shuttle valve in primary circuit and in
secondary circuit. When the vehicle brakes are not applied during engine running or when
applying the non-ABS operating brakes, the normally-open separation valve and the inlet valve
are open, whereas the normally-closed shuttle valve and the outlet valve are closed. When the
ESP system is operating, the normally-open separation valve will be closed by the solenoid
valve operation and the hydraulic circuit will be established by the shuttle valve. Then, the inlet
and outlet valves will be
closed or open depending on the braking pressure increase, decrease or unchanged
conditions.
<0d96007b008f008c0047009e00880099009500900095008e004700930088009400970047008a00960094008c009a004700960095004700880095008b0047009e00880099009500900095008e00470089008c008c00970047009a0096009c0095008b009a00
47009e008f008c00950047009b008f008c0047006c007a0077> is operating
▶Driving feeling when the ESP is operating
<0d96007500960090009a008c004700880095008b0047009d0090008900990088009b0090009600950047009b008f0088009b0047008b00990090009d008c00990047009a008c0095009a008c009a0047009e008f008c00950047009b008f008c0047006c00
7a007700470090009a004700960097008c00990088009b0090>ng When the ESP operates during vehicle movement, the ESP warning lamp on the instrument
panel flickers and beep comes on every 0.1 seconds. The ESP operation shows that the
vehicle stability is extremely unstable and it is used to warn the driver. The ESP system is just a
supplementary system for the vehicle motion and it cannot control the vehicle when it exceeds
the physical limits. Do not solely rely on the system but be advised to drive the vehicle safely.
When the ESP system activates, the driving feeling can be different depending on vehicle
driving conditions. For example, you will feel differently when the ESP system is activated
during when ABS is operating with the brakes applied and when brakes are not applied on a
curve. Thus, the ESP system would make the driver feel more abruptly when the brakes are
applied during the ESP system activation.
The ESP system may transfer noise and vibration to the driver due to the pressure changes
caused by the motor and valve operations in a very short period of time. Extreme cornering will
trigger the ESP operation and this will make the driver feel noise and vibration due to sudden
brake application. Also, the ESP system controls the engine output. So, the driver may notice
the engine output decrease even when the accelerator pedal is being applied.

0-19
ESP SYSTEM
RODIUS 2005.07
4892-01
▶Hydraulic Diagram of HBA
The above figure shows one front and one rear wheel and the same hydraulic circuit forms as
in the ESP operation.
When HECU recognizes that it is an emergency and it is required for hard braking, depending
on the pressure value of the brake pressure sensor and pressure changes caused by the
pressure sensor timing, it operates the pump immediately to apply the brake pressure at the
wheels.
Then, the pressure in the pump increases until just before the corresponding wheel gets locked.
The motor still keeps rotating and the outlet valve and the separation valve are will stay closed.
When the wheel starts to lock, the HBA function cancels and switches to ABS operation.